HD785-5LC Gen00027-03

GEN00027-03
Field Assembly Instruction
DUMP TRUCK HD785 -5

SERIAL NUMBERS 4001 and up
CONTENTS
FRONT AXLE, F/T, CHASSIS, HD785-5 (COMMON TO ALL SPECIFICATIONS) ........................................... 3

TIRE ASSEMBLY (INCLUDING TIRES), REAR AXLE, HD785-5 ...................................................................... 4
R.H. PLATFORM, CABIN, HD785-5................................................................................................................... 5
BODY ASSEMBLY (INCLUDING BODY), HD785-5 .......................................................................................... 6
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3) ........................................... 7
LIST OF TOUTH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS............................................. 9
SKETCHES OF SPECIAL TOOLS .................................................................................................................... 10
MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY ..................................................................... 14
ASSEMBLING PROCEDURES ON SITE ......................................................................................................... 16
1. Lifting and mounting rear axle assembly ............................................................................................ 16
2. Lifting chassis assembly ....................................................................................................................... 18
3. Transferring chassis assembly onto rear axle assembly .................................................................... 20
4. Connecting rods to rear axle suspension ............................................................................................ 22
5. Placing mount for front side ................................................................................................................. 24
6. Connecting rear axle and parking brake line ....................................................................................... 25
7. Lifting front axle assembly .................................................................................................................... 26
8. Assembling front axle ........................................................................................................................... 28
9. Connecting tie rod of steering cylinder ................................................................................................ 30
10. Connecting front axle hoses ................................................................................................................. 32
11. Installing steps on A-shaped arm and bumper ................................................................................... 34
12. Installing front tire ................................................................................................................................. 36
13. Installing propeller shaft ....................................................................................................................... 38
14. Installing fuel tank (1/2) ........................................................................................................................ 40
15. Installing fuel tank (2/2) ........................................................................................................................ 42
16. Installing left- and right-hand stays of frame ...................................................................................... 44
17. Installing left-and right-hand fenders ................................................................................................... 46
18. Installing front supports ........................................................................................................................ 48
19. Installation of front support (-40 °C specification for POLYUS) ......................................................... 50
20. Installation of front support (Diagonal ladder + Large-capacity air cleaner specification) .............. 52
21. Installation of air cleaner assembly indicator hoses (Large-capacity air cleaner specification) ..... 54
22. Installation of right front support air cleaner assembly (Large-capacity air cleaner specification).... 56
23. Connecting steering oil line .................................................................................................................. 58
24. Connection of air cleaner piping (Large-capacity air cleaner specification) ..................................... 60
25. Removing engine hood ......................................................................................................................... 62
26. Installing right-hand platform handrail ................................................................................................ 63
27. Installing right-hand platform ............................................................................................................... 64
28. Fixing of air cleaner piping (Large-capacity air cleaner specification) .............................................. 66
29. Wiring along right-hand platform side................................................................................................. 68
30. Wiring in battery box ............................................................................................................................. 70
31. Installation of diagonal ladder (1/3) (Diagonal ladder + Large-capacity air cleaner specification) ..... 72
34. Replacing side bracket of cabin ............................................................................................................ 78
35. Installing handrail of cabin .................................................................................................................... 79
36. Installing cabin ....................................................................................................................................... 80
37. Connecting steering column ................................................................................................................. 82
38. Clamping drain hose of air conditioner ............................................................................................... 84
39. Installing rops and payload lamp ......................................................................................................... 85
40. Connecting dump control...................................................................................................................... 86
41. Installing air intake (1/2) ....................................................................................................................... 88
42. Installing air intake (2/2) ....................................................................................................................... 89
43. Installing air intake (1/2) (Front air intake specification) .................................................................... 90
44. Installing exhaust pipe .......................................................................................................................... 91
1
45. Drawing harness into inside of cabin ................................................................................................... 92
46. Connecting harnesses inside cabin (1/2) ............................................................................................. 93
47. Connecting harnesses inside cabin (2/2) ............................................................................................. 94
48. Connecting air conditioner hoses ......................................................................................................... 96
49. Installing washer tank ............................................................................................................................ 97
50. Installing and connecting air horn ........................................................................................................ 98
51. Wiring around cabin (1/2) ..................................................................................................................... 99
52. Wiring around cabin (2/2) .................................................................................................................... 100
53. Installation and connection of fuel filter (-40 °C specification for POLYUS) ................................... 102
54. Connecting right-hand front brake and radiator surge tank............................................................. 104
55. Wiring for head lamp ........................................................................................................................... 106
56. Connecting air charge line .................................................................................................................. 108
57. Air piping .............................................................................................................................................. 110
58. Connecting left-hand front brake ........................................................................................................ 112
59. Installing parts around hood ............................................................................................................... 113
60. Checking for oil and cooling water ..................................................................................................... 114
61. Filling gas into air conditioner ............................................................................................................ 115
62. Bleeding air from brake ....................................................................................................................... 116
63. Removing parts from host cylinder after transportation .................................................................. 118
64. Equipping machine body .................................................................................................................... 120
65. Installing grease tubes on hoist cylinder ........................................................................................... 122
66. Adjustment of body bottom mount.................................................................................................... 124
67. Adjustment of body positioner ........................................................................................................... 126
68. Welding by determining dimensions with actual parts (body front mount) ................................ 128
69. Welding by determining dimensions with actual parts (swing prevention of body) .................... 130
70. Welding by determining dimensions with actual parts (exhaust flange) ..................................... 131
71. Installing body seating switch ............................................................................................................ 132
72. Installing body accessories ................................................................................................................. 133
73. Painting ................................................................................................................................................. 134
74. Body stopper pin .................................................................................................................................. 136
75. Adjustment of suspension .................................................................................................................. 137
76. Smoothing of floating seal .................................................................................................................. 138
PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS ........................... 139
WORK PROCEDURES FOR TURNING OVER THE BODY ........................................................................... 154
2900 mm TRANSPORTATION POSTURE (IF EQUIPPED)........................................................................... 157
APPENDIX
FIELD ASSEMBLY INSPECTION REPORT
2
Note 1: Install fittings such as bolts, washers, nuts, retaining plates, and Front Axle, F/T, Chassis, HD785-5
pins on their specified locations. Those fittings was used to Remarks:
mount separated package during transportation. (common to all specifications) A ... Single part of assembly
Note 2: Install or weld the components specified in the delivery instruc- L ... Single part of lot
tion in place, except those specified to make package separate. B ... Single part of bulk
Component
Quantity/ Classifi- Description
No Part name Part No.
machine cation
01 Chasis A’ssy 561-00-00000 1 A For Japan...........without rack,
with air cleaner
Except Japan .....cleaner sepa-
rated
01 F. Axle Ass’y (R.H.) 561-27-R0000 1 A
02 F. Axle Ass’y (L.H.) 561-27-L0000 1 A
03 Fuel Tank Ass’y 561-04-6111 1 A

(Note) Two spill lines added
for HD785-5.
3
4
Note 1: Install fittings such as bolts, washers, nuts, retaining plates, Tire Assembly (including Tires), Rear Axle,
and pins on their specified locations. Those fittings was used Remarks:
to mount separated package during transportation. HD785-5 A ... Single part of assembly
Component
machine cation
01 R. Axle Ass’y 561-22-60001 1 A (Note) Stopper pin bracket
added for HD785-5.
02 Tire Ass’y (L.H.) 561-30-X0000 2 A

Note 1: Install fittings such as bolts, washers, nuts, retaining plates, R.H. Platform, Cabin, HD785-5
to mount separated package during transportation. A ... Single part of assembly
Component
machine cation
01 Cabin A’ssy 561-54-67003 1 A (Note) Improved cabin to make
assembling easy for
HD785-5
02 R.H. Platform Ass’y 561-54-61411 1 A (Note) Standardization of pres-

sure reducing valve for
HD785-5
5
6
Note 1: Install fittings such as bolts, washers, nuts, retaining plates, Body Assembly (Including Body), HD785-5
to mount separated package during transportation. A ... Single part of assembly
Component
machine cation
01 Body Ass’y 561-74-00000 1 A
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD
ASSEMBLING (1/3)
No. Item Specification Q’ty Remarks
1 Truck crane 25 tons 1
2 Truck crane 45 tons 1
3 Forklift truck 2.5 tons 1
4 Gas cutting machine No. A type Novac 112R 1
5 Torch 1220N2 1
6 Acetylene gas 1 For gas cutting machine
7 Oxygen gas 150kg/cm2 1 For gas cutting machine
8 Grinder (round) FG50L-1 1
9 Grindstone SCW50 × 19 • 10 1
10 Grinder LISG-7S 1 For finishing
11 Grindstone 180d × 6 × 22 3
12 Dia. bar CB7C105 1
13 Dia. bar blade 6GH 1
14 Semi-automatic welding 500A 3
machine
15 Hand shield GP-1S 3

16 Welding wire for semi-au- 1.2 mm 80kg
tomatic welding machine
17 Chipper scaling hammer FCM-20F 2

18 Port power 300 mm for 10 tons 1 For adjustment of dump body deviation
19 Hydraulic jack 10 tons 1 For dump body
20 Hydraulic jack 5 tons 1 For dump body
21 Pin for body hinge WJ-H46-74001-023 1
22 Refractory cloth 1 m × 10 m 1 Protection when field welding
23 Spacer ATH-465-027 3 Use when welding exhaust flange in field
24 Nitrogen gas injector 566-88-14003 1

2
25 Nitrogen gas bottle 150 kg/cm 1 Injection into suspension
26 Tire inflation gauge No. 2252 1

27 Electric nut runner For 200 kgm NR-30T 1 For tire tightening
28 Extension ATH-785-014 1 For tire tightening
29 Cord reel For 200V 1 For electric nut runner
30 Generator 220V 1
31 Grease pump gun For 20kg can 1
32 Grease GL-2 5 kg
33 Footstool Three steps 1
34 Footstool Six steps 1
35 Blue sheet 5 m × 10 m 5 Protection for equipment
36 Square timber 300 mm square, 1 m long 16
7
ASSEMBLING (2/3)
37 Oil jack 5L 1 For oil injection
38 Oil Engine oil SAE10W 100l See Field Assembling Procedures.
39 Oil Engine oil SAE30W 20l See Field Assembling Procedures.
40 Oil sump, washing can 2
41 Drained oil can Empty drum can 1
42 Cloth 5kg
43 Diesel fuel No. 2 for summer Special No. 3 for For refilling fuel
winter (ASTM D975 No. 2)
44 Antifreeze 5l For adding in subtank (to change mix-

ing ratio depending on local weather)
45 Air hose 6d × 1m 1 For air bleeding
46 Three-bond #1521 Tube of 100 gram 1 Use for windshield glass
47 Washer liquid 3l
48 Sanding machine for 914B 1

scaling-off coating
49 Sandpaper #80 100
50 Sandpaper #180 10
51 Cup gun set W87-20R2S 1 Use for coating
52 Brush 1 Use to repair coating.
53 Air compressor Not less than 3.5 m3 or 7 kg/cm2 1
54 Air hose With mouthpiece of d12 5 For impact grinder
55 Impact wrench UW-13SK 2
56 Impact wrench KW-3800P 1
57 Impact wrench UW-9SK 2
58 Extension for impact 150 mm long 1

wrench 38S
59 Socket 1 inch × 41 mm 1 For tightening tire
60 Socket 1 inch × 36 mm 1 For tightening ROPS (option for over-

seas specification)
61 Socket 1 inch × 30 mm 1 For tightening support
62 Wrench Width across flats: 36 mm 1
63 Wrench Width across flats: 41 mm 1
64 Torque-wrench 1800QL 1 For propeller shaft
65 Torque-wrench 10000QLE 1
66 Torque-wrench, open type 24 × 1200SP 1
67 Torque-wrench, open type 36 × 2200SP 1
68 Torque-wrench, box type Width across flats: 27 mm, 4200CL 1
69 Torque wrench, box type Width across flats: 30 mm, 7000CL 1
70 Convex 5m 2
8
ASSEMBLING (3/3)
71 Locktite LT-2 1
72 Vinyl tape 1 Use to bundle harnesses
73 Standard tool (ISO specifi- 700SX 2

cation)
74 Bar 1m 1
75 Shino 1 For hole alignment
76 Sledgehammer 10 lb 1
77 Shackle BD10 for 500 kg 4
78 Shackle BC40 for 10 tons 4 For mounting body
79 Chain ATH-465-042 1 Multi purpose
80 Nylon shoe ring 100 mm wide × 5 m 2 For mounting fuel tank
81 Nylon shoe ring 250 mm wide × 5 m 1 For mounting R.H. platform to cabin
82 Nylon shoe ring 60 mm wide × 3 m 2 For mounting support and small articles
83 Nylon shoe ring 100 mm wide × 12 m 1 For mounting front tires
84 Nylon shoe ring 30 mm wide × 2 m 3 For installing front axle
85 Nylon shoe ring 100 mm wide × 3 m 1 For installing front axle
86 Pin d60 × 250 mm 2 For slinging chassis, rear side
87 Jig for slinging body ATH-785-006 4 For mounting body
88 Lever block 3/4 tons, LB008 3 For installing front axle
89 Lever block 2 tons, LB020 1 For installing front axle
90 Wire 7m 28d 2 For slinging chassis
91 Wire 4m 28d 2 For mounting body
92 Wire 5m 28d 2 For installing body
The following items may be substituted for No. 90 to 92.

ATH-465-039 1 For mounting body
ATH-465-040 2 For slinging chassis
ATH-465-041 1 For slinging separated body
LIST OF TOUCH-UP COATING ON BODY FOR OVERSEAS

SPECIFICATIONS
No. Part Name Unit Q’ty
1 Retane GP primer 4kg 1
2 Retane GO hardener 0.8kg 1
3 Retane GP thinner 16 1
4 AX Mightylacq G2KB type natural yellow 10kg 2
5 NAX Mightylacq G2KB type hardener 2kg 2
6 X Mightylacq G2 500 standard thinner 16kg 1
7 Acryliquid cloud gray Spray can 1
8 Heat-resistance silver Spray can 1
9
SKETCHES OF SPECIAL TOOLS
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
When welding by actually positioning exhaust flange on machine
HEAT TREATMENT MATERIAL

PU-4 SS40
PART NAME QTY
SPACER 3
ATH-465-027
Body assembly lifting tool

— —
PART NAME QTY
Body assembly lifting tool 1
ATH-465-039
10
Chassis lifting tool

— —
PART NAME QTY
Chassis lifting tool 2
ATH-465-040
Dump body lifting tool

— —
PART NAME QTY
?? dump body lifting tool 1
ATH-465-041
11
Universal lifting tool

— —
PART NAME QTY
Universal lifting tool 1
ATH-465-042
Body lifting pin

— SS400
PART NAME QTY
Body lifting pin 4
ATH-785-006
12
Chassis lifting tool

— STKM13A
PART NAME QTY
Shaft 1
WJ-H46-74001-023
No. Parts Name Parts No. Material

01 BOLT M33 × 170 SCM435
02 SOCKET P850ML

1124001600
PART NAME QTY
Extension 1
ATH-785-014
13
MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY
Body mounting, connec-

tion of exhaust pipes
Maintenance
Remarks
Inspection
Assembly
Welding
Coating
Total
HD465 series (day) 1.5 3 1 0.5 0.5 1 6
with lock (field welding) 1.5 5 1 0.5 0.5 2 9
HD785 series (day) 2.5 3 1 1.5 0.5 1 7
lock (field welding) 2.5 5 1 1.5 0.5 2 10
Assembly (per day) 3 3 1 3 Total shows max. man/day.
Man-power
Welding (per day) 3 2 3 Total shows max. man/day.

Inspection (per day) 1 1
Coating (per day) 2 2
45 ton crane (day) 1 1 1 3 1st day (when shipment received), 2nd day
(when reversing), and when mounting body
2 1st day (when shipment received), 2nd day
Equipment
25 tone crane 1 1
(when reversing)
Working car with crane 1 1 Everyday
Semi-automatic welding machine 3 2 3 Total shows max. welding work days.
Gas cutting machine 1 1 1 Total shows max. welding work days.
Generator 1 1 1 Total shows max. welding work days.
Compressor 1 1 1 1 1 1 everyday
Note: This schedule is made on the assumption that work day is not rainy (for welding and coating.)
If it is rainy, postpone the work.
14
ASSEMBLING PROCEDURES ON SITE
1. LIFTING AND MOUNTING REAR
AXLE ASSEMBLY
1. Remove rod retaining bolts for pins 1 and 2
on upper face of differential case and then with-
draw pins. Hook sling at pins. Then, install
pins in place again with sling.
Æ Rear axle: 9.5 tons for single body.
Æ Tire assembly: 1.5 ton per each tire.
(Tire weight varies according to its
specification.)
Æ Rear axle assembly: approx. 16 tons
Î Remember to remove spacers.
2. Lower rear axle on ground. Place chocks 3

and rectangular timbers to mount parking disc
plate assembly.
Î Select flat ground for assembling operation.
Î Adjust stack height of rectangular timbers
4 so that axle is placed horizontally.
3. Remove sling.
16
Photo shows sling operation by
simultaneously using two cranes.
17
2. LIFTING CHASSIS ASSEMBLY
1. Use two cranes.
Æ Chassis assembly: approx. 22 tons
For movable crane:
45 tons for front side
25 tons for rear side
2. Hook sling at chassis and then sling up chassis

assembly.
Î Protect bumper on front side not to dam-
age.
Î Be careful not to interfere assembly with
grease tubes on rear side.
18
Chassis assembly is slung.
Use hook located under frame Use holes for body stopper pin
on front side. on rear side.
19
3. TRANSFERRING CHASSIS ASSEMBLY
ONTO REAR AXLE ASSEMBLY
1. Lift rod (upper rod) before installing upper side
of differential.
2. Move chassis assembly onto rear axle assem-

bly.
Upper rod lifted.
Chassis assembly is transferring onto rear axle.
20
4. CONNECTING RODS TO REAR AXLE
SUSPENSION
1. Connect rods A, B, and C in this order as
shown in left-hand figure.
2. Align pin with hole, and temporally move rod.

Î When alignment, be careful not to be
caught your finger.
3. Place spacer in rubber portion on spherical

bushing.
Î Force spacer carefully,but not so strong as
to deform spacer.
4. Again, align pins with holes.

Î When driving pins with hammer, be care-
ful not to damage grease fittings.
5. Place lock bolts and washers.

½ Tightening torque:
157 to 196 Nm {16 to 20 kgm},
desired value: 177 Nm {18 kgm}
6. Supply grease in related lubrication points.
22
23
5. PLACING MOUNT FOR FRONT SIDE
1. Place rectangular timbers under vertical mem-

ber up to 1 m in height.
Î Stack timbers crosswise in parallel
2. Lower frame.
24
6. CONNECTING REAR AXLE AND
PARKING BRAKE LINE
1. Remove blind parts A from elbow of relay valve

on parking brake line.
Î For machine with two-way brake system,
only one hose is provided.
2. Connect hose from rear axle.

29 to 69 Nm {3.0 to 7.0 kg},
desired value: 49 Nm {5.0 kgm}
3. Remove blind parts B from connector of brake

chamber on brake chamber line.
4. Connect hose from rear axle

108 to 167 Nm {11.0 to 17.0 kgm},
desired value: 137 Nm {14.0 kgm}
Î Keep hoses from interfering with each
other.
5. Place oil sump.
6. Remove blind parts C (total four on both sides)

of cooling tube on rear axle.
7. Remove blind parts D (total two on upper and

lower sides) of cooling tube on chassis side.
8. Connect two hoses on each left and right side

respectively.
Î Keep hoses uncrossed.
Î Remember to mount spacer on lower right
side.
Î Keep hoses from interfering with each
other.
9. Clean any greasy surfaces.
25
7. LIFTING FRONT AXLE ASSEMBLY
1. Remove pins and spacers from portions A, B,
and C on chassis side.
Î Dimensions of pin vary on each portion.
Place pins near relevant locations to install
pins in place with ease.
2. Lifting front axle as shown in photo.

Î Adjust sling so that suspension cylinder
becomes vertical against ground.
Hook slings at suspension cylinder assem-
bly and hub stud portion.
26
27
8. ASSEMBLING FRONT AXLE
1. While controlling crane and lever block, insert
A-shaped arm into mounting portion on chas-
sis and align pins with holes once. Then, lower
A-shaped arm with lever block.
Caution: When making alignment, watch your
fingers!
2. Insert 8 spacers previously removed into rub-

ber cover on spherical bushing (four places on
both sides) of A-shaped arm. Align pins with
holes again using lever block.
Î Check spacer for deviation.
Î Check for O-ring on spherical bushing.
3. Set pins and install lock bolts.

157 to 196 Nm {16 to 20 kgm},
5. Remove sling from A-shaped arm.
6. Install upper portion of suspension in the same

way as for A-shaped arm while controlling
crane.
7. Supply grease in related lubrication points.
28
Left side
Right side
29
9. CONNECTING TIE ROD OF STEERING
CYLINDER
1. Remove grease tube from portion over pins on
front axle lever assembly. Remove pins and
boots.
Î When working on machine equipped with
auto-suspension, remove air cylinder cover.
2. Control crane so that lever assembly becomes

parallel to ground surface.
3. Place boots on upper and lower sides and align

them with related pin holes. Insert pins into
bushings.
Î Check that O-ring locates in spherical bush-
ing.
4. Install lock bolts and connect grease tubes

again.
5. Supply grease into related lubrication points.
30
31
10. CONNECTING FRONT AXLE HOSES
1. Remove four blind parts (two on each side)
from portion X (front brake hose).
When working on machine equipped with auto-
suspension, remove six blind parts (three on
each side) on portion Y.
½ Tightening30torque for brake hose:
to 69 Nm {3.0 to 7.0 kgm},
desired value 49 Nm {5.0 kgm}
2. Connect all hoses after making sure of each

hose number.
Î In figure,
Symbols A, B, and C: port number
Nos. 20, 21, and 22: hose number
3. Remove sling from axle.
4. Lock hub parallel to machine body.
32
33
11. INSTALLING STEPS ON A-SHAPED
ARM AND BUMPER
1. Remove mounting bolts from A-shaped arm.
Install steps on A-shaped arm by using re-
moved bolts.
Î Install steps symmetrically on both sides.
2. Install steps in the same way as for A-shaped

arm.
Î Install steps symmetrically on both sides.
34
561-54
31690
(2)
35
12. INSTALLING FRONT TIRES
1. Remove the clamps and nuts from the hub. (8
places each on right and left sides)
Î Remove the paint and foreign matter from
the tapered part of the hub.
2. Match the air valve of the tire to the cut part of

the hub and install the tire to the hub.
Î Take care not to break the air valve.
3. Install the clamps and tighten the nuts lightly.
4. Tighten the clamps in the order shown in the

photo.
Î Tighten all the clamps evenly.
5. Measure the runout of the tire with a scribing

block, etc. as shown in the figure. If the runout
is 5 mm or larger, loosen the nuts and tighten
them again to reduce the runout.
6. Tighten the nuts permanently.

1.961 – 2.452 Nm {200 – 250 kgm},
Target: 2.207 Nm {225 kgm}
(When oil, etc. is not applied)
1.520 – 1.912 Nm {155 – 195 kgm},
Target: 1.716 Nm {175 kgm}
(When oil, etc. is applied)
7. Remove the blocks under the chassis.
36
37
13. INSTALLING PROPELLER SHAFT
1. For machine equipped with propeller shaft
guard, remove guard.
2. Remove 8 bolts, 510-20-12820, located rear axle

and transmission side from coupling.
3. Face female portion of propeller shaft toward

transmission and align female with faucet joint.
Fit propeller shaft into faucet joint portion with
hammer.
Î Make sure that coupling surface is free from
dust and dirt.
Î Do not connect faucet joint by tightening
bolts.
4. After applying LT-2 to bolts removed in step 2,

tighten bolts temporarily.
Î Tighten bolts to not more than 157 Nm {16
kgm}
5. Tighten bolts properly.

157 to 196 Nm {16 to 20 kgm},
(Always use torque wrench.)
6. Install propeller shaft again in place.
7. Supply grease.
38
39
14. INSTALLING FUEL TANK (1/2)
1. Remove nuts, washers, and spacers tightened
temporarily to bolts on chassis side.
Î Support hoist cylinder.
2. Align bolts with bolt holes on fuel tank and

place nuts, washers, and spacers on bolts.
Then, tighten nuts.
490 to 608 Nm {50 to 62 kgm},
desired value 549 Nm {56 kgm}
3. After removing upper cover, remove blind

parts. (3 places)
4. Clamp 3 hoses from chassis with attached clip

marked Î(tm)and connect hoses to related
ports.
20 to 30 Nm{2.0 to 3.0 kgm}, desired
value 25 Nm {2.5 kgm} for spill hose
30 to 69 {3.0 to 7.0 kgm}, desired value
49 Nm {5.0 kgm} for overflow hose
5. Replace cover as before.
40
Return hose cover
41
15. INSTALLING FUEL TANK (2/2)
6. Remove under cover and remove blind parts
on all connectors. (2 places)
7. Clamp 2 hoses on chassis with attached clips,

marked ✩(tm), and connect hoses to related
ports.
Î After connecting hoses, open cock to sup-
ply fuel.
8. Install cover as before.
9. Clamp ground cable and connector of fuel

gauge. Connect connector CN-61 and clamp
it.
Î Remove coating on surface to be soldered
ground cable.
10. Install step with bolts attached on fuel tank.
42
43
16. INSTALLING LEFT- AND RIGHT-
HAND STAYS OF FRAME
1. Install left- and right-hand supports with bolts
attached on chassis.
824 to 1030 Nm {84 to 105 kgm},
44
45
17. INSTALLING LEFT- AND RIGHT-
HAND FENDERS
1. Sub-assemble upper and lower portions of
right-hand fender.
2. Install left- and right-hand fenders on chassis

supports.
3. Install mudguards on fender with plates at-

tached on fender.
29 to 49 Nm {3.0 to 5.0 kgm},
4. Clamp breather tube connected to upper face

of fuel tank with clips on side face of right-hand
fender, (except machines with quick-charge
specifications).
46
Left side Right side
47
18. INSTALLING FRONT SUPPORTS
1. Remove 10 bolts each on left and right sides
attached on front support and 6 bolts each on
left and right sides attached on chassis.
2. Mount temporarily left and right-hand front

supports with bolts removed in step 1.
3. After adjusting with shims clearances between

front and rear supports and between front sup-
ports, install front supports with bolts removed
in step 1.
490 to 608 Nm {50 to 62 kgm}, desired
value 549 Nm {56 kgm} for stay between
rear and front supports
245 to 309 Nm {25 to 31.5 kgm}, desired
value 279 Nm {28.5 kgm} for stay be-
tween front supports
4. Tighten bolts properly on chassis.
48
49
19. INSTALLATION OF FRONT SUPPORT
(-40 °C SPECIFICATION FOR POLY-
US)
1. Remove the 12 sets of bolt(3 and 5 ) and
washer (4 and 6 ) attached to each of the
right and left sides of the front support , 4
sets (q, w) installed to each of the right and
left sides of the frame, and 6 sets of right
stay mounting bolt and washer (e, r).
2. Install right stay 9 with e and r.
3. Install the front support temporarily.
4. Adjust the clearance at parts D and C with -

and tighten with q and w.
Î If the holes are not aligned, loosen the
stay mounting bolts, align the holes, ad-
just the shims, and tighten each part.
5. Adjust the clearance at parts Z1 and Z2 with

7 and 8 and tighten with 5 and 6.
6. Tighten front support and parts A and B of

the frame with 3 and 4.
* 5 Bolt tightening torque : 245 – 308.7 Nm (25 – 31.5 kgm)

3, q, e Bolt tightening torque : 490 – 607.6 Nm (50 – 62 kgm)
Part No. Part Name Q’ty Condition

(1) 561-54-6131A Front support L.H assembly 1 Packed separately (H7-C-146)
(2) 561-54-6132A Front support R.H assembly 1 Packed separately (H7-C-146)
(3) 01010-82050 BOLT 12 Installed to frame
(4) 01643-32060 WASHER 12 Installed to frame
(5) 01010-81655 BOLT 12 Installed to right and left supports
(6) 01643-31645 WASHER 12 Installed to right and left supports
(7) 561-54-61160 SHIM 8 Packed separately (H7-C-146)
(9) 561-84-6749A STAY 1 Packed separately (H7-C-146)
50
51
20. INSTALLATION OF FRONT SUPPORT
(DIAGONAL LADDER +
LARGE-CAPACITY AIR CLEANER
SPECIFICATION)
1. Remove the 10 bolts each from the right and
left sides of the front support and the 6 bolts
each from the right and left sides of the frame
mounting section.
2. Install the front support temporarily.
3. Adjust the clearances at parts D and C with 9

and tighten with 7 and 8.
Î If the holes are not aligned, loosen the stay
mounting bolts, align the holes, adjust the
shim, and then tighten each part.
4. Adjust the clearances at parts Z1 and Z2 with

- and q and tighten with 5 and 6.
5. Parts A and B
* 5 Bolt tightening torque : 245 – 308.7 Nm (25 – 31.5 kgm)

3, 7 Bolt tightening torque : 490 – 607.6 Nm (50 – 62 kgm)

(1) 561-84-6981A Front support L.H assembly 1 Packed separately (H7-C-230)
(2) 561-84-6831A Front support R.H assembly 1 Packed separately (H7-C-230)
52
53
21. INSTALLATION OF AIR CLEANER
ASSEMBLY INDICATOR HOSES
(LARGE-CAPACITY AIR CLEANER
SPECIFICATION)
1. Remove the indicator hose from the right plat-
form assembly.
2. Connect the removed hose to air cleaner as-

sembly 1.
Î Install the indicator hose to the air cleaner
first. It cannot be installed in the following
processes.

(1) X251224820 Air cleaner assembly 1 Packed separately (H7-C-240)
54
55
22. INSTALLATION OF RIGHT FRONT
SUPPORT AIR CLEANER ASSEMBLY
SPECIFICATION)
1. Remove 4 – - from the front support.
2. Using 2 and 3, install air cleaner assembly

1 to right front support.
3. Install fixing bracket 4 with 5 and 6.
4. Install mudguard q with removed 7 – -.

(1) X251224820 Air cleaner assembly 1 Packed separately (H7-C-240)
(2) 01010-81635 BOLT 16 Packed separately (H7-C-240)
(3) 01643-31645 WASHER 16 Packed separately (H7-C-240)
(4) 561-84-68490 BRACKET 1 Installed to right front support
(5) 01010-81635 BOLT 3 Installed to right front support
(6) 01643-31645 WASHER 3 Installed to right front support
(7) 561-84-68320 BRACKET 1 Installed to right front support
(8) 01024-81230 BOLT,SEMS 5 Installed to right front support
(9) 561-84-68340 PLATE 1 Installed to right front support
(10) 01024-81230 BOLT,SEMS 5 Installed to right front support
(11) 561-84-68331 GUARD 1 Packed separately (H7-C-240)
56
57
23. CONNECTING STEERING OIL LINE
1. Remove blind parts on hoses and tubes.
2. Connect hoses and tubes.

147 to 206 Nm {15.0 to 21.0 kgm}, desired
value 177 Nm {18.0 kgm} for big hose
value 49 Nm {5.0 kgm} for small hose
Rear side of left-hand front support
58
24. CONNECTION OF AIR CLEANER
PIPING
SPECIFICATION)
1. Connect the tubes to the air cleaner and fix it
with the attached clamps.
Î Remove the vinyl bags etc. used to prevent
entry of dirt.
When connecting the tubes, take care of
their insertion length.
2. Fix the tubes with the bands.
3. Connect the tubes to the engine and fix them

with the attached clamps.
4. Connect the tubes by the hoses.
* Hose clamp tightening torque : 8.8 ± 0.5 Nm

(0.9 ± 0.05 kgm)
Set the tightening portions of the clamps on
the exactly opposite side to each other so
that they can be tightened from the same
direction.
If the hoses cannot be inserted easily, use

neutral detergent. (Do not use adhesive.)

(1) 561-84-68120 TUBE 1 Packed separately (H7-C-242)
(3) 565-44-12310 BAND 2 Packed separately (H7-C-242)
(4) 01582-11008 NUT 4 Packed separately (H7-C-242)
(6) 568-02-22230 HOSE 2 Packed separately (H7-C-242)
(7) 07289-00195 CLAMP,HOSE 4 Packed separately (H7-C-242)
(10) 568-02-22230 HOSE 1 Packed separately (H7-C-242)
(11) 07289-00195 CLAMP,HOSE 2 Packed separately (H7-C-242)
(12) 07042-30108 PLUG 1 Packed separately (H7-C-242)
60
61
25. REMOVING ENGINE HOOD
1. Remove 3 caps and bolts and 2 caps and nuts.
Remove hood.
62
26. INSTALLING RIGHT-HAND
PLATFORM HANDRAIL
1. Install guards , mirrors etc.
(Parts without parts number mean accessories.)
63
27. INSTALLING RIGHT-HAND PLATFORM
1. Remove mounts attached on right-hand plat-
form. (4 places)
2. Set upper half of mount in support mounting.
3. Install right-hand platform on machine.
4. Set lower half of mount on bolts and tighten

nuts.
Á Apply LT-2.
490 to 608 Nm {50 to 62 kgm},
5. Remove bolt attached temporarily on front sup-

ports and connect ground cable.
64
65
28. FIXING OF AIR CLEANER PIPING
SPECIFICATION)
1. Install the brackets to the right stay. (Upper
and lower ones)
2. Fix the tubes with the band.
3. Take the indicator hoses out of the through

holes of the right front support and fix them
with the temporary clips.
4. Install the indicator hoses to the right platform

assembly as fixed in No. 20 and connect them.

(1) 561-84-68240 BRACKET 1 Packed separately (H7-C-245)
66
67
29. WIRING ALONG RIGHT-HAND PLAT-
FORM SIDE
1. Clamp 3 cables and a harness from machine
body with clamping devices attached on plat-
form and draw them in battery box.
Four clamps for harness
Two clamps for cable
2. Connect machine harness to right-hand plat-

form harness with connector (CN-30 and CN-
31)
68
69
30. WIRING IN BATTERY BOX
1. Remove cover.
2. Connect total 7 harnesses, cables, and connec-

tors of cab J07 terminal, engine starter B ter-
minal, alternator B terminal, emergency steer-
ing motor M terminal, and cab J03 terminal.
Numbers are marked on related connecting
areas.
1. 73 for alternator B
2. 1 and 2 for engine starter B
3. 3 for emergency steering motor M
4. 70 for J07 in cab
5. FU and 69 for J03 in cab
3. Install cover.
70
31. INSTALLATION OF DIAGONAL
LADDER (1/3)
(DIAGONAL LADDER +
SPECIFICATION)
1. Install the ladder mount bracket to the right
front support.
2. Install the upper step.
3. Install the lower step to the left side of the

bumper.

(7) 566-54-12212 CUSHION 4 Packed separately (H7-C-205)
(8) 566-54-21910 BUSHING 2 Packed separately (H7-C-205)
(9) 566-54-21920 PLATE 4 Packed separately (H7-C-205)
(13) 09415-03614 CAP 4 Packed separately (H7-C-205)
(14) 561-84-68410 STEP 1 Packed separately (H7-C-205)
(18) 561-54-6A151 BOLT 10 Packed separately (H7-C-205)
(19) 01024-81230 BOLT 10 Packed separately (H7-C-205/206)
72
73
LADDER (2/3)
(DIAGONAL LADDER +
SPECIFICATION)
1. Install the ladder between the right and left
steps.
2. Install the rod to under the step.

(1) 561-84-68930 STEP 1 Packed separately (H7-C-206)
(10) 09415-03614 CAP 2 Packed separately (H7-C-205)
(11) 562-89-16161 ROD 2 Packed separately (H7-C-206)
74
75
LADDER (3/3)
(DIAGONAL LADDER +
SPECIFICATION)
1. Install the covers to the clearance between the
radiator guard and ladder.
2. Install the handrail to the front ladder.

(1) 561-84-68470 COVER 1 Packed separately (H7-C-206)
(3) 561-84-68480 COVER 2 Packed separately (H7-C-206)
(5) 561-84-68420 GUARD 1 Packed separately (H7-C-206)
(6) 561-54-61910 CLAMP 5 Packed separately (H7-C-206)
(9) 568-06-15910 UNDER MIRROR U. 2 Packed separately (H7-C-206)
(10) 569-54-61831 STAY 1 Packed separately (H7-C-206)
(11) 07283-32236 CLIP 2 Packed separately (H7-C-206)
(12) 07283-52232 SEAT 2 Packed separately (H7-C-206)
76
77
34. REPLACING SIDE BRACKET OF
CABIN
1. Remove bracket (see photo) from rear right side
of cabin once and install bracket in direction as
shown in figure.
Î Carry out bracket removal before cabin in-
stallation.
78
35. INSTALLING HANDRAIL OF CABIN
1. Install guard and mirrors
79
36. INSTALLING CABIN
1. Remove 4 mounts from cabin floor.
2. Set upper half of mount in support mounting.

Do not use shims.
Î During this time, place steering column on
floor.
3. Install cabin on machine body.
4. Measure dimension L while not tightening nut.
5. If dimension L exceeds specified value, add

shims so that difference among 4 dimensions
L is within 0.5 mm.
6. Set lower half of mount in support mounting

and tighten nut.
343 to 426 Nm {35 to 43.5 kgm},
7. Seal doors as before.
8. Connect ground cables to front support on front

side, and hood mounting bracket on rear side.
Î Remove coating on zone to be soldered as
ground.
80
81
37. CONNECTING STEERING COLUMN
1. Remove cover from front support.
2. After removing cover from cabin column, con-

nect steering column to steering valve.
3. Mount cover on cabin column as before.
4. Place rubber cover.

20 to 39 Nm {2.0 to 4.0 kgm},
5. Mount cover on front support as before.
82
83
38. CLAMPING DRAIN HOSE OF AIR
CONDITIONER
1. Remove rear cover from left-hand front sup-
port.
2. Clamp drain hose of air conditioner with two

clips attached on support.
3. Mount cover as before.
84
39. INSTALLING ROPS AND PAYLOAD
LAMP
1. Install ROPS on rear support with bolts attached
on support.
2. Install external indicator lamp of payload meter

with bolts attached on ROPS.
3. Connect connector CN-14 to external indicator

lamp.
85
40. CONNECTING DUMP CONTROL
1. Install dump control bracket assembly with
bolts attached on lower side of cabin.
2. Connect cable from hydraulic tank to dump

control and clamp cable. (For dimensions see
figure.)
3. Connect rod to lever.
4. Make sure that dump lever in cabin can be set

on neutral stopper when holding dump.
86
87
41. INSTALLING AIR INTAKE (1/2)
1. Install air cleaner and air cleaner box.
88
2. Install bracket to clamp synflex tubes.
89
(FRONT AIR INTAKE
SPECIFICATION)
1. Remove air cleaner assembly and air cleaner
box accessories.
2. Install air cleaner A and air cleaner box.
3. Connect air intake tube.

(1) 561-84-6211A AIR BOX assembly 1 Packed separately
(2) 561-84-6931A AIR CLEANER assembly 1 Packed separately
(3) 01024-81235 BOLT 4 Packed separately
(4) 561-02-12150 ELBOW 3 Packed separately
(5) 07289-00170 CLAMP 6 Packed separately
90
44. INSTALLING EXHAUST PIPE
1. Remove fire prevention cover from machine
body.
2. Install exhaust pipe with bolts, bands and the

like attached on machine body.
3. Install cover as before.
Fire prevention
cover
91
45. DRAWING HARNESS INTO INSIDE
OF CABIN
1. Draw harnesses attached machine body into
inside of cabin.
(Number of harnesses varies depending on
specification.)
2. Clip them.
92
46. CONNECTING HARNESSES INSIDE
CABIN (1/2)
1. Draw harnesses into cabin and carry out wir-
ing.
93
47. CONNECTING HARNESSES INSIDE
CABIN (2/2)
Engine controller wiring harness

(To be brought from chassis)
Fix with clips installed temporarily
(4 places marked with ✩)
Connection
Engine controller
View Z
Interruption wiring
harness for EC regulation
Engine controller wiring (Electronic governor specification model)
Connection
View Y
Connection of chassis wiring harness
No.
1 Connect each wiring Check connector No.
harness. and terminal No.
94
Connect the engine controller wiring harness according to Fig. 1 - 4.
95
48. CONNECTING AIR CONDITIONER
HOSES
1. Remove cover and clamp from side face of
cabin.
2. Pass hoses 1 to 4 through cover and clamp.

Replace hoses as before.
3. Loosen 4 bolts and remove cover from air

conditioner unit located on lower right side of
dashboard.
4. Replace cover as before.
96
49. INSTALLING WASHER TANK
1. Install washer tank with bolts attached on
side face of cabin.
2. Connect connector CN-12.
3. Connect hose.
Î Hose may be cut to suitable length if it is
too long.
97
50. INSTALLING AND CONNECTING AIR
HORN
1. Install air horn with bolts attached on left-hand
front support.
2. Connect harness of left-hand front support to

air horn. (CN-04 and CN-D5-2)
3. Connect harness to air conditioner receiver.

(CN-04 for machine with air conditioner)
4. Clamp harness with clips. (one place)

Clamp synflex tube with clip. (two places)
Clamp harnesses with clips.
CN-04 (for machine with air conditioner.)
CN-D5-1
CN-D5-2
561-35
62900
98
51. WIRING AROUND CABIN (1/2)
1. Connect connectors.
2. Connect harnesses with related clips.
99
52. WIRING AROUND CABIN (2/2)
Machine with
auto-suspension
or pay load meter
Side view of cabin
Rear lower portion of cabin
100
53. INSTALLATION AND CONNECTION
OF FUEL FILTER
(-40 °C SPECIFICATION FOR
POLYUS)
1. Remove the fuel filter hose clips.
Î Discard removed parts.
2. Install the fuel filter and connect and fix the

piping.
2-1. Remove bracket 5 installed temporarily to

the right stay.
Î Do not discard clips, cushions and bolt
installed temporarily to bracket 5 since
they will be used in Assembly manual
No. 0430.
2-2. Install fuel filter mounting bracket 1 to the

right stay with bolts 2.
2-3. Install fuel filter assembly 3 to bracket 1

with bolts 4.
2-4. Install right hose clamp bracket 5 to the right

stay with bolts 6.
2-5. Direct the 2 hose joint elbows of fuel filter as-

sembly 3 down.
2-6. Check Nos. "15" and "16" of the fuel hoses

and the O-ring of the connection-end elbow
and connect the hoses.
2-7. Fix the fuel hoses to bracket 5 with clips 7,

cushions 8 and bolt 9.
Part No. Part Name Q’ty Condition (Parts list No.)

(2) 01024-81230 BOLT, SEMS 4 Packed separately (H7-C-145)
(3) 6215-71-620A FUEL FILTER A. 1 Packed separately (H7-C-145)
(5) 561-84-67520 BRACKET 1 Install temporarily to right stay
(6) 01024-81225 BOLT, SEMS 2 Install temporarily to right stay
(7) 20Y-977-1160 CLIP 2 Packed separately (H7-C-145)
(8) 07095-00523 CUSHION 2 Packed separately (H7-C-145)
102
54. CONNECTING RIGHT-HAND FRONT
BRAKE AND RADIATOR SURGE
TANK
1. Connect hose from reservoir tank to radiator.
Clamp hose at two points with clips and insu-
lator attached on radiator.
2. Clamp drain hose and front brake hose respec-

tively at two points enclosed by circle as shown
in photo.
3. Connect brake hose and tighten it together with

filter line hose.
½ Tightening torque of hose:
29 to 69 Nm {3.0 to 7.0 kgm},
4. Clamp drain hose with clips and insulator at-

tached on U-bolt of transmission cooling tube.
104
Tighten brake hose together
with filter line hose
105
55. WIRING FOR HEAD LAMP
1. Remove head lamp. Draw in right-hand ??plat-
form?? harness and carry out wiring.
2. Install head lamp as before.
Clamp wire with clip.
106
56. CONNECTING AIR CHARGE LINE
1. Connect tube to hose from air compressor and
clamp hose with clips. Connect hose to hose
of right-hand platform side.
108 to 167 Nm {11.0 to 17.0 Kgm},
2. Connect synflex tube from air governor to

synflex tube of wet reservoir.
7 to 10 Nm {0.7 to 1.0 kgm},
108
109
57. AIR PIPING
1. Connect synflex tubes after making sure tube
their number.
Î Cut tube to suitable length.
value 4 Nm {0.4 kgm} for nominal diam-
eter 04
value 8 Nm {0.85 kgm} for nominal di-
ameter 06
7 to 14 Nm {0.70 to 1.4o kgm}, desired
value 10 Nm {1.05 kgm} for nominal di-
ameter 08 and 10
2. Remove cover from right-hand platform once.
3. After connection is completed, bundle tubes

with band etc.
110
Beside cabin
Behind right-hand platform
111
58. CONNECTING LEFT-HAND FRONT
BRAKE
1. Clamp and connect hoses of right-hand plat-
form one after the other.
½ Tightening29torque of hose:
to 69 Nm {3.0 to 7.0 kgm},
112
59. INSTALLING PARTS AROUND
HOOD
1. Replace hood as before.
2. Install guard and cover of air joint assembly

with attached bolts.
3. Seal gaps between cabin and hood and be-

tween cabin and radiator guard.
113
60. CHECKING FOR OIL AND COOLING
WATER
Î Check oil and cooling water according to Op-
eration and Maintenance Manual.
1. Fill cooling water to H level in radiator sub-tank.
2. Fill cooling water into radiator to water filler

port.
3. Check for oil level in all units by indication on

gauge.
4. Supply fuel up to required volume.
5. Start engine.
Î Do not raise engine speed abruptly. Other-
wise, floating seal oil of rear axle will drain
excessively.
6. Stop engine. Check for all units again.

Î Check for water level at sub-tank side. (un-
necessary for radiator side)
114
61. FILLING GAS INTO AIR
CONDITIONER
1. Fill gas after connecting gas charger of air con-
ditioner (at engine idling).
Î Gas: R 134a (6 cylinders of 20Y-979-3310)
2. Adjust gas in weight properly while observing

gas through sight glass on receiver.
Î Gas weight: Approx. 1.1 kg
115
62. BLEEDING AIR FROM BRAKE
Î Connect vinyl tube to air bleeding plug. Drain
oil from brake and discard oil.
Î First, bleed air from rear brake.
116
117
63. REMOVING PARTS FROM HOST
CYLINDER AFTER
TRANSPORTATION
1. Right-hand hoist cylinder:
Using lever block, support right-hand hoist
cylinder once removed when installing fuel
tank.
Left-hand hoist cylinder:
Remove brackets etc. and support left-hand
hoist cylinder in the same way of right-hand
hoist cylinder.
At this time, replace mounting bolts of hydrau-
lic tank and tighten new bolts.
490 to 608 Nm {50 to 62 kgm},
2. Place oil sump.
3. After making sure that dump lever in cabin lo-

cates at neutral position, uncap hydraulic tank
to release internal pressure.
4. Remove 4 blind parts on both sides.

Replace bolts and tighten new bolts.
Î Replace O-ring of loose-supply item with
new O-ring.
Use previous washers.
5. Cap hydraulic tank.

Î After removing blind parts, do not rise en-
gine speed until hydraulic tank is installed.
(Otherwise, cylinder will extend regardless
of lever operation.)
118
119
64. EQUIPPING MACHINE BODY
1. Insert 4 pins A of special sling for body into
holes from outer side of body.
Æ Body weight: 15 tons (standard)
Î Select flat ground for this work.
2. Hook chain of body sling at pins A with shack-

les.
Use two short chains out of 4 chains at front
left and front right of body.
3. After checking for balance, lift body.

Î Use rope etc. to prevent swing.
4. Move machine near body mounting portion.

Î Never access under lifted load.
5. By controlling crane, align mounting holes on

chassis with those on body.
6. Adjust shims to mount body in place and then

insert pins.
Î In this time, make sure that gap between
chassis and body does not exceed 25 mm.
(If gap exceeds 25 mm, re-adjust shim thick-
ness.
7. Carry out this work on both sides in the same

way.
8. Install lock bolt as shown in Fig. 2.

245 to 309 Nm {25 to 31.5 kgm},
9. Controlling crane and lever block, align upper

pin on hoist cylinder with pin hole on body and
insert pin.
Î If cylinder hole is located under hole on
body, operate lever through emergency
steering switch to lift cylinder.
10. Install lock bolt as shown in Fig. 3.

157 to 196 Nm {16.0 to 20.0 kgm},
11. Place stopper of approx. 50 mm to keep space

between body and chassis.
12. Remove lever block from both sides.
13. Lower crane and remove chains and pins.
14. Supply grease to lubrication points.
120
121
65. INSTALLING GREASE TUBES ON
HOIST CYLINDER
1. Carry out grease lubrication tubing as shown
in figure.
Î Insert tube firmly into bottom of upper
nipple.
2. Fill grease.
122
66. ADJUSTMENT OF BODY BOTTOM
MOUNT
1. Raise body and tighten left- and right-hand pads
on most front side of body.
Î When carrying out body bottom work, set
dump lever at neutral stop position in cabin.
Place square timber etc. as chock between
frame and body.
2. Lower body near frame once. Then, while low-

ering body gradually, check that pad seats uni-
formly on frame. If either side of pad seats later
than another, add shims to such side and ad-
just pads on both side can seat on frame at the
same time.
3. Measure space at 6 points between center of

pad mounting position and frame while hold-
ing frame at seating posture.
Î If gap is under 35 mm, increase same num-
ber of shims on both side of most front
portion in order to keep 35 mm.
4. Mount pads by using shims to thickness of

measurement minus 35 mm (pad thickness). If
necessary, use cut shims so that no gap occurs
between pad and frame.
5. After mounting all pads, check that no lateral

runout and no gap between pad and frame are
found.
124
125
67. ADJUSTMENT OF BODY
POSITIONER
1. Loosen two bolts A and remove cover B.
2. Operate dump lever to raise body (at position

1, UP).
Î Lock lever at body UP position and loose
your hold.
3. Adjust lever with nut C so that it is automati-

cally set to position 2, HOLD, 50 to 100 mm
before cylinder stroke end, i.e. position 1.
4. After adjustment, tighten lock nut C firmly.

8 to 15 Nm {0.9 to 1.5 kgm}
In this case, plate to be free from skew
during installation.
5. Mount cover B with bolts A.
6. Check following items.

(1) Positions 1, 2, 3, and 4 can function
properly.
(2) Position 2 can hold or stop body at any
position.
(3) Lever is automatically set to position 2
when lever is loosened from HOLD at posi-
tion 1. (EC regulation)
(4) Safety stop works correctly without inter-
ference.
(5) Lever is automatically set to position 3
when lever is loosened from EC HI-IDLE at
position 4.
(6) ”Pressure adjustment” can be carried out
at position 4.
126
68. WELDING BY DETERMINING
DIMENSIONS WITH ACTUAL PARTS
(BODY FRONT MOUNT)
1. Mount bracket on upper face of rear support.
Adjust bracket to locate at center of mount of
body.
Î Before welding, protect overall machine
body with refractory cloth etc.
2. Raise body and weld bracket permanently.
3. After welding, set pad and shims and tighten

bolts. Make tightening force uniform with
shims.
Î If force is not uniform, then cut shims.
4. Check for gap between pads and body.

Î If gap is found, re-adjust gap with shims
5. Install cable clamp onto right-hand mount por-

tion with bolts attached around mount.
128
129
(SWING PREVENTION OF BODY)
1. Paste shims of 1 mm onto bracket. Align shims
with center of contact face of frame and adjust
bracket to contact to both of body and frame.
2. Tack-weld them.
3. Raise body and remove shims and then weld

bracket permanently.
130
(EXHAUST FLANGE)
1. Tighten lock nut at position matching dimen-
sion A (221 mm) shown in figure.
2. Place 3 spacers, 20 mm, ATH-465-027, between

tube and nut.
3. Insert plate into flange and mount plate and

tube in exhaust inlet on body.
4. Fix plate and tube with C clamp at center of

exhaust tube flange.
Î Runout of center to be within 3 mm.
5. Lift plate toward body side and tack-weld plate

and tube.
6. Lift body and weld plate and tube permanently.
7. Remove spacers.
131
71. INSTALLING BODY SEATING
SWITCH
1. Install bracket assembly on body side to match
dimension (99.5 mm) shown in figure.
2. Check that switch can move down 3 to 4 mm.
3. If switch does not move down 3 to 4 mm, keep

specified switch depth by adjusting mounting
bracket or spring force.
132
72. INSTALLING BODY ACCESSORIES
1. Install mud guard and roke ejector.
133
73. PAINTING
1. Coat weld zones with coatings listed below.
Î Wear mask, goggles, and gloves for pro-
tection from spray
2. Use coating mixed base and hardner at speci-

fied rate (5:1).
3. In addition to body, apply coating to area de-

fected when assembling.
Î In addition to body, repair defective coat-
ing when assembling.
Primer coating
 Urethane GP Primer
 Urethane GP Hardener
 Urethane GP Thinner
Top coating
 NAX Mightyracq GIIKB type natural yellow
 NAX Mightyracq GIIKB type hardener
 NAX Mightyracq GIIKB type thinner
Exhaust pipe
Heat resistance silver
134
135
74. BODY STOPPER PINS
1. Stow body stopper pins into axle housing.
136
75. ADJUSTMENT OF SUSPENSION
Nitrogen gas filler valve
Air bleeder valve
Air bleeder
Nitrogen gas cylinder Location of air bleeder valve

of front suspension
Suspension gas filler unit (7826-10-1000)
Adjustment value
250 ± 10 mm
Reference
When cylinder is fully
retracted: 108 ± 1 mm
When charged with
oil of specified quantity:
175 ± 3 mm
When truck is empty:
250 ± 10 mm
Front When cylinder is fully
Rear extracted: 302 ± 1 mm
1. Loosen the air bleeder valves of the right and left front suspensions to bleed all air.
(Check that air does not come out any more (only oil flows out), and then tighten the valves again.
(Tightening torque: 39 – 49 Nm {4 – 5 kgm}))
2. Check that the valves are closed and install the suspension gas filler unit to the suspension cylinders.
3. Connect the hoses of the suspension gas filler unit to the nitrogen gas filler valves. (Since there are
2 hoses, connect them to the right and left suspension cylinders so that pressure will be applied to
both cylinders evenly.)
4. Open the valve of the suspension gas filler unit gradually.
5. When the suspension cylinders rise to the specified level shown above, close the valve.
(Supply the gas to the front side according to the decal and to the rear side so that the dimensions in
the figure will be obtained.)
6. Remove the hoses from the nitrogen gas filler valves and move the chassis forward and in reverse to
fit the suspension cylinders, and then stop without applying the brake. (Finally, stop the truck without
applying the brake to prevent an uneven load caused by braking.)
7. Apply the parking brake and check the length of the suspension cylinders.
8. If the length of the suspension cylinders is out of the standard range, repeat steps 3 – 7. (Usually,
adjustment is completed by repeating those steps 3 – 4 times.)
Precautions Necessary tools Necessary equipment
1. Bleed air from the cylinders. Name Q'ty Name Q'ty
2. Fill both suspension cylinders simultaneously. Suspension gas filler unit 1
3. Do not extract the suspension cylinders to the stroke (7926-10-1000)
end.
4. After moving the truck forward and in reverse, stop
it without applying the brake.
5. Do not steer the truck before finishing this adjust- Other remarks
ment. (If it is steered, the piping may be broken.)
137
76. SMOOTHING OF FLOATING SEAL
1. Before traveling
Î Travel completed machine to make float-
ing seal smooth inside rear axle.
2. Traveling
Conditions
Shift Traveling distance (approximately)
F1 500 m
F2 500 m
F3 1000 m
F4 1000 m
F5 1000 m
F6 1500 m
F7 1500 m
Travel not less than total 7000 m.
3. Checking
After traveling, check visually that amount of
drain oil is very small.
(Standard: not more than 30 cc per 7 km)
138
PROCEDURE FOR WELDING AND ASSEMBLING THREE
SEPARATED BODY PARTS
CONTENTS
Preparatory work for assembling three separated body parts ................................................................. 140
Welding process for three separated body parts ....................................................................................... 144
Welding of the body assembly .................................................................................................................... 152
Work procedures for turning over the body ............................................................................................... 154
139
PREPARATORY WORK FOR ASSEMBLING THREE SEPARATED
BODY PARTS
Process drawing
Welding machine Genetator CO2 welding machine
Lowering separated body
140
Order of work Work procedure
1. Select the place for welding work. • The total of floor or ground area moust be at
least 169 m2 (13 m x 13 mm).
2. Prepare the welding machine, ganerator, and
tools. • The flatness of the floor or ground must be
less than 0.05 m over 10 m.
3. Unload the body. (Unload in the specified
condition.) • Set the separated body on suitable wooden
blocks.
4. Remove the protector stored in the body.
• If there is a plate holding the protector, re-
move it with a gass cutter.
5. Place to remove primer and paint. • A range of 15 mm along the whole line for
the body mating portion.
• Burn off with a gas heater, or grind off the

primer and paint with a grinder.
6. Turn over the separated body.
7. Set supports on the ground where the sepa-

rated body is to be assembled as shown in
the deagram below.
141
Process drawing
142
1. Set one part of the separated body on the

support stand.
2. Set the opposite side of the separated body • If the two pieces do not match properly, use a
on the suopprt stand so that the clearance is hydraulic cylinder to adjust them.
constant.
• After tack welding, remove the bolt, washer,
3. Use brackets 568-74-11610 (front) and 561- nut, and tube.
83-69430 (bottom), and join the set pieces of
the body with the following parts.
 01011-52000 Bolt 
 
 01643-32060 Washer 
 01580-12016 Nut 
 
 581-74-11630 Tube 
4. Pass the alignment pin through the bottom • If the separated parts do not match properly,
hinge brackets (561-74-61183, 561-74-61193), correct with a hydraulic cylinder.
check the height and position, then remove
the pin.
5. Tack weld the body.
6. Position the brakets (561-74-68111), then tack

weld.
• When correcting, check that the tighening

bolts are loosened.
143
WELDING PROCESS FOR THREE SEPARATED BODY PARTS
Process drawing
144
1. Weld the front (X portion). • Use arc welding for the front with vertical
(Large sheet connection portion and chan- welding.
nel connection poortion) (Follow the vertical welding conditions in
Table 1.)
2. Next, position one plate each (561-83-69440, • Weld the inside of the channel also.
561-83-69450, 561-83-69471) on the channel,
and weld in position. • Insert backup material in the joints between
channel and channel.(Only joint of bottom
plates)
(For backup material, use SS41B 9.)
3. Set the cottom (Y portion) horizontal and • Insert a support under bottom rear.
weld.
(Large sheet connection portion, channel
connection portion and two brackets 561-86-
6H110).
4. Use gas to make a hole in the position shown

in below in one of the five plates 561-83-
69462.
• Perform backstep weldign for bead joint and

start of the arc.
5. Next, position 5 plates (561-83-69462), 2

plates (561-83-69521), and 1 plate (561-74-
62B70) on the channel, and weld in position.
(Note: The one plate of the five plates 561-
83-69462 that has a hole made by gas is
welded to the 7th rib from the front on the
bottom.)
6. Next, position 1 plate (561-83-69411), 1 plate

(561-83-69481), and 1 tube (561-74-62B20)
(12), and weld in position.
7. When the welding is finished, remove the

spatter with a grinder and finish the bead.
145
Process drawing
146
Process drawing
147
Process drawing
148
8. Check for any welding defects.

(1) Depositive metal check
(2) Undercuts, overlaps, adhesion of spat-
ter
(3) Lack of welding leg (Minus leg length is
rejectde)
9. Turn over • Turn over the body according to the attached

Prepare to turn the body over. work procedures.
Carry out reversing work by using sling holes

on both sides.
Reversing work procedures
(Turning procedure)
10. After turning over the body, arc-weld the • Carry out arc welding at vertical position. (For
joints of the front part in a vertical position. welding conditions see Chart 1.)
(Apply the welding condition in Table 1.) • Place timber under front and back portions
of bottom.
11. Weld the mating portion of the bottom. • Connect ground for welding securely with
main body.
Table 1. Welding conditions • Normally use CO2 gas shield welding. If CO2
gas shield welding is difficult, arc welding
Method CO2 gas chield
may be used.
Arc welding Remarks • Drying time for arc welding electrode
welding
(1) Temperature: 150 to 200°C
Welding Flat position (F) Flat position (1) Do not use (2) Time: 120 minutes
posture vertical position (V) CO2 gas
welding if
the wind
Welding rod d1.2, d1.6 d5.0,d 4.0 speed is
JIS Z3312 YGW11 JIS Z3212 D5016  more than 2
or equivalent or equivalent  – 3 m/sec.
Welding 320 – 350 A 220 – 260 A (2) Remove all
current 380 – 420 A 130 – 160 A moisture,
dirt, and
Preheating, Unnecessary Unnecessary paint from
postheating the locations
to be
Gasshield CO2 25 – 35 l/ — welded.
amount min.
12. Finish
Use a grinder to remove the spatter and
finich the head.
149
Process drawing
150
13. Welding the protector • Area of the floor or ground must be at least
(1) Place the protector on the top of the side plate 126m2 (9m x 14m).
and front plate with a crane.
Weight of protector : Approx. 1,585 kg • Level difference of the floor or ground must
Crane : Must have capacity of 2 tons and lift be 0.05m maximum in 10m.
of 7m or higher.
Wire rope, chain, • Place wood blocks around the bottom plate
chain block : Must have breaking strength so that both side plates will be almost paral-
of 2.1 tons or higher. lel with each other.
(2) Position the protector side plate in parallel • If the protector is secured with any plate, cut
with end of the body side plate. it with gas.
(3) When positioning, gas-cut the front and side • Remove by heating with gas or cut with a
of the protector so that the top of the body grinder.
side plate will be parallel with the top of the
protector.
Note : The protector and front plate are de-

formed by welding as shown below.
Accordingly, the front and side plates
of the protector must be cut with gas
to minimize the gap that may be made
by welding. (Gap must be 3mm max-
imum.)
(4) After positioning, secure the front of the pro-

tector by tack-welding.
• When welding the side plate of the protector,

hang with a crane so that the front of the pro-
(5) Weld the protector. tector will be raised about 1° (Check visually)
Welding order : Weld side plates (on after welded as shown above.
both sides) first.
Welding symbol : Shown at right.
Welding condition : Shown in Table 1.
151
WELDING OF THE BODY ASSEMBLY
Process drawing
152
1. Install the body to the frame, set in the dump-

ing position, and adjust.
(When installing, see the assembly
pocedure.)
2. Adjust the dimension between the body and

frame with shims beforehand.
3. Welding of front body mount (561-46-61861, • Move the body to the dump position while
61871 brakets) doing this.
• Set the brackets (561-46-61861, 61871) on
top of the frame, and weld so that the
clearance from the body brackets (561-
83-61563, 61573 ) is 57 mm.
4. Welding of stopper bracket (561-74-6A810) • Reduce misalignment of exhaust flange to 3

• Weld so that the clearance between the mm or less.
body and frame is 1 – 2 mm.
5. Welding of exhaust (flange 561-02-61150,

plate 582-02-11230)
• Insert the plate (562-02-11230) into the
tube assembly (561-02-61150), then set
on the body exhaust inlet port.
• Align the center at the flange mating sur-
face, then weld the tube and plate to the
body.
153
WORK PROCEDURES FOR TURNING OVER THE BODY
1.
2.
3.
4.
154
Work procedure Points of work Remarks
1. Prepare a 50-ton crane and a Weight of body

25-ton crane. STD 15,510 kg
2. Insert hanging pins 1 in the Other options :

body from inside (All four Side extension (300mm) 1,100 kg
pins). Steel liner 6,000 kg
3. Install 2-piece chains 3 to Bring the crane trucks as near to the body
pins 1 with shackles 2 (Four as possible.
places on both sides).
4. Wind both 50-ton and 25-ton Take care of the center of gravity.
cranes simultaneously.
5. Wind the 50-ton crane and Only one man shall make signs clearly.
unwind the 25-ton crane to
place the body on its side.
6. Remove the sling from the 25-

ton crane, but keep the sling
of the 50-ton crane installed.
7. Move the 25-ton crane to the

opposite side.
8. Install the sling to the 25-ton

crane.
9. Wind the 25-ton crane and

unwind the 50-ton crane.
10. When the body becomes hori-

zontal, unwind both cranes to
lower the body to the ground,
then remove the slings.
155
2900 mm transportation posture (If equipped)
CONTENTS
1. Necessary tools and equipment .................................................................................................... 157
2. Field assembly procedure

A-1 Removed components list ............................................................................................. 161
A-2 Installation and connection of fuel filter ......................................................................... 162
A-3 Installation and connection of bypass filter ................................................................... 163
A-4 Installation of hydraulic tank .......................................................................................... 164
A-5 Connection of piping around hydraulic tank .................................................................. 165
A-6 Installation of hydraulic tank and connection of piping (1)............................................. 166
A-7 Installation of hydraulic tank and connection of piping (2)............................................. 167
A-8 Assembly of radiator guard ........................................................................................... 168
A-9 Installation of front stay ................................................................................................. 169
A-10 Installation of right hoist cylinder ................................................................................... 170
A-11 Installation of right combination lamp ............................................................................ 171
3. Field welding work on frame divided for transportation

Welding procedure
Preparation for welding .................................................................................................................. 172
Temporary assembly process of vertical (1) .................................................................................. 174
Welding process of vertical (1) ....................................................................................................... 176
Temporary assembly process of vertical (2) .................................................................................. 178
Welding process of vertical (2) ....................................................................................................... 180
Temporary assembly process of bumper ....................................................................................... 182
Welding process of bumper ........................................................................................................... 184
157
2900 mm transportation posture
Necessary tools and equipment
1) Necessary tools
No. Tool name Specification Q'ty Remarks
1 Ring wrench 14/17/19/24/30/36 1 each
2 Impact wrench GT-S12M or equivalent 1
3 Impact wrench GT-S22M or equivalent 1
4 Impact wrench RSP220Nx22 or equivalent 1
5 Impact wrench RSP310Nx24 or equivalent 1
6 Impact wrench GTP-800P or equivalent 1
7 Socket 36 (Insertion angle: 25.4)/46 mm 1
8 Socket 14/17/19/22/24/30 1 each
9 Spanner 14/17/19/24/30/36 1 each
10 Torque wrench For measurement of 28 Nm {2.9 kgm} 1
11 Torque wrench For measurement of 94 Nm {9.6 kgm} 1
12
13
14
15
16
17
18
19
2) Necessary equipment
No. Equipment name Specification Q'ty Remarks

1 Mobile crane Min. 441 kN {45 ton} 1 For raising front side
2 Mobile crane Min. 245 kN {25 ton} 1 For raising rear side
3 Compressor Min. capacity of 32 l 1 For impact wrench
4 Stepladder (Work stand) 4 steps (About 1.5 m) 1 For work
5 Wood block 350 × 350 × 350 4 For positioning workpiece
6
7
8
9
For the other tools and equipment, see the standard model.
159
3) Necessary slings
No. Sling name Specification Q'ty Remarks
1 Nylon sling For 147 kN {15 ton} × L4000 4
2
3
1 : Nylon sling
4,000
Using load:
Min. 147 kN {15 ton}
160
Assembly process No. Removed components list
A-1
The components of this specification are removed as shown below.

Components in boxes are the same as
those of the standard model.
Bare machine H/T F/T
R-A/X Radiator guard
F-A/X(Right and left)

CAB Right platform
Right bumper
Hood
Body Stay 1
Stay 2 Filter tube Fuel filter Bypass filter
Tail lamp Hoist cylinder (Right) Block Bracket 1 Bracket 2
161
Assembly process No. Installation and connection of fuel filter
A-2
1. Install the fuel filter and connect the piping.
Hose numbers
FWD
View Z
When connecting the hoses, check their Nos. Name Q'ty Name Q'ty
• Spanner (24 mm) 1
Other remarks
162
Assembly process No. Installation and connection of bypass filter
A-3
1. Install the bypass filter and connect the piping.
Z
Using bolts installed to
frame temporarily, install
bypass filter.
Y
View Z
Matching the Nos., connect

View Y the hoses.

Other remarks
163
Assembly process No. Installation of hydraulic tank
A-4
1. Install the hydraulic tank.
Use bolts installed to

Hydraulic tank frame temporarily.
assembly
798 kg

Name Q'ty Name Q'ty
Crane 1
Other remarks
164
Assembly process No. Connection of piping around hydraulic tank
A-5
a Nos. in this page correspond to the

item Nos. in the following pages.
Connect wiring
harnesses.
165
Assembly process No. Installation of hydraulic tank and connection of piping (1)
A-6
Installation of hydraulic tank and connection of piping

1. Connect rear brake oil line. 2. Connection of steering valve line
3. Connection of oil cooler line 4. Connection of high-pressure filter and transmis-

sion filter line
5. Hoist line 6. Hoist line and brake cooling
brake cooling
a The circled Nos. are the Nos. printed on the hoses.

Other remarks
166
Assembly process No. Installation of hydraulic tank and connection of piping (2)
A-7
7. Hoist suction line and brake cooling line 9. Assembly of transmission filler tube
Fix piping as shown in photo.

8. Brake cooling valve line
10. Cable
a The circled Nos. are the Nos.

printed on the hoses.

Other remarks
167
Assembly process No. Assembly of radiator guard
A-8
1. Install radiator guard
Bolt tightened to
frame temporarily
Main Frame

Name Q'ty Name Q'ty
Other remarks
168
Assembly process No. Installation of front stay
A-9
1. Assembly of front stay
Tightened to support
temporarily
• Insert shims to eliminate the clearance between

the support and stay.
• Insert the shims evenly to the right and left sides.
Part No. Part name Q’ty Condition of part

(1) 561-54-6133A Stay assy 1 Single part
(2) 561-54-61160 Shim 8 Single part
(3) 561-54-61170 Shim 8 Single part

Name Q'ty Name Q'ty
Other remarks
169
Assembly process No. Installation of right hoist cylinder
A-10
1. Installation of hoist cylinder
• Install the hoist cylinder and fix it with the jig.
• Connect the hoist piping.
Hoist Sylinder
Thick
Thin
Fix cylinder with

Fix cylinder with lock plate bracket attached
installed temporarily. to hoist cylinder.

(1) 561-63-62103 Cylinder assy 1 Single part
(2) 561-61-63510 Block assy 1 Single part
(3) 01024-81085 Bolt 4 Single part
(4) 07000-F3035 O-ring 1 Single part

Name Q'ty Name Q'ty
Other remarks
170
Assembly process No. Installation of right combination lamp
A-11
1. Installation of rear
combination lamp
X
• Install the rear
combination lamp.
• Connect each wire.
56 Connection
Connection
565-06-12280
57
Connection
67 Connection
DB1
Payload meter
Z Connection L.H
63
62
Backup alarm 08036-01414 CN 62

56
57 Backup lamp CN 60
DB1 Seating
switch
59 Tail lamp
CN 59
59 Connection
60 Tail lamp
60 08193-01512 CN 63
Connection
67 Ground
R.H
561-06-63730
62 Payload meter 63 Connection 01643-31032 View Z
01010-81016

(1) 561-06-X1180 Tail lamp assy 1 Single part
(2) 01010-81420 Bolt 4 Fixed to frame temporarily
(3) 01643-31445 Washer 4 Fixed to frame temporarily
Name Q'ty Name Q'ty
Other remarks
171
Preparation for welding
Process drawing
(Welding machine) (Generator) (CO2 welding machine)
172
1. Select a place for welding work. a The area of the work floor or ground must be at
least 144 m² (12 m × 12 m).
2. Position the welding machine, generator, and (HD785-5 frame measurements 3.3 m × 8 m)
tools. a The gradient of the work floor or ground must
not exceed 0.05 m in 10 m.
3. Unload the frame.
At this time, place the supports on the ground
as shown below (4 places).
a This drawing shows only the main frame.
4. Removal of primer and paint

Burn the primer and paint on the area about 15
mm around the welding lines with a gas burner
or cut them off with a grinder.
173
Temporary assembly process of vertical (1)
Process drawing
(However,1 piece of 561-40-61541 PIN,

2 pieces of 569-52-11130 PIN,
1 piece of 01010-81425 PIN,
1 piece of 569-40-61710 PIN
have been installed.)
174
1. Sling 561-46-61581 (right bracket) and set it to

the frame installing position.
2. Match the temporary mounting plates (3 a Take care that the weight of the bracket will not
places) installed to 561-46-61581 (right be applied to the temporary mounting plate.
bracket) and 561-46-61106 (frame), and fix
them temporarily with 01010-81260 (bolts),
01580-11210 (nuts), and 01643-31232 (wash-
ers).
a Check the pitch of the A-frame mounting part of
3. Matching to the scribed (punched) lines on the the vertical (Fig. 2).
front, rear, and top of the bracket and frame,
tighten the bolts securely (Fig. 1).
a Insulate the crane hook.
4. Install the bracket and frame temporarily a Install temporarily so that the bracket will not
move by its weight when the sling is removed.
a Before starting welding, cover the engine

exhaust pipe and air intake pipe with heat-resis-
tant cloths, etc. (to prevent dirt, spatters, etc.
from entering).
175
Welding process of vertical (1)
Process drawing
(Note) Take care that spatters will not stick to the pin which is installed in advance. If
the patters may stick to the pin, remove the pin. In this case, the spatters must
not stock to the inside wall of the bracket boss. If spatters stick, remove them
with an inside grinder (hub).
176
1. Weld the frame and bracket. Do not weld the a Apply arc welding in vertical position to the front
front and rear of the temporary mounting plate, and rear parts of the bracket.
however. Apply arc welding in overhead position to lower
part of the bracket.
2. After finishing welding, remove the temporary (Observe the welding condition in Table 1.)
mounting plate. a When connecting a welding bead, check that
there is not an overlap. If there is an overlap,
3. Weld the mounting part of the temporary remove the bead from the toe of weld by goug-
mounting plate. ing or with a grinder.
4. After finishing welding, remove spatters and fin-

ish the beads with a grinder. Finish the bead of
part P flatly, in particular.
(Finish the mounting part of the temporary
mounting similarly.)
5. Check the welded parts for a welding defect.

(1) Check the deposited metal (appearance of a Connect the ground cable as near to the
the bead). welded part as possible.
(2) Check for an undercut, overlap, and spatter. a When connecting a bead and when starting
(3) Check the welding leg length for insuffi- welding, apply return welding.
ciency (Leg length less than the specified
value is not permitted).
Table 1 Welding condition

CO2 gas-shielded welding Arc welding
Welding position Flat Flat Vertical/Overhead(1) When wind
velocity is 2 – 3
JIS Z3312 YGW11 or JIS Z3312 D5016 or JIS Z3312 D5016 or
Welding rod m/sec, do not
equivalent equivalent equivalent
apply CO2 gas
Wire/Rod diameter welding.
ø1.2 ø1.6 ø4.0 ø5.0 ø4.0 ø5.0
(mm) (2) Remove mois-
ture, dust, and
Welding current (A) 200 – 350 300 – 500 150 – 190 190 – 240 110 – 150 130 – 170
paint from the
Preheating/ Unneces- Unneces- Unneces- Unneces- Unneces- Unneces- surface to be
Post-heating sary sary sary sary sary sary welded.
Seal guard CO2 --- --- --- --- ---
Gas shielding rate
25 – 35 --- --- --- --- ---
(l/min)
1) Apply CO2 gas welding as standard. If it is diffi-

cult to apply CO2 gas welding, however, apply
arc welding.
2) Drying condition of arc welding rod: (1) Temper-
ature: 300 – 350 °C, (2) Time: 60 minutes
177
Temporary assembly process of vertical (2)
Process drawing
178
1. Set 561-46-62741 bracket to the frame mount-

ing part.
2. Set the bracket so that there will not be clear- a There must not be spatters on the positioning
ance in the positioning plates which have been plate and bracket contact face.
installed (3 places). Install it along the frame in
the longitudinal direction and check the parallel-
ism with the right bracket (561-46-62731) and
check the pitch of the tap holes. Adjust, if nec-
essary.
3. Install the bracket and frame by tack welding. a Prevent floating of the workpiece caused by
tack welding.
4. Remove the positioning plates.
179
Welding process of vertical (2)
Process drawing
180
1. Weld the frame and bracket. a Apply arc welding in vertical position to the
sides of the bracket.
2. After finishing welding, remove spatters and fin- a Apply arc welding in overhead position to lower
ish the beads with a grinder. part of the bracket.
(Observe the welding condition in Table 1 in
3. Check the welded parts for a welding defect. page 155.)
(1) Check the deposited metal (appearance of
the bead).
(2) Check for an undercut, overlap, and spatter. a Take care that spatters will not enter the tap
(3) Check the welding leg length for insuffi- holes of the bracket (20 × 2.5, 6 places). If any
ciency (Leg length less than the specified spatter enters a tap hole, chip it or cut the screw
value is not permitted). with the tap again.
a For other precautions for welding, see "Welding

process of vertical (1)".
181
Temporary assembly process of bumper
Process drawing
182
1. Sling 561-46-61211 (bumper: removed part)

and set it to the frame installing position.
2. Match the temporary mounting plates (3 a Take care that the weight of the bumper will not
places) installed to 561-46-61581 (bumper) and be applied to the temporary mounting plate.
561-46-61106 (frame), and fix them temporarily a Place a stand under the bumper.
with 01010-81260 (bolts), 01580-11210 (nuts),
and 01643-31232 (washers).
3. Matching to the scribed (punched) lines on the

front, rear, and top of the bumper and frame,
tighten the bolts securely (Fig. 1).
4. Checking the pitch of the tap holes of 561-46- a Insulate the crane hook.
62720 plates (right and left) at the top of the a Install temporarily so that the bumper will not
bumper, install the plates by tack welding. (Fig. move by its weight when the crane hook is
2) removed.
183
Welding process of bumper
Process drawing
184
1. Weld the frame and bumper. Do not weld the a Apply arc welding in vertical position to the front
front and area of the temporarily mounting and rear of the bumper.
plates, however. a Apply arc welding in overhead position to lower
part of the bumper.
2. After finishing welding, remove the temporarily (Observe the welding condition in Table 1 in
mounting plates. page 155.)
3. Weld the mounting part of the mounting plate.
4. After finishing welding, remove spatters and fin- a Take care that spatters will not enter the tap
ish the beads with a grinder. In particular, finish holes of 561-46-62720 plate (20 × 2.5, 6
the joints of the beads and ribs smoothly on the places).
front side of the bumper. If any spatter enters a tap hole, chip it or cut the
screw with the tap again.
a For other precautions for welding, see "Welding

process of vertical (1)".
5. Check the welded parts for a welding defect.

(1) Check the deposited metal (appearance of
the bead).
(2) Check for an undercut, overlap, and spatter.
(3) Check the welding leg length for insuffi-
ciency (Leg length less than the specified
value is not permitted).
185
1/8
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
HD785-5 SA12V140-1
Service Meter Reading Date of Inspection

Attachment
1 2
Location of Machine at Inspection Manufacture
Model
Distributor’s Name
Serial No.
Customer’s Name Address: Signature: Delivery

Report
No. attached
Date:
Inspector’s Comments:
Inspector’s Name: KOMATSU USE ONLY :
C. Sheet Receiving Date:

Title
By :
Signature: Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgement

!..... Normal ..... Correction made on abnormal point
..... Abnormal ..... Not applied
2. Enter actually measured values in parenthese, [ ].
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY
FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE RE-
PORT.
Printed in Japan
2/8
No. Mainte-
Inspection item Judgment procedure and standards Check nance Remarks
Check electronic devices in operator’s cab.
Write down part No. and serial No. of controller.

Part No. ( ), Serial No. ( )
1 Engine controller No.
Write down version No. of software.
Version of software of engine controller: ( )( )( )
( )
Write down part No. and serial No. of controller.
Part No. ( ), Serial No. ( )
2 Transmission controller No.
Write down version No. of software.
Version of software of transmission controller: ( )( )
( )( )
Fuses in rear box of operator’s cab must be free from loose-
3 Installation of fuse terminals
ness. (Check by touching with hand.)
Relays in rear box of operator’s cab must be free from loose-

4 Installation of relays
ness. (Check by touching with hand.)
Connectors of PMC6 (for S-NET monitor) and PMCD (for
Installation of PMC6 and PMCD
5 power supply to off-board PMC) must be so installed that
connectors
operator can handle them.
Check oil and water levels.
Level must be between (H) and (H - 10 mm).

Engine oil level
6 Check with engine stopped.
(Marking: ENGINE STOPPED) Any water and fuel must not be mixed in oil. (Filler cap
must be free from water drop.)
7 Hydraulic oil level Level must be within inspection window range.
Level must be between (H) and (center between H and L).

8 Transmission oil level
* Check with engine at low idling.
9 Front brake oil level Level must be between Full and Low.
Level must be at center between Full and Low or higher.

Oil or fuel must not be mixed in coolant.
10 Coolant level
Oil or fuel must not be mixed in coolant.
Turn switch ON.
Sound must be proper in volume and must not have beat

11 Function of horn noise. (Sensory check)
Sound must be proper in volume and must not have beat

12 Function of back buzzer noise. (Sensory check)
When wiper switch is turned to [LO] or [HI], wiper must op-

erate. (Wiping speed must change between LO and HI.)
When wiper switch is turned to [INT], wiper must operate

intermittently.
Wiping range must be proper. (Wiper must not project from

13 Function of windshield wiper glass.)
When wiper switch is turned to [OFF], wiper must stop at
stopping position automatically. (Wiper must stop at proper
position.)
When windshield washer switch is turned to [ON], washing
fluid must be splashed over glass and wiper must operate.
(Washing fluid must be splashed over proper position.)
Engine must not start when transmission lever is set to any
position other than N position. At this time, transmission
14 Safety function (1) mechatronic caution lamp must flash, centralized warning
lamp must light up, and centralized alarm buzzer must sound.
* User code and error code must not be displayed.
3/8
No. Mainte-
When parking lever is set to ON and transmission lever is set to any
15 Safety function (2) position other than N position, centralize warning lamp must light up
and centralized alarm buzzer must sound.
16 Starting of engine Engine must start smoothly.
17 Abnormal noise from engine No abnormal noise must be generated. (Sensory check)
When dump lever is set to any position other than FLOAT

and transmission lever is set to any position other than N
18 Safety function (3) position, centralized warning lamp must light up and cen-
tralized alarm buzzer must sound.
* Check with engine started and parking brake turned off.
When dump lever is set to any position other than FLOAT
and transmission lever is set to any position of D to L, gear
19 Safety function (4) can be shifted but cannot be shifted in R.
When body is not seated and transmission lever is shifted

to D – L,“ only 2nd speed must be selected at D and only 1st
20 Safety function (5) speed must be selected at 5 to L”.
When light switch is turned ON (1st, 2nd stage), front right
21 Function of clearance lamp and left clearance lamps and rear right, center, and left clear-
ance lamps (3 lamps) must light up.
When light switch is turned ON (2nd stage), 2 headlamps
22 Check of headlamps (right and left) must light up.
When dimmer switch is operated with headlamps ON, lamps
Check of high beam (Function
23 of dimmer switch) must change (2 lamps ↔ 4 lamps). (Irradiating direction
must change.)
When turn signal lever is operated, front and rear turn sig-
24 Function of turn signal lamps nal lamps must flash on correct side.
When hazard lamp switch is turned to ON, right and left

turn signal lamps and pilot (arrow) lamp inside operator’s
25 Function of hazard lamp cab must flash. In this case, if key switch is turned to OFF,
pilot lamp must not flash.
26 Function of back-up lamps
When brake pedal is depressed, 3 red rear brake lamps

27 (right, center, and left) must light up.
Function of brake lamps
When retarder lever is pulled, 2 red rear brake lamps (right
28 and left) must light up. Center lamp must not light up at
this time.
When emergency (or automatic) steering system operates,
Check of emergency steering
29 pilot lamp emergency stop pilot lamp must light up and centralized
warning lamp must flash.
30 Function of room lamp When switch is ON, lamp must light up.
Check of function of air pres- As air pressure rises while engine is running, bar meter must
31 sure bar gauge move toward High side.
Check of function of air gover- When air charge is performed, bar meter must stop at 2nd
32 nor or 3rd level from top (814 ± 29 kPa {8.3 ± 0.3 kg/cm2}).
Function of engine cooling As cooling water temperature rises while engine is running,
33 water temperature gauge bar meter must move toward High side.
Function of torque converter As oil temperature rises while engine is running, bar meter
34 oil temperature gauge must move toward High side.
Function of brake oil temperature
When brake oil temperature rises because of operation of
35 gauge of retarder, bar meter must retarder, bar meter must move toward High side.
move toward High side.
When dump lever is set to any position other than FLOAT or body is
Check of function of body op-
36 eration caution lamp not seated, This lamp must light up. * Centralized warning lamp
must not light up and centralized alarm buzzer must not sound.
4/8
No. Mainte-
When stroke sensor is projected, this lamp must light up. At this time, cen-
Check of function of rear brake
37 stroke end caution lamp tralized warning lamp must light up and centralized alarm buzzer must sound
and user code“ E-04” and error code“ b0-F6” must be displayed.
Low idling speed, Measured value: ( / ) rpm
Standard value: 1000 ± 30 rpm (LiH), 650 ± 25 rpm (LiL)
Engine speed High idling speed, Measured value: ( / ) rpm

• Standard value of HD785: 2350 ± 50 rpm (Power), 2300 ± 50
* Engine coolant temperature: rpm (Economy)
In green range
Engine oil temperature: 70 – • Standard value of HD985: 2450 ± 50 rpm (Power), 2300 ± 50
38 *
80°C rpm (Economy)
* Torque converter oil tem- Torque converter stall speed, Measured value: ( /
perature: 70 – 80°C
) rpm
* Check in service mode. • Standard value of H785: 2040 ± 100 rpm (Power), 1950 ±
100 rpm (Economy)
• Standard value of H985: 2067 ± 100 rpm (Power), 1950 ±
100 rpm (Economy)
Engine acceleration time (LiL →
39 Hi), in power mode Standard value: Max. 3.5 sec, Measured value: ( ) sec
Engine acceleration time (LiL →

40 Stall), in power mode Standard value: Max. 5.4 sec, Measured value: ( ) sec
When AISS switch is turned ON, low idling speed of engine must
be set to LiL (650 rpm).
* Regardless of engine water temperature and operation of brake.
While AISS switch is turned OFF, if engine water tempera-
ture is below 50°C, low idling speed of engine must be kept
at LiH (1000 rpm).
41 Function of AISS
While AISS switch is turned OFF, if engine water tempera-
ture is above 50°C, low idling speed of engine must be kept
at LiL (650 rpm). If parking brake and retarder brake are
both turned OFF at this time, low idling speed of engine
must be set to LiH (1000 rpm).
When truck is steered to end, engine must not stop at low
42 Low idling regulation idling speed. Engine oil pressure caution lamp must not
light up.
Exhaust gas color must be proper during sharp acceleration
43 Exhaust gas color (Li → Hi). Sensory check.
(Standard value: 6 bosch or less)
Exhaust gas must not leak from exhaust pipe joint, exhaust
44 Exhaust gas leakage shutter, etc.
When engine emergency stop switch at rear of console box
Function of engine emergency
45 stop switch is turned ON, engine must stop.
* Check after operating engine for at least 15 minutes.
Drive and check truck.
Abnormal noise from transmis-

46 sion No abnormal noise must be generated. (Sensory check)
Abnormal noise from differen-

47 tial No abnormal noise must be generated. (Sensory check)
When shift limiter switch is turned ON, transmission lever

48 Function of shift limiter must not shift to“ F7” in D-range and to“ F2” in L-range.
When shift lever is set to D with brake turned ON (rear brake
49 Braking mode function pilot lamp turned ON), gear speed must not change from
F2.
When engine speed is set to high idling in N-range, truck
50 Dragging of power train must not start.
While truck is traveling, steering wheel must not turn by

51 Straight travel of truck itself.
After truck travels inside yard, check by touching with hand

52 Heating of parking brake that parking brake is not heated.
Heating of front brake discs After truck travels inside yard, check by touching with hand
53 (Both sides) that front brake discs are not heated.
After truck travels inside yard, check by touching with hand

54 Heating of differential that differential is not heated.
5/8
No. Mainte-
Heating of final drives (Both After truck travels inside yard, check by touching with hand
55 sides) that final drive covers are not heated.
Heating of rear axles (Both After truck travels inside yard, check by touching with hand
56 sides)brake that axle housings are not heated.
Check performance of brake.
(1) When lockup operates and brake is turned ON (rear brake

pilot lamp lights up), exhaust brake must operate (regard-
less of operation of exhaust brake switch).
(2) When lockup operates and accelerator pedal is turned
Function of exhaust brake
57 (Overseas opt.) OFF, exhaust brake must operate (only when exhaust brake
switch is ON).
When (1) or (2) occurs, exhaust brake pilot lamp must light
up.
Uneven working of service When service brake is applied sharply, truck must not turn
58 brake and steering wheel must not turn by itself.
Uneven working of retarder When retarder brake is applied sharply, truck must not turn
59 brake and steering wheel must not turn by itself.
Truck must not move at ”F2” stall (2070 rpm or above).
60 Function of parking brake Measured value (F : rpm)
* Check in service mode.
61 Function of service brake Measured value (F : rpm)
62 Function of retarder brake Measured value (F : rpm)
When emergency brake switch is turned ON, service brake and parking
brake must be applied. (Check that pilot lamp lights up.) * Centralized
warning lamp must light up and centralized alarm buzzer must sound.
Function of emergency brake Write down limit where truck moves.
63 Measured value (F : rpm)
When air pressure lowers below 216 kPa {2.2 kg/cm2}, emer-
gency brake must operate automatically.
While front brake cut switch is turned ON, front brake must
Function of front brake cut
64 switch not operate even if service brake pedal is pressed. (This
may be confirmed by checking change of oil level in oil tank.)
Check steering function.
Abnormal noise and vibration

65 in steering operation No abnormal noise must be generated. (Sensory check)
There must be no hitch and operating effort must not change.

66 Smooth steering operation (Sensory check)
Steering effort must not be heavy. (Sensory check)

67 Steering effort (When empty) Standard: Max. 29 N {3 kg}
Standard: Max. 150 mm – With engine stopped, measure
68 Play of steering wheel peripheral length of steering wheel.
Measured value: ( ) mm
Lock-to-lock turns of steering Standard: 3.2 – 3.7 turns
69 wheel Measured value: Left ( ) turns, Right ( ) turns
(1) Standard: Max. 4.0 sec (Engine speed: 650 rpm)

Turning to left ( ) sec, Turning to right ( ) sec
Steering speed (Rock-to-rock
70 time) (2) Standard: Max. 3.6 sec (Engine speed: Constant speed
above 1500 rpm)
Turning to left ( ) sec, Turning to right ( ) sec
When key switch is ON and parking brake is OFF, emergency steering
Automatic emergency steering
71 function system must operate (for at least 24 seconds). * Do not operate emer-
gency steering pump for more than 90 seconds continuously.
Steering effort must not be heavy. (Sensory check)
72 Emergency steering effort Reference: Max. 29 N {3 kg}
Emergency steering speed
Standard: Max. 12.0 sec (With battery charged fully)
73 (Oil temperature: 80°C Atmo- Turning to left ( ) sec, Turning to right ( ) sec
spheric temperature: 25°C)
6/8
No. Mainte-
Check operating performance.
Check that operation is correct (FLOAT → RAISE: 49 N {5.0

74 Operating effort of dump lever kg}, FLOAT → LOWER: 69N {7.0 kg}). Lever must not be
hitched. Evaluate by sensing.
Shock made when dump body When dump body is seated, unpleasant shock must not be
75 is lower to end
made. (Sensory check)
Operate lever to RAISE position and check that it does not

return to HOLD when released.
76 Function of body positioner
Operate lever to RAISE position to raise dump body and
check that it automatically returns to HOLD at a point 50 –
100 mm before end of hoist cylinder stroke.
When dump body is raised fully, it must not sway to right
or left. (Difference in dimension between right and left hoist
cylinders: Max. 7 mm)
Alignment of dump body on When dump body is lower fully, it must come in contact
77 right and left
with mount evenly. (Contact area must be at least 80%.)
When dump body is lower fully, it must come in contact

with vibration stopper evenly.
Body lifting speed (Oil tem- Engine speed: 2000rpm

78 perature: 80°C
Standard: 13.0 ± 1.5 sec, Measured value: ( ) sec
Body lowering speed (Lever at Engine speed: Low idling speed (650 rpm) * Encircle body
79 FLOAT, Oil temperature: 80°C type → (Standard • Lock)
Standard: 17.0 ± 1.5 sec, Measured value: ( ) sec
Hydraulic drift in 5 minutes must be 85 mm or less. (From
80 Hydraulic drift of dump body point where cylinder No. 2 is extended by 100 mm) Mea-
sured value: ( ) mm
Function of lifting dump body
81 with emergency starting motor Stop engine and check that dump body can be lifted with
emergency steering motor.
Inspect each part.
Length of suspension cylinder Length must be shorter than dimension A. Dimension A:

82 (Front) 262 (Position of label) ± 10 mm
* Measure with dump body empty. Measured value: Left ( ) mm, Right ( ) mm
Length of suspension cylinder Length must be shorter than dimension A. Dimension A:
83 (Rear) 239 (Position of label) ± 20 mm
* Measure with dump body empty. Measured value: Left ( ) mm, Right ( ) mm
(1): When dump lever is set to any position other than FLOAT,
display must change from [Soft] to [Hard].
(2): When service brake or emergency brake is turned ON,

Automatic suspension control display must change from [Soft] to [Medium].
84 function
Measure with dump body empty. (3): Display must show [Soft] in all cases other than (1) and
(2) above.
Operation of pneumatic cylinder installed to front axle must conform to display in
operator’s cab.
• Link position of cylinder: [Soft → Upper], [Hard → Middle], [Medium → Lower]
Locknut must not be loosened.

Installation of dump control
85 linkage
Boots (Rubber covers) of cable must not be twisted. (At
right side of cab, hoist valve, and positioner)
Installation of drive shaft All mounting bolts must be free from looseness and abnor-
86 (Engine
→ Torque converter) mal play.
I n s t a l l a t i o n o f d r i v e s h a f t All mounting bolts must be free from looseness and abnor-

87 (Transmission
→ Differential) mal play.
88 Engine mount Mounting bolts must be free from looseness.
89 Transmission mount Mounting bolts must be free from looseness.
90 Operator’s cab mount Mounting bolts must be free from looseness.

7/8
No. Mainte-
91 Front supports (Both sides) Mounting bolts must be free from looseness.
92 Rear support Mounting bolts must be free from looseness.
Mounting bolts must be free from looseness, and from beat

93 Engine undercover
sounds while engine is running.
Mounting bolts must be free from looseness, and from beat

94 Transmission undercover
sounds while engine is running.
95 Hydraulic tank Mounting bolts must be free from looseness.
96 Fuel tank Mounting bolts must be free from looseness.
97 Inspection around engine No oil and water leakage.
Inspection around transmis-

98 No oil leakage.
sion
Installation of transmission
99 Cable must be clamped.
output shaft sensor cable
Water leakage from cooling

100 No leakage.
water system
No leakage. (Check gauges installed to tank for leakage in

101 Fuel leakage from fuel system
particular.)
Oil leakage from hydraulic oil
102 system (tank, cylinder, pump, No leakage.
piping)
Oil leakage from transmission
103 No leakage.
system
Oil leakage from torque con-

104 No leakage.
verter system
Oil leakage from differential

105 No leakage
and final drive system
106 Oil leakage from brake system No leakage.
Oil leakage from steering sys-

107 No leakage.
tem
Oil leakage from suspension

108 No leakage
(Both sides, front)
Oil leakage from suspension

109 No leakage.
(Both sides, rear)
Air leakage from pneumatic

110 No leakage.
devices (including piping)
Impurities must be drained securely.

111 Function of air tank drain valve
Valve must not be rusted.
Dust indicator must be installed to air tube (air cleaner →

112 Installation of dust indicator engine).
1 piece/truck
Car radio antenna (Front of
113 Antenna must be free from harmful flaw.
cab)
Rear view mirror, undermirrors

114 Must not be loosened.
(Both sides)
When belt is pushed with thumb (approx. 59 N {6 kg}), its
115 Tension of fan belt deflection must be 7 – 10 mm. Belt must be free from flaw
and twist.
8/8
No. Mainte-
When belt is pushed with thumb (approx. 59 N {6 kg}), its
Deflection of air conditioner deflection must be 10 – 15 mm. Belt must be free from flaw
116
compressor belt and twist.
Plated surfaces must be free from rust, harmful flaw, spat-
117 Steering cylinders (Both sides) ter, paint, etc.
Plated surfaces must be free from rust, harmful flaw, spat-

118 Hoist cylinders (Both sides) ter, paint, etc.
Suspension cylinders Plated surfaces must be free from rust, harmful flaw, spat-
119 ter, paint, etc.
(Both sides, front)
Suspension cylinders Plated surfaces must be free from rust, harmful flaw, spat-
120 ter, paint, etc.
(Both sides, rear)
121 Appearance of cab glass Glass must be free from flaw, paint, etc.
122 Installation of battery Double nuts for installation of battery must be tightened.
123 Tightness of battery terminals Terminals must not move when swing with hand.
Rubber caps of battery termi- Must be installed securely.

124
nals and positive cable (+)
(1) Airflow must be changed to 4 levels with blower switch.
(2) When air conditioner switch is turned ON after blower

switch is turned ON, cab must be cooled and dried.
Function of air conditioner (3) When temperature control switch is set to green side,
125 Large capacity type: cold air must come out. When former is set to red side, hot
3250 → 4000 kcal/h air must be come out.
(4) Fresh air or circulating air must be selected with fresh/
circulating air selector switch.
(5) Air outlet must be set to ”Vent”, ”Vent & foot”, ”Foot”,
”Defrost & Foot”, or ”Defrost” with air outlet selector switch.
If error code history saved in each controller is recognized,

record it below. (Check in error history display mode.)
Error code: ( )
Elapsed time 1: ( ) h, Elapsed time 2: ( ) h, Number
of occurrence: ( ) times
Error code: ( )
126 Check of error codes Error code: ( )
Error code: ( )
Error code: ( )
After recording error codes, delete error memory in control-
127 Clearing of error codes ler. (Check in error history display mode.)
HD785-5 DUMP TRUCK
Form No. GEN00027-03
©2008 KOMATSU
All Rights Reserved
Printed In Japan 07-08

HD785-5LC Gen00027-03

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GEN00027-03

Field Assembly Instruction

DUMP TRUCK HD785 -5

FRONT AXLE, F/T, CHASSIS, HD785-5 (COMMON TO ALL SPECIFICATIONS) ........................................... 3

WORK PROCEDURES FOR TURNING OVER THE BODY ........................................................................... 154

2900 mm TRANSPORTATION POSTURE (IF EQUIPPED)........................................................................... 157

01 F. Axle Ass’y (R.H.) 561-27-R0000 1 A

02 F. Axle Ass’y (L.H.) 561-27-L0000 1 A

03 Fuel Tank Ass’y 561-04-6111 1 A

02 Tire Ass’y (L.H.) 561-30-X0000 2 A

02 R.H. Platform Ass’y 561-54-61411 1 A (Note) Standardization of pres-

15 Hand shield GP-1S 3

17 Chipper scaling hammer FCM-20F 2

24 Nitrogen gas injector 566-88-14003 1

26 Tire inflation gauge No. 2252 1

28 Extension ATH-785-014 1 For tire tightening

29 Cord reel For 200V 1 For electric nut runner

36 Square timber 300 mm square, 1 m long 16

38 Oil Engine oil SAE10W 100l See Field Assembling Procedures.

39 Oil Engine oil SAE30W 20l See Field Assembling Procedures.

40 Oil sump, washing can 2

41 Drained oil can Empty drum can 1

44 Antifreeze 5l For adding in subtank (to change mix-

45 Air hose 6d × 1m 1 For air bleeding

46 Three-bond #1521 Tube of 100 gram 1 Use for windshield glass

48 Sanding machine for 914B 1

49 Sandpaper #80 100

51 Cup gun set W87-20R2S 1 Use for coating

52 Brush 1 Use to repair coating.

53 Air compressor Not less than 3.5 m3 or 7 kg/cm2 1

54 Air hose With mouthpiece of d12 5 For impact grinder

55 Impact wrench UW-13SK 2

56 Impact wrench KW-3800P 1

57 Impact wrench UW-9SK 2

58 Extension for impact 150 mm long 1

59 Socket 1 inch × 41 mm 1 For tightening tire

60 Socket 1 inch × 36 mm 1 For tightening ROPS (option for over-

61 Socket 1 inch × 30 mm 1 For tightening support

62 Wrench Width across flats: 36 mm 1

63 Wrench Width across flats: 41 mm 1

64 Torque-wrench 1800QL 1 For propeller shaft

66 Torque-wrench, open type 24 × 1200SP 1

67 Torque-wrench, open type 36 × 2200SP 1

68 Torque-wrench, box type Width across flats: 27 mm, 4200CL 1

69 Torque wrench, box type Width across flats: 30 mm, 7000CL 1

72 Vinyl tape 1 Use to bundle harnesses

73 Standard tool (ISO specifi- 700SX 2

75 Shino 1 For hole alignment

77 Shackle BD10 for 500 kg 4

78 Shackle BC40 for 10 tons 4 For mounting body

79 Chain ATH-465-042 1 Multi purpose

80 Nylon shoe ring 100 mm wide × 5 m 2 For mounting fuel tank

83 Nylon shoe ring 100 mm wide × 12 m 1 For mounting front tires

84 Nylon shoe ring 30 mm wide × 2 m 3 For installing front axle

85 Nylon shoe ring 100 mm wide × 3 m 1 For installing front axle

86 Pin d60 × 250 mm 2 For slinging chassis, rear side

87 Jig for slinging body ATH-785-006 4 For mounting body

88 Lever block 3/4 tons, LB008 3 For installing front axle

89 Lever block 2 tons, LB020 1 For installing front axle

90 Wire 7m 28d 2 For slinging chassis

91 Wire 4m 28d 2 For mounting body

92 Wire 5m 28d 2 For installing body

The following items may be substituted for No. 90 to 92.