Manual de Armado HD785-7 - Compressed (1) - Compressed-54-69

Assembly process No.
Installation of oil quick charge box

0200 (If equipped: Oil quick charge specification)
Installation of oil quick charge box
1. Install box (1) with bolts (2).
Hydraulic tank
: 5 places
Transmission
and brake Brake
cooling oil control oil
Steering
Engine oil and H/T oil
Section A-A View Z
Part No. Part name Q'ty Condition of part (Parts list No.)
(1) X251156860 Box, sub-assembly 1 Packed separately (HD785-7-200)
(2) 01024-81225 Bolt, sems 5 Packed separately (HD785-7-200)
Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
Other remarks
46
Assembly process No. Installation of engine side cover
0203 [Russian specification]
Installation of engine side cover [Engine side cover: 6HM998001 for Russia]
P part
③, ⑤, ⑥
④, ⑥
①
Q part
FWD
FWD
Fix (1) and (2) with bolts installed already

Part No. Part name Q'ty State of parts
(1) 561-98-81110XC COVER, L.H. 1 Unit shipment
(2) 561-98-81120XC COVER, R.H. 1 Unit shipment
(3) 561-98-81130 PLATE 6 Temporarily installed to machine body
(4) 561-98-81140 COLLAR 1 Temporarily installed to machine body
(5) 01643-31232 WASHER 3 Temporarily installed to machine body
(6) 01024-81235 BOLT, SEMS 4 Temporarily installed to machine body

Name Q'ty Name Q'ty
Other remarks Sales code: 6HM998001
47
Assembly process No. Installation of fuel tank wiring harness cover
0260
FUEL TANK
Wiring harness
cover
Installation procedure
for cover (1)
Installation of fuel tank wiring harness cover

1. Install cover (1) with the bolts installed to the fuel tank.
(1) 561-04-81322 Cover 1 Installed to fuel tank

Name Q'ty Name Q'ty
Other remarks
48
Assembly process No. Installation of toolbox and tool kit
0270
Installation of toolbox
(1) 561-98-86110 Tool box, sub-assembly 1 Packed separately (HD785-7-270)
(2) 01024-81225 Bolt 4 Temporarily installed to fuel tank
(3) 09460-00000 Lock 1 Packed separately (HD785-7-270)
1. Remove the toolbox sub-assembly mounting bolts
(installed to the fuel tank temporarily).
2. Fix toolbox sub-assembly (1) with the bolts removed in step 1.
3. Install the attached tool kit.
4. Close the cover of box (1) and tighten the wing screw.
5. Install lock (3).

Name Q'ty Name Q'ty
Other remarks
49
Assembly process No. Installation of fuel tank step (If equipped)
0275
Installation of fuel tank step

1. Remove bolts (2) installed to the
fuel tank.
2. Install ladder (1) with bolts (2)
removed in step 1.
3. Install step (3) to ladder (1) with
bolts (4).
EU
specification
EU specifica-
tion reference
EU drawing
EU specifica-
specification tion reference
drawing
(1) 561-54-8A981 Ladder 1 Packed separately (HD785-7-275)
(2) 01024-D1230 Bolt 8 Installed to fuel tank
(3) 561-54-8A960 Step 1 Packed separately (HD785-7-275)
(4) 01024-D1230 Bolt 4 Packed separately (HD785-7-275)
(5) 561-54-8A982 Ladder 1 Packed separately (HD785-7-277)
(6) 561-54-8A900 Step 1 Packed separately (HD785-7-277)
Name Q'ty Name Q'ty
Other remarks
Sales code: 6HH68-A or 5AC11
50
Assembly process No. Installation of rear support
0280
Installation of rear support

1. Remove the bolts and washers installed to the machine body temporarily.
2. Install the rear support assembly.
* For adjustment, keep bolts (2) and (5) tightened
temporarily until installing the right platform and cab.
* Remove rust pre-

ventive paint from
rear support ground
face (on machine
frame side).
* Remove rust preventive paint

from rear support ground face
(on machine frame side). Z
(1) 561-46-80200 Rear support LH 18 Packed separately (HD785-7-280)
(2) 01010-82475 Bolt 18 Installed to frame
(3) 01643-32460 Washer 18 Installed to frame
(4) 561-46-81791 Rear support RH 1 Packed separately (HD785-7-280)
Fixing of air tube
1. Fix the air tube.
(7) 04434-51210 Clip 18 Packed separately (HD785-7-280)
(8) 01024-81020 Bolt 18 Packed separately (HD785-7-280)
View Z
Diagonal front view

Name Q'ty Name Q'ty
Nylon sling 1 Crane (25 ton) 1
(60 mm wide × 3 m)
Torque wrench 1
Other remarks
51
0281 (Muffler specification: If equipped)

1. Remove the bolts and washers installed to the machine body temporarily.
* For adjustment, keep bolts (2) and (5) tightened
temporarily until installing the right platform and cab.
Muffler
specification
* Remove rust pre-
ventive paint from
rear support ground
face (on machine
frame side).

from rear support ground face
(on machine frame side). Z
(4) 561-84-84391 Rear support RH 1 Packed separately (HD785-7-281)
Fixing of air tube
View Z
Diagonal front view

Name Q'ty Name Q'ty
(60 mm wide × 3 m)
Torque wrench 1
Other remarks
52
0282 (ABS specification: If equipped)
Installation of rear support * Keep bolts (2) and (5) tightened lightly
for adjustment until the right platform and
1. Remove the bolts and washers installed to the machine.
cab are installed.
(Before installing the left rear support assembly, install ABS assembly (9) with bolts (10).
* Remove rust preventive paint from rear support
grounding surface (on machine frame side).
View Y

from rear support grounding sur-
face (on machine frame side).
(1) 561-46-80300 Rear support L.H. 18 Packed separately (HD785-7-282)
(4) 561-84-84391 Rear support R.H. 1 Packed separately (HD785-7-282)
(9) 561-88-80201 ABS front sub-assembly 1 Packed separately (HD785-7-282)
Fixing of air tube

Name Q'ty Name Q'ty
(60 mm wide x 3 m)
Torque wrench 1
Other remarks
53
0283 (Sand terrain specification: If equipped)

1. Remove the bolts and washers installed to the machine.
2. Install the rear support assembly. * Keep bolts (2) and (5) tightened lightly for adjust-
ment until the right platform and cab are installed.
* Remove rust preven-

tive paint from rear
support grounding
surface (on machine
frame side).

from rear support grounding sur-
face (on machine frame side).
(4) X250783640 Rear support RH 1 Packed separately (HD785-7-283)
Fixing of air tube

Name Q'ty Name Q'ty
(60 mm wide × 3 m)
Torque wrench 1
Other remarks
54
Assembly process No. Installation of muffler
0290
Installation of muffler
Fire prevention cover
<Points of work>
* Before tightening the bolts permanently, install all the parts
Tightening torque: 8.8 – 9.8 kgm * Tightening bolts to secure fire

{0.9 – 1.0 kgm} prevention cover. View Z
(1) 561-02-81210 Tube 1 Packed separately (HD785-7-290)
(2) 6502-12-1722 V coupling 1 Packed separately (HD785-7-290)
(4) 561-02-81350 Band 1 Installed to frame
(5) 01580-11008 Nut 4 Installed to frame
1. Remove the fire prevention cover installed to machine body (rear support).
2. Remove parts (4) – (6) installed to the frame temporarily and
install tube (1) to the frame with parts (2) and (3).
3. Clamp tube (1) with parts (4) – (6) removed in step 2. See
"Tightening procedure for exhaust pipe band" (below).
4. Reinstall the fire prevention cover removed step 1.
Tightening procedure for exhaust pipe band

Tighten the nuts of exhaust pipe band ((4) 561-02-81350)
according to the following procedure (See view X).
1) Tighten nut "a" to 13.7 Nm {1.5 kgm}. a
2) Tighten nut "b" to 59 – 74 Nm {6 – 7 kgm} and then return b View X
nut "a" slightly.
Name Q'ty Name Q'ty
Other remarks
55
Assembly process No. Installation of muffler
0291 (Body heating-less/Exhaust selector box specification: If
equipped)
Installation of muffler
Tighten torque:
a: 4 places
8.8 – 9.8Nm
{0.9 – 1kgm}
Front view of machine

Rear view of machine (Sectional view of rear support)
1. Install muffler sub-assembly (1) with bolts (2).

2. Install the exhaust pipe on the machine side and muffler sub-assembly (1) with V-coupling (3). See
"Assembly procedure for exhaust pipe at muffler connecting part".
(1) 561-84-80101 Muffler sub-assembly 1 Packed separately (HD785-7-291)
(2) 01024-81230 Bolt, sem 4 Packed separately (HD785-7-291)
(3) 6502-12-1722 V coupling 1 Packed separately (HD785-7-291)
(4) 561-84-84341 Tube 1 Installed to machine
Assembly procedure for exhaust pipe at muffler connecting part
1) When installing exhaust pipe (4) and muffler sub-assembly ((1)),

1. Install frame-side V-coupling (3) temporarily.
* At this time, adjust the flexible pipe length to 336 ± 9 mm.
* If the flexible pipe is tightened after extended, its sealing performance may lower and it may
be disconnected. Take care.
If the flexible pipe needs to be shortened, shorten it while twisting it to the left. (Twisting
distance: 3 – 5 mm)
2. Permanently tighten V-coupling (3) on the frame side.
Twisting distance to left: 3 – 5 mm
Twisting distance to right: 0 mm
A
336±9
A-A
A

Name Q'ty Name Q'ty
1
Other remarks
56
Assembly process No. Installation of fire prevention cover
0300
Installation of fire prevention cover
<Point of work>
* Install the fire prevention cover before installing the fender (for higher workability).
(1) 561-89-86111 Cover 1 Packed separately (HD785-7-300)
(2) 561-89-86120 Cover 1 Packed separately (HD785-7-300)
1. Install the fire prevention cover to the right rear support.

Name Q'ty Name Q'ty
Other remarks
57
Assembly process No. Installation of front support
0310
Installation of front support
Tightening torque:
662 – 829 Nm
{67.5 – 84.5 kgm}
Tightening torque:
662 – 829 Nm
{67.5 – 84.5 kgm}
Connection of headlamp wiring harness
(1) 561-54-80301 Front support sub-assembly L.H. 1 Packed separately (HD785-7-310)
(3) 01643-32260 Washer 11 Packed separately (HD785-7-310)
(4) 561-54-80401 Front support sub-assembly R.H. 1 Packed separately (HD785-7-310)
1. Install front support assemblies (1) and (4) with bolts (2) and (5) and washers (3) and (6).
2. Fix the wiring harness to the clip and connect connector (CN-RP and CN-LP3).
3. After installing the front support, touch it up.

Name Q'ty Name Q'ty
(60 mm wide x 3 m)
Torque wrench 1
Other remarks
58
0315 (Fog lamp specification: If equipped)
Tighteningtorque:
662 – 825 Nm
{67.5 – 84.5 kgm}
Tightening torque:
662 – 829 Nm
{67.5 – 84.5 kgm}
Connection of headlamp wiring harness
(1) 561-54-80100 Front support sub-assembly L.H. Fog 1 Packed separately (HD785-7-315)
(4) 561-54-80200 Front support sub-assembly R.H. Fog 1 Packed separately (HD785-7-315)
2. Fix the wiring harness to the clip and connect connector (CN-RP and CN-LP3).
3. After installing the front support, touch it up.

Name Q'ty Name Q'ty
(60 mm wide x 3 m)
Torque wrench 1
Other remarks
59
0317 (Fog lamp, beacon lamp, HID headlamp specification:
If equipped)
Tightening torque:
662 - 829 Nm
{67.5 - 84.5 kgm}
Tightening torque:
662 - 829 Nm
{67.5 - 84.5 kgm}
Connection of headlamp harness
(1) 561-85-80V00 Front support sub-assembly L.H. 1 Packed separately (HD785-7-317)
(4) 561-85-80W00 Front support sub-assembly R.H. 1 Packed separately (HD785-7-317)
2. Fix the harness to the clips and connect connectors (CN-RP and CN-LP3).
3. After installing, touch up the damaged surfaces.

Name Q'ty Name Q'ty
(60 mm wide x 3 m)
Torque wrench 1
Other remarks
60
Assembly process No. Installation of steering valve
0320
Installation of steering valve

1. Remove the blind plugs and caps from the frame
steering piping (5 places).
2. Install the steering valve to the left front support.
Tightening torque : 44.1 -- 58.8 Nm

{4.5 -- 6.0 kgm}
(1) 561-40-83300 Valve,steering 1 Packed separately (HD785-7-320)
(2) 561-40-42620 Cushion 4 Packed separately (HD785-7-320)
(3) 561-40-42630 Collar 4 Packed separately (HD785-7-320)
(4) 561-40-42650 Plate 4 Packed separately (HD785-7-320)
(7) 569-40-83470 Bracket 2 Packed separately (HD785-7-320)
(8) 569-40-83480 Seal 1 Packed separately (HD785-7-320)
(11) 01580-10605 Nut 2 Packed separately (HD785-7-320)
3. Install the nipple to the steering valve.
View Z
(12) 02896-21012 O-ring 1 Packed separately (HD785-7-320)
(13) 569-61-84770 Nipple 2 Packed separately (HD785-7-320)
(14) 437-40-22310 O-ring 2 Packed separately (HD785-7-320)
(15) 569-61-84780 Nipple 2 Packed separately (HD785-7-320)
(16) 418-62-11620 O-ring 2 Packed separately (HD785-7-320)
(17) 02896-21018 O-ring 4 Packed separately (HD785-7-320)

1. Take care that the O-ring will not be projected. Name Q'ty Name Q'ty
Other remarks
61

Manual de Armado HD785-7 - Compressed (1) - Compressed-54-69

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Assembly process No.

Installation of oil quick charge box

Installation of oil quick charge box

1. Install box (1) with bolts (2).

Section A-A View Z

Precautions Necessary tools Necessary equipment

Fix (1) and (2) with bolts installed already

Precautions Necessary tools Necessary equipment

Other remarks Sales code: 6HM998001

Installation of fuel tank wiring harness cover

Precautions Necessary tools Necessary equipment

Precautions Necessary tools Necessary equipment

Installation of fuel tank step

Installation of rear support

* Remove rust pre-

* Remove rust preventive paint

Diagonal front view

Precautions Necessary tools Necessary equipment

Installation of rear support

* Remove rust preventive paint

Diagonal front view

Precautions Necessary tools Necessary equipment

* Remove rust preventive paint

Precautions Necessary tools Necessary equipment

Installation of rear support

* Remove rust preven-

* Remove rust preventive paint

Precautions Necessary tools Necessary equipment

Tightening torque: 8.8 – 9.8 kgm * Tightening bolts to secure fire

Tightening procedure for exhaust pipe band

Front view of machine

1. Install muffler sub-assembly (1) with bolts (2).

Assembly procedure for exhaust pipe at muffler connecting part

1) When installing exhaust pipe (4) and muffler sub-assembly ((1)),

Precautions Necessary tools Necessary equipment

Installation of fire prevention cover

1. Install the fire prevention cover to the right rear support.

Precautions Necessary tools Necessary equipment

Installation of front support

Connection of headlamp wiring harness

Precautions Necessary tools Necessary equipment

Installation of front support

Connection of headlamp wiring harness

Precautions Necessary tools Necessary equipment

Connection of headlamp harness

Precautions Necessary tools Necessary equipment

Installation of steering valve

2. Install the steering valve to the left front support.

Tightening torque : 44.1 -- 58.8 Nm

Precautions Necessary tools Necessary equipment

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