Field Assembly HD787!7!7001 Up

GEN00058-07

Field Assembly Instruction

DUMP TRUCK

HD785 -7 SERIAL NUMBERS

7001

and up

CONTENTS 1. Outline of division (Only main components)................................................................................................. 1 2. Dimensions of main components ................................................................................................................. 2 3. Layout of work space ................................................................................................................................... 3 4. Rough schedule of assembly and welding ................................................................................................... 4 5. List of jigs, tools, and consumables for field assembling............................................................................. 9

CONTENTS 6. Assembly process No. No.

Item

Page

0010 Oil, grease, and coolant

16

0020 Levels of oil, grease, and coolant

17

0030 Positioning rear axle assembly

18

0040 Slinging and moving of bare machine

19

0050 Connection of rod and rear suspension

20

0060 Positioning bare machine

21

0070 Connection of rear axle cooling hose

22

0080 Connection of rear axle brake hose

23

0085 Connection of rear axle brake hose (ASR specification: If equipped)

24

0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped)

25

0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)

26

0090 Connection and fixing of rear grease piping and supply of grease

27

0100 Preparation for installing front axle

28

0110 Installation of front axle

29

0120 Connection of front axle suspension pressure sensor

30

0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)

31

0130 Connection of steering cylinder and tie rod

32

0140 Connection of front axle brake cooling hoses

33

0150 Connection of front axle brake hoses

34

0160 Connection of front axle auto suspension piping

35

0165 Fixing of front axle auto suspension piping

36

0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification)

37

0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)

38

0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)

39

0170 Installation of bumper and front axle steps

40

0171 Installation of front axle step (EU specification)

41

0180 Installation of tire and wheel assembly

42

0190 Installation of drive shaft

43

0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)

44

0260 Installation of fuel tank wiring harness cover

45

0270 Installation of toolbox and tool kit

46

0275 Installation of fuel tank step (If equipped)

47

0280 Installation of rear support

48

0281 Installation of rear support (Muffler specification: If equipped)

49

0282 Installation of rear support (ABS specification: If equipped)

50

0283 Installation of rear support (Sand terrain specification: If equipped)

51

0290 Installation of muffler

52

0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)

53

0300 Installation of fire prevention cover

54

0310 Installation of front support

55

0315 Installation of front support (Fog lamp specification: If equipped)

56

0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)

57

0320 Installation of steering valve

58

0330 Preparation for installing cab

59

0340 Installation of cab

60

0345 Connection of ABS piping (If equipped)

61

0350 Connection of column

62

0355 Installation of washer tank

63

0360 Connection of cab piping

64

0370 Connection of cab wiring

65

0375 Connection of cab wiring (ASR/ABS specification: If equipped)

66

0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)

67

0377 Connection and fixing of engine compartment lamp wiring harness (if equipped)

68

0378 Connection of auto grease harness to cab (If equipped: Auto grease specification)

69

0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)

70

0380 Installation and fixing of steering hoses

71

CONTENTS No.

Item

Page

0385 Fixing of air conditioner drain hose

72

0390 Installation of steering hose cover

73

0395 Connection of air conditioner and heater hoses

74

0400 Connection of cab floor wiring

75

0405 Fixing of ASR/ABS wiring harness (If equipped)

76

0406 Connection and fixing of ABS wiring harness (ABS specification: If equipped)

77

0410 Installation of cover under cab

78

0415 Wiring of front glass with heater wire (If equipped)

79

0420 Installation of cab seal

80

0430 Installation of ambient temperature sensor wiring harness

81

0440 Installation of undercab wiring harness connector

82

0445 Connection and fixing of rear view camera wiring harness (if equipped)

83

0450 Installation of R.H platform assembly

84

0470 Installation of right fender

85

0472 Installation of right fender (If equipped: Body heating-less muffler specification)

86

0475 Installation of fuel tank quick charge-less hose (If equipped)

87

0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)

88

0480 Installation of cab step

89

0481 Assembly of diagonal ladder (if equipped)

90

0482 Installation of cab step: Diagonal ladder specification (if equipped)

91

0483 Installation of diagonal ladder 1 (if equipped)

92

0484 Installation of diagonal ladder 2 (if equipped)

93

0485 Installation of diagonal ladder 3 (if equipped)

94

0486 Installation of diagonal ladder (EU specification)

95

0487 Installation of diagonal ladder-2 (EU specification)

96

0488 Installation of diagonal ladder-3 (EU specification)

97

0490 Installation of L.H underview mirror (If equipped)

98

0500 Installation of fire extinguisher (If equipped)

99

0510 Installing radio antenna and fixing its cable

100

0520 Installation of L.H fender

101

0530 Installation of left side mudguard

102

0540 Installation of grille guard

103

0550 Installation of left payload lamp (If equipped)

104

0555 Installation of left side lamp (If equipped)

105

0560 Installation of right payload lamp (If equipped)

106

0565 Installation of right side lamp (If equipped)

107

0570 Installation of left fender side lamp wiring harness (If equipped)

108

0580 Installation of right fender side lamp wiring harness (If equipped)

109

0581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification) 110 0590 Installation of KOMTRAX (If equipped)

111

0595 Fixing of ORBCOMM antenna (If equipped)

112

0597 Connection and fixing of harness and hose going to auto grease pump - 1 (If equipped: Auto grease specification)

113

0598 Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification)

114

0600 Removal of hoist cylinder fixing bracket

115

0610 Connection of hoist cylinder piping

116

0620 Welding of body

117

0630 Sticking of body decal

118

0640 Supply of oil

119

0650 Slinging of body

120

0660 Installation of hinge pin

121

0670 Connecting hoist cylinder

122

0680 Hoist cylinder grease piping

123

0685 Fixing of auto grease piping to body (If equipped: Auto grease specification)

124

0700 Installation of field welding protection cover

125

0710 Installation of body mount

126

0720 Procedure for adjusting body mount shim

127

0730 Field welding of exhaust tube

128

CONTENTS No.

Item

Page

0740 Assembly of body heater cover

129

0770 Installation of poke ejector

130

0780 Installation of poke ejector storage pin

131

0790 Installation of body mudguard

132

0800 Installation of body lock pin

133

0810 Installation of transmission underguard

134

0830 Installation of front handle

135

0850 Connection of dump sensor

136

0860 Procedure for adjusting dump sensor

137

0870 Calibrating dump control

138

0880 Adjustment of optical axis of light

139

0900 Bleeding air from brake

140

0901 Bleeding air from brake of ASR specification (ASR specification: If equipped)

141

0905 Bleeding air from ABS circuit (ABS specification: If equipped)

142

0910 Adjusting suspension

143

0920 Charging air conditioner with refrigerant

144

0930 Fitting of floating seal

145

0950 Painting

146

0960 Touchup

147

1000 Sticking of front axle decal

148

1020 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)

149

1100 Installation of chocks (If equipped)

151

1200 Installation of radiator curtain (If equipped)

152

1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)

153

7. Adjustment procedure No.

Item

Page

T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)

154

T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)

155

T-0030 Setting of machine monitor

156

T-0040 Selection of machine model

157

T-0050 Selection of optional component

158

T-0060 Selection of option

159

T-0070 Option setting/no-setting selection screen - Saving of change of option selection

160

T-0080 OFF setting of corrosion resistor with maintenance monitor

161

T-0090 Adjustment of body positioner sensor

162

T-0100 Deletion of electrical system fault history (1)

163

T-0110 Deletion of electrical system fault history (2)

164

8. Welding procedure No.

Item

Page

C-0010 Preparation of welding body

165

C-0020 Assembly of split body (1/2)

166

C-0030 Assembly of split body (2/2)

167

C-0040 Tack welding body

168

C-0050 Welding body (1/2)

169

C-0060 Welding body (2/2)

170

C-0070 Welding body instruction (1/2)

171

C-0080 Welding body instruction (2/2)

172

C-0090 Turn over the body

173

C-0100 Welding body protector (1/2)

174

C-0110 Welding body protector (2/2)

175

C-0120 Finishing and painting welded parts of body

176

C-0130 Welding front body mount bracket

177

Appendix Field assembly inspection report

1. Outline of division (Only main components) 1. Bare machine

2. Dump body (Divided into 3)

3. Front axle assembly

4. Rear axle and tire assembly

5. Front tire and wheel assembly

6. Cab assembly

1

2. Dimensions of main components Weight (kg)

Overall length (mm)

Overall width (mm)

Overall height (mm)

Bare machine

21,600

7,930

3,190

3,120

2

Dump body

15,400

7,250

3,100

3,100

3

Right and left front axle assembly

2,400

2,200

1,700

2,100

4

Rear axle and tire assembly

17,000

4,390

2,700

2,700

5

Front tire and wheel assembly (1 set)

2,000

2,700

750

2,700

6

Cab

3,000

2,760

2,010

2,190

No.

Unit name

1

Drawing of bare machine on trailer

3,800 150

1,680

G.L. 530 6,200 11,980

3,000

2,780

Reference Specifications of completed truck Specifications In selfpropelled travel

2

HD785-7

Related items Weight (kg)

Overall length (mm)

64,600 (Mass of machine)

10,290 (Front bumper – End of body)

Overall width (mm)

Overall height (mm)

5,528

5,047 (When empty)

3. Layout of work space (The work space should be wider for the ease of work and must be at least 30 m square.) Caution: The work space must be level and drained well.

30M

Tire and wheel assembly

CAB

Body

Front axle

Bare machine

50-t crane

Forklift

30M

Rear axle assembly and tire assembly

Light units keeping place Platform, front support, mudguard, rear support, fire prevention cover, poke ejector, drive shaft, etc.

Compressor parts and tools keeping place 50-t crane

3

4-1. Rough schedule of assembly and welding Day Hour

1st day 1

2

3

4

5

6

7

8

Condition of chassis

Rough contents of assem- Positioning rear axle bly work Positioning chassis

Installing front axle Installing tires

Crane 490 kN {50 ton}

245 kN {25 ton}

245 kN {25 ton} (98 kN {10 ton})

Forklift

Approx. 2 m

4 ton * Fork length: Approx. 2 m Number of workers

2

Day Hour

1st day 1

2

3

4

5

6

7

8

Condition of body

Contents of welding work

Unloading Removal of stands and fixing parts

Crane 245 kN {25 ton} Number of workers

4

245 kN {25 ton} 3

Positioning and fixing split body Welding back side

4-2. Rough schedule of assembly and welding Day Hour

2nd day 1

2

3

4

5

6

7

8

Condition of chassis

Rough contents of assem- Installing support bly work Installing cab

Piping and wiring

Crane 490 kN {50 ton}

490 kN {50 ton}

Forklift

Number of workers

2

Day Hour

2nd day 1

2

3

4

5

6

7

8

Condition of body

Contents of welding work

Positioning and fixing split body Welding back side

Turning over

Crane 245 kN {25 ton} Number of workers

3

5

4-3. Rough schedule of assembly and welding Day Hour

3rd day 1

2

3

4

5

6

7

8

7

8

Condition of chassis

Rough contents of assem- Installing platform bly work Painting

Supply of oil and coolant Starting engine

Crane

Forklift

Number of workers

2

Day Hour

3rd day 1

2

3

4

5

6

Condition of body

Contents of welding work

Welding inside of body

Crane 245 kN {25 ton} Number of workers

6

3

Welding protector

4-4. Rough schedule of assembly and welding Day Hour

4th day 1

2

3

4

5

6

7

8

Condition of chassis

Mounting body Rough contents of assemAdjusting shims bly work Field welding

Crane 490 kN {50 ton} Number of workers

245 kN {25 ton}

245 kN {25 ton} (98 kN {10 ton})

2

Day Hour

4th day 1

2

3

4

5

6

7

8

Condition of body

Contents of welding work

Crane

Number of workers

7

4-5. Rough schedule of assembly and welding Day Hour

5th day 1

2

3

4

5

6

7

8

7

8

Condition of chassis

Installing exterior parts Rough contents of assemPainting bly work

Maintenance, adjustment Inspection

Crane 245 kN {25 ton} (98 kN {10 ton}) Number of workers

2

Day Hour

Condition of body

Contents of welding work

Crane

Number of workers

8

4th day 1

2

3

4

5

6

5-1 List of jigs, tools, and consumables for field assembling (1/2) No.

Item

Specification

Q'ty

Remarks

1

Truck crane

25 tons

2

See Field Assembling Procedures

2

Truck crane

50 tons

2

See Field Assembling Procedures

3

Forklift

4 tons

1

See Field Assembling Procedures

1220N2

1

4

Gas cutting machine

5

Torch

6

Acetylene gas

7

Oxygen gas

8 9 10

1 1

For gas cutting machine

14.7 MPa {150kg/cm²}

1

For gas cutting machine

Grinder (round)

FG50L-1

1

Grindstone

SCW50 × 19 • 10

1

Grinder

LISG-7S

1

11

Grindstone

180ø × 6 × 22

3

For finishing

12

Dia. bar

CB7C105

1

13

Dia. bar blade

6GH

1

14

Semi-automatic welding machine

500A

3

15

Hand shield

GP-1S

3

16

Welding wire for semi-auto1.2 mm matic 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

Shaft

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

7926-10-1000

1

25

Nitrogen gas bottle

14.7 MPa {150 kg/cm²}

1

26

Tire inflation gauge

No. 2252

1

27

Grease pump gun

For 20kg can

1

28

Grease

GL-2

5 kg

29

Footstool

3-step

1

30

Footstool

6-step

1

31

Blue sheet

5 m × 10 m

5

Protection for equipment

80kg

Injection into suspension

32

Wood block

300 mm square, 1 m long

12

* Quantity depends on using condition.

33

Oil jack

5l

1

For oil injection

34

Oil

See Field Assembling Procedures.

–

See Field Assembling Procedures.

35

Oil sump, washing can

36

Drained oil can

37

Cloth

38

Diesel fuel

39

Antifreeze

40

Air hose

2 Empty drum can

1 5kg

See Field Assembling Procedures.

For refilling fuel 5l

6ø × 1m

1

For adding in subtank (to change mixing ratio depending on local weather) For air bleeding

9

5-2 List of jigs, tools, and consumables for field assembling (2/2) No. 41

Item Sanding machine for scaling-off coating

Specification 914B

Q'ty

Remarks

1

42

Sandpaper

#80

100

43

Sandpaper

#180

10

44

Cup gun set

W87-20R2S

1

Use for coating

45

Brush

1

Use to repair coating.

46

Air compressor

Not less than 3.5 m³ or 7 kg/cm²

1

47

Air hose

With mouthpiece of ø12

5

48

Impact wrench

UW-13SK

2

49

Impact wrench

KW-3800P

1

50

Impact wrench

UW-9SK

2

51

Extension for impact wrench 38S

150 mm long

1

For impact grinder

52

Socket

1 inch × 46 mm

1

For tightening tire

53

Socket

1 inch × 30 mm

1

For tightening support

54

Torque-wrench

2800QL

1

For drive shaft and body pin

55

Torque-wrench

21000QLE

1

For tightening tire

56

Convex

5m

1

57

Locktite

LT-2

1

58

Vinyl tape

59

Standard tool (ISO specification)

700SX

2

60

Bar

1m

1

61

Pointed steel bar

62

Large hammer

10 lb

1

63

Axle pin installation guide

ATH-785-078

2

64

Shackle

BD10 for 500 kg

4

65

Shackle

BC40 for 10 tons

4

For mounting body

1

1

Use to bundle harnesses

For hole alignment

66

Chain

ATH-465-042

1

Multi purpose

67

Nylon shoe ring

100 mm wide × 5 m

2

For mounting fuel tank

68

Nylon shoe ring

60 mm wide × 3 m

2

For mounting support and small articles

69

Nylon shoe ring

100 mm wide × 12 m

1

For mounting front tires

70

Nylon shoe ring

30 mm wide × 2 m

3

For installing front axle

71

Nylon shoe ring

100 mm wide × 3 m

1

For installing front axle

72

Pin

ø60 × 250 mm

2

For slinging chassis, rear side (Safety pin can substiture)

73

Jig for slinging body

ATH-785-006

4

For mounting body

74

Lever block

3/4 tons, LB008

3

For installing front axle

75

Lever block

2 tons, LB020

1

For installing front axle

76

Wire

7m 28ø

2

For slinging chassis

77

Wire

4m 28ø

2

For mounting body

78

Wire

5m 28ø

2

For installing body

1 2 1

For mounting body For slinging chassis For slinging separated body

The following items may be substituted for No. 76 to 78. ATH-465-039 ATH-465-040 ATH-465-041

10

List of touch-up coating on body for overseas specifications No. 1

Part Name Retane GP primer

Unit

Q'ty

4kg

1

0.8kg

1

4l

1

2

Retane GO hardener

3

Retane GP thinner

4

AX Mightylacq G2KB type natural yellow

16kg

1

5

NAX Mightylacq G2KB type hardener

15kg

1

6

X Mightylacq G2 500 standard thinner

17l

1

7

Acryliquid cloud gray

Spray can

1

8

Heat-resistance silver

Spray can

1

11

5-3. Tools and consumables Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Body alignment shaft

HEAT TREATMENT

MATERIAL

—

STKM13A

PART NAME

QTY

Shaft

1

WJ-H46-74001-023

Body lifting pin

HEAT TREATMENT

MATERIAL

—

SS400

PART NAME

QTY

Body lifting pin

4

AHT-785-006

12

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

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Body assembly lifting tool

1

ATH-465-039

13

Chassis lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Chassis lifting tool

2

ATH-465-040

Dump body lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Split dump body lifting tool

1

ATH-465-041

14

Universal lifting tool

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Universal lifting tool

1

ATH-465-042

Front axle installation guide

HEAT TREATMENT

MATERIAL

—

—

PART NAME

QTY

Front axle installation guide

2

ATH-785-078

15

Assembly process No.

Oil, grease, and coolant

0010 Method of using fuel, lubricant, and coolant according to ambient temperature t Fuel, oil Use the correct type for the ambient temperature as shown in the table below. a Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. a When starting the engine in an ambient temperature of less than 0°C, always use EOS0W30, or EOS5W40, even though the temperature goes up to 10°C during the daytime. t Coolant Komatsu genuine super coolant (AF-NAC) is added to the cooling water, so there is no need to change it for temperatures down to -10°C. If the temperature goes below -10°C, adjust the density. For details, see CLEANING INSIDE OF COOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.

a For details of the notes (e.g., Note. 1, Note.2

16

) in the table, see the Operation and Maintenance Manual.

Assembly process No.

Levels of oil, grease, and coolant

0020

Lubrication point

Type of oil

Specified capacity (l)

Refill capacity (l)

Volume of refilled oil (l)

Engine oil pan

Engine oil

134

129

—

Transmission case (Including brake sub tank)

404

241

200

Steering and hoist oil tank

270

175

150

Front suspension

29.8 each on right and left sides

—

—

Rear suspension

16.5 each on right and left sides

—

—

Differential case

137

137

—

Power line oil

64 each on right and 64 each on right and left sides left sides

Final drive case

—

Fuel tank

Diesel fuel

1,308

—

—

Cooling system

Coolant

283

279

—

Caution) Before starting the engine, be sure to check each oil/coolant level. Do not steer the machine largely before adjusting the suspension (If it is steered largely, the piping may be damaged).

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

17

Assembly process No.

Positioning rear axle assembly

0030 Slinging of rear axle 1. Sling the rear axle and tire assembly with a 50 ton crane. Slinging position: Rod mounting portion on differential Weight: 20 ton (Including sling)

Positioning of rear axle 1. Position the rear axle. See the following figure. (Secure the ground clearance under the coupling section so that the rear axle assembly will be horizontal.) When positioning the rear axle on the ground, prevent slanting of the machine caused by subsidence of the ground. 2. Lock the wheels with chocks to prevent the rear axle from moving.

Wood block 1,200

Precautions

Necessary tools Name Lock the wheels with chocks to prevent the rear axle Nylon sling from moving. (250 mm wide × 5 m)

Other remarks

18

Necessary equipment Q'ty Name Q'ty 1 Crane (50 ton) 1

Assembly process No.

Slinging and moving of bare machine

0040 Sling of bare machine Front 12.5 ton (Including sling) Crane: 50 ton

Rear 10.8 ton (Including sling) Crane: 25 ton

Body lock pin

Slinging positions View f rom rear of bare machine

1. Apply cloths etc. to the body so that the body will not be damaged when it is slung. 2. Sling the bare machine with 2 cranes (Front side: 50 ton, Rear side: 25 ton). Sling : Chain sling (ATH-465-040) or ø28 wire Slinging position on front side : Frame slinging bracket Slinging position on rear side : Body lock pin installing position * Insert the body lock pin from inside of the machine (See the above figure). 3. Raise the differential upper part installing rod (upper rod).

Raised upper rod

Moving of bare machine 1. Move the bare machine to above the rear axle. Precautions Insert the body lock pin for slinging the rear side from inside of the machine. (If it is inserted from outside, it cannot be removed after the tire is installed.)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty Cranes (50 ton, 25 ton) 1 each Sling (ATH-465-040) 2 Pin (60 ø × 250 mm) 2 Wire (7 m, 28 ø) 2

Other remarks

19

Assembly process No.

Connection of rod and rear suspension

0050 Connection of rod and rear suspension Tack-weld nylon sling and lever block. (Used to fix lower arm)

* Carry out work simultaneously. 1. Connect A, B and C in order. Remove the pins installed temporarily and the spacers and bolts to be used in step 3. A (1) (2) (3) B (4) (5) (6) C (7) (8) (9)

2. 3. 4. 5. 6.

Part No. 561-52-81210 01010-81430 569-40-61710 561-52-81210 01010-81430 569-40-61710 561-52-81210 01010-81425 569-40-61710

Part name Pin Bolt Washer Pin Bolt Washer Pin Bolt Washer

Q'ty 2 2 2 2 2 2 2 2 2

Condition of parts Temporarily installed to rear axle A Temporarily installed to rear axle A Temporarily installed to rear axle A Temporarily installed to frame B Temporarily installed to frame B Temporarily installed to frame B Temporarily installed to rear axle C Temporarily installed to rear axle C Temporarily installed to rear axle C

Adjust the pin holes and remove the rod from the pin holes temporarily. Put the spacer in the rubber part of the spherical bushing. (See the figure at right.) Adjust the pin holes and insert the pin. Install the lock bolt and washer. Supply grease. Precautions

1. 2. 3. 4.

Necessary tools Name When adjusting the holes, take care not to catch Nylon sling your finger. If the spacer is installed forcibly, it is deformed. Take (60 mm wide × 3 m) care. Lever block When hitting the pin, take care not to crash the (2 ton, LB020) grease fitting. Clean the pins installed temporarily and parts A, B and C. Other remarks

20

3

Q'ty 2 2

Necessary equipment Name Q'ty

Assembly process No.

Positioning bare machine

0060

2,800

1,000

Wood block

Steel plate

Remove chock on front side.

Wood block

Sttel plate

1. Set the wooden blocks 1 m high under the vertical member as shown above. (If wooden blocks are set under the bumper, the machine is more stabilized.) When positioning the bare machine on the ground, place a steel plate under the wood blocks so that the bare machine will not sink and lean. 2. Remove the sling. 3. Discard the bolts and washers used to install the sling since they are not used any more. Precautions

Necessary tools Name Take care that the chassis will not move. Wood block Set the bare machine to proper height so that you can (300 mm square, 1 m) install the front tires. Steel plate

Q'ty 6

Necessary equipment Name Q'ty

1

Other remarks

21

Assembly process No.

Connection of rear axle cooling hose

0070 Connection of rear axle cooling hose Rear axle Hose plug on machine side, 2 pieces

Rear axle

Rear axle plug, 4 pieces

If flange is loosened a little and a plate is inserted before piping is disconnected, oil leakage is decreased (*1).

Fig.1

Plate

Flange

1. Remove all of the hose plugs on the machine side (2 pieces) and rear axle plugs (4 pieces). 2. Connect the hoses by using the following parts. (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 07371-21465 07372-21245 01643-51232 07000-F3048 07371-32076 07372-21240 01643-51232 07000-F2060

Part name Flange Bolt Washer O-ring Flange Bolt Washer O-ring

Q'ty 4 8 8 2 4 8 8 2

Note) Do not damage the O-ring. Condition of parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts Installed parts

3. Clean the parts stained with oil. Precautions

Necessary tools Name When connecting each hose, check that no dirt is in the Impact wrench hose and the O-ring is fitted securely. (For M12 mm) When removing each plug, set an oil drain case to Socket (19 mm) receive the leaking oil. *1. Dimension of plate (See "Fig 1") Large pipe: W = 63 mm Small pipe: W = 55 mm

22

Other remarks

Q'ty 1 1

Necessary equipment Name Q'ty

Assembly process No.

Connection of rear axle brake hose

0080 Connection of rear axle brake hose

a

b

c

a b View Y c Connection: From block to front side of valve (Reuse O-ring)

b

c

View Z Connection: From tube to rear side of valve (Reuse O-ring)

1. Remove the plugs from each part. 2. Connect the 3 hoses. 3. Clean the parts stained with oil. Caution: Install the hoses horizontally.

Precautions 1. Take care extremely not to mistake the connecting positions.

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

2. When removing each plug, do not lose the O-ring.

Other remarks

23

Assembly process No.

0085

Connection of rear axle brake hose (ASR specification: If equipped)

Connection of rear axle brake hose

c

b

a a

View Y

b

Connection: From block to front side of valve (Reuse O-ring)

c

Connection: CNJ13

d

Connection: CNJ12

c

a

1. Remove the plugs from each part. 2. Connect the 3 hoses.

View Z

3. Connect connectors "CNJ12" and CNJ13".

Connection: From tube to rear side of valve (Reuse O-ring)

4. Clean the parts stained with oil. Caution: Install the hoses horizontally.

Precautions 1. Take care extremely not to mistake the connecting positions.

Necessary tools Name

2. When removing each plug, do not lose the O-ring.

Other remarks

24

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0086

Connection of valve sub-assembly wiring harness (ASR specification: If equipped)

Connection of valve sub-assembly wiring harness * Wiring harness length between a -- b: 600 mm Wiring harness length between c -- d: 600 mm

Rear view of machine body

Connect CN WSRR.

Connect CN WSRL.

Remove clip and bolt and fix wiring harness.

(1) (2) (3)

Part No. 04434-51512 01024-81016 08193-21012

View Z

View Y

Part name Clip Bolt, sems Clip

Q'ty 5 6 2

Condition of part (Parts list No.) Installed temporarily to machine Installed temporarily to machine Installed temporarily to machine

1. Remove the clips and bolts installed temporarily and fix the wiring harness. 2. Connect connectors "CN WSRR" and "CN "WSRL". 3. Fix the sensor on the back side of the valve sub-assembly. Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

25

Assembly process No.

0087

Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)

Connection and fixing of piping going to rear axle

Z

(190)

(225)

ASR valve Rear axle slack adjuster

Rear axle

View X

Connection

Rear axle

View Z

1. Fix the hose going to the rear axle to the rear axle tube. (See view X.) 2. Connect the hose fixed in step 1 to the rear axle.

(1) (2) (3) (4) (5) (6)

Part No. 416-88-11140 04434-52110 07095-20314 07283-32236 01643-31032 01580-11008 Precautions

Part name Plate Clip Cushion Clip Washer Nut

Q'ty 2 2 2 2 4 4

Condition of part (Parts list No.) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Packed separately (HD785-7-087) Necessary tools Name

Other remarks

26

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0090

Connection and fixing of rear grease piping and supply of grease

Connection and fixing of rear grease piping and supply of grease

FWD

X

b

Y

c a

A

a b

View X

c

FWD 1. Connect 1 tube to part A (1 each on the right and left sides). (Left side: (2), Right side: (6)) b

2. Install elbows (4) to the ends of tubes (2) and (6) (directing them straight down) and connect them to the frame.

a

3. Fix tubes (2) and (6) with clips (8) and bolts (9).

c

4. Supply grease (G2-LI) through part A.

a A

b

View Y

c

5. Supply grease until it flows out of the lubricated spherical bushing, seal, or boot lip. 6. Grease must not ooze from the pipe joints

(2) (4) (6) (8) (9)

Part No. 561-52-82641 421-09-12540 561-52-82631 04434-50608 01024-80816

Part name Tube Elbow Tube Clip Bolt sems

Precautions 1. Take care extremely not to mistake the connecting positions.

Q'ty 1 2 1 4 4

Condition of part (Parts list No.) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Packed separately (HD785-7-090) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

27

Assembly process No.

Preparation for installing front axle

0100 Preparation for installing front axle 1. Remove the packing materials for each part.

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 561-40-61550 561-40-61560 566-52-41950 01010-81425 569-40-61710 561-40-81540 566-52-61150 01010-81425 569-40-61710

Part name Pin Pin Spacer Bolt Washer Pin Spacer Bolt Washer

Q'ty 2 2 4 4 4 2 4 2 2

Condition of parts Temporarily installed to machine (L = 260 mm) Temporarily installed to machine (L = 290 mm) Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine Temporarily installed to machine

2. Sling the front axle (See the attached photo).

Precautions

Necessary tools Name

Necessary equipment Q'ty Name Q'ty 1. Dimensions of pin vary on each portion. Place pins Nylon sling (30 mm wide × 2 m) 3 Crane (25 ton) 1 near relevant locations to install pins in place with Nylon sling (100 mm wide × 3 m) 1 ease. 2. Adjust sling so that suspension cylinder becomes Lever block (3/4 ton, LB008) 3 vertical against ground. Lever block (2 ton, LB020) 1 Hook slings at suspension cylinder assembly and hub stud portion. Other remarks

28

Assembly process No.

Installation of front axle

0110 Installation of frontxle

Fix with spacer, pin and lock bolt.

Move up.

o When installing steering cylinder

Move up.

How to sling

Fix with spacer, pin and lock bolt.

o When installing suspension cylinder

Lever block

1. Move up the A-arm mounting part with a Fix to fuel tank crane. bracket. 2. While adjusting the crane and lever block, adjust the A-arm to the pin holes of the frame once and then lower it with the lever block. 3. Insert the removed spacers (8 pieces) in the rubber covers of the spherical bushings of the A-arm (4 places on right and left sides) and then adjust the pin holes again with the lever block. (Adjust the horizontal direction with the lever block, too. See the right upper photo.) 4. Install the spacers and pins and fix them with the lock bolts. (If you use the guide as shown at right, you can install easily.) 5. Remove the sling from the A-arm. 6. While adjusting the crane, install the upper part of the suspension similarly to the A-arm. 7. Remove the sling and supply grease to each part. Precautions

Guide ATH-785-078

A-arm

Necessary tools Name

Necessary equipment Q'ty Name Q'ty 1. Check spacer for deviation. Nylon sling (30 mm wide × 2 m) 3 Crane (25 ton) 1 2. When making alignment, take care not to catch your Nylon sling (100 mm wide × 3 m) 1 fingers in it. Lever block (3/4 ton, LB008) 3 3. Check for O-ring on spherical bushing. Lever block (2 ton, LB020) 1 Guide pin (ATH-785-078)

Other remarks

29

Assembly process No.

Connection of front axle suspension pressure sensor

0120 Connection of front axle suspension pressure sensor

Z

Connection Suspension oil pressure sensor (Left) CN SUFL Suspension oil pressure sensor (Right) CN SUFR

1. After installing the front axle, connect the suspension oil pressure sensor wiring harness. 2. Fix the suspension oil pressure sensor wiring harness of the left front axle with clips (1) and bolts (2). 3. Fix the suspension oil pressure sensor wiring harness of the right front axle with clips (1) and bolts (2).

Suspension oil pressure sensor (Right) CN SUFR

A

A 2

Suspension oil pressure sensor (left) CN SUFL View Z

(1) (2)

Part No. 04434-50810 01024-81020 Precautions

Part name Clip Bolt, sems

Section A-A

Q'ty 3 3

Condition of parts Temporarily installed to machine Temporarily installed to machine Necessary tools Name

Necessary equipment Q'ty Name Q'ty Nylon sling (30 mm wide × 2 m) 3 Crane (25 ton) 1 Nylon sling (100 mm wide × 3 m) 1 Lever block (3/4 ton, LB008) 3 Lever block (2 ton, LB020) 1

Other remarks

30

Assembly process No.

0125

Connection of front axle wheel speed sensor (ABS specification: If equipped)

Connection of front axle wheel speed sensor 1. Fix and connect the wheel speed sensor wiring harness with the clip installed to the front axle.

Connection: CN WSFL Wheel speed sensor (FL)

Y

View Y Fixing with clip (installed to front axle)

30°

Left front axle

Fixing with clip (installed to front axle): Direct down 5°

Connecting: CN WSFR Wheel speed sensor (FR)

Z

Fixing with clip (installed to front axle)

View Z

50°

Right front axle Fixing with clip (installed to front axle): Direct down 5°

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

31

Assembly process No.

Connection of steering cylinder and tie rod

0130 Connection of steering cylinder and tie rod

L = 260mm

Reconnection

Reconnection

L = 240mm

(1) (2) (3) (4) (5)

Part No. 561-40-61531 561-40-61570 01010-81425 569-40-61710 561-40-61631

Part name Pin Pin Bolt Washer Boot

Q'ty 2 2 4 4 8

Condition of parts Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle Temporarily installed to front axle

1. Take out the remote grease tube from the top of the pin of the front axle lever and remove pins (1) and (2) and bellows (5). Remove the air cylinder cover, too. 2 Set the lever in parallel with the ground by adjusting the crane. 3. Set boots (5), adjust the pin holes, and install the pins. 4. Tighten the lock bolts. 5. Connect the remote grease tube again. 6. Supply grease to each part.

Precautions

Necessary tools Name

Necessary equipment Q'ty Name Q'ty 1. Check that the O-rings are fitted to the steering cylNylon sling (30 mm wide × 2 m) 3 Crane (25 ton) 1 inder and tie rod spherical bushing. 2. Note that the lengths of the pins are different from Nylon sling (100 mm wide × 3 m) 1 Lever block (3/4 ton, LB008) 3 one another. Lever block (2 ton, LB020) 1

Other remarks

32

Assembly process No.

Connection of front axle brake cooling hoses

0140 Connection of front axle brake cooling hoses Connection

Connection

Connect rear side to rear side.

Connect rear side to rear side.

Connect front side to front side

Connect front side to front side.

Left side

Right side

1. Remove all of the hose plugs on the machine side (2 pieces) and front axle plugs (4 pieces). 2. Connect the hoses by using the following parts. (Connect the right and left side similarly.)

(1) (2) (3)

Part No. 07371-21465 07375-21240 07000-F3048

Part name Flange Bolt O-ring

Q'ty 8 16 4

Condition of parts Installed parts Installed parts Installed parts

3. Clean the parts stained with oil.

* Before connecting the front axle brake cooling hose, set the hose clamp as shown in the following figure.

(Flange face - center of clip width)

Frame seen from front Precautions When removing each pipe plug, prepare a drain case to receive the leaking oil.

Necessary tools Name

Q'ty

(Flange face - center of clip width)

Necessary equipment Name Q'ty

Other remarks

33

Assembly process No.

Connection of front axle brake hoses

0150 Connection of front axle brake hoses Connection

a

a

b

After connecting hose, reassemble.

a b

b

Left front axle

Connection

a

b

b a a

After connecting hose, reassemble.

b

Right front axle

1. Remove the plugs, clamps, cushions and bolts from each part. 2. Connect 4 hoses (2 pieces each on right and left sides) and install the clamps, cushions and bolts removed in step 1. 3. Clean the parts stained with oil. Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring.

Necessary tools Name

Other remarks

34

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Connection of front axle auto suspension piping

0160 Color of SOL B-A band: Black Color of SOL B-B band: Green

Connection of front axle auto suspension piping

Color of SOL A-A band: Yellow

Color of SOL A-B band: Red

Section A-A Connection

Color of SOL A-A band: Yellow

Color of SOL A-B band: Red Color of SOL B-A band: Black

Color of SOL A-B band: White

SOL B-B

Color of SOL B-B band: Green

Left front axle

Color of SOL B-A band: Blue Color of SOL A-A band: Brown

Section B-B

Color of SOL A-A band: Brown Color of SOL A-B band: White

Connection

Color of SOL B-A band: Blue

SOL B-B

Right front axle

1. Remove the plugs from each part. 2. Connect 8 hoses (4 pieces on right side and 4 on left side). 3. Clean the parts stained with oil. Precautions 1. Take care extremely not to mistake the connecting positions. 2. When removing each plug, do not lose the O-ring.

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

35

Assembly process No.

Fixing of front axle auto suspension piping

0165 Fixing of front axle auto suspension piping 1. Fix the front axle and auto suspension piping. * For the clamp locations, see the following figure.

View Q

: 3 places

View P

: 8 places View Y: Right axle

View X: Left axle

107 (Actual length of center of brake hose)

420 (Actual length of center of brake hose) 193 (Actual length of center of brake hose)

466 (Actual length of center of brake hose)

532 (Actual length of center of auto suspension hose)

268 (Actual length of center of auto suspension hose)

Right axle seen from front

Left axle seen from rear

(1) (2) (3) (4) (5) (6) (7) (8)

Part No. 04434-53212 04434-53412 07095-00420 07095-00423 01024-81025 01580-11008 01024-81020 01643-31032 Precautions

Part name Clip Clip Cushion Cushion Bolt, sems Nut Bolt, sems Washer

Q'ty 8 4 1 3 4 4 4 4

Condition of part (Parts list No.) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Packed separately (HD785-7-165) Necessary tools Name

Other remarks

36

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0166

Fixing of front axle auto grease piping (If equipped: Auto grease specification)

Fixing of front axle auto grease piping 1. Fix the front axle and auto grease piping. * For the clamp locations, see the following figure.

View Z

190 (Actual length of center of brake hose) 80 (Actual length of center of brake hose)

270 (Actual length of center of brake hose)

480 (Actual length of center of brake hose)

300 (Actual length of center of auto grease hose)

(1) (2) (3) (4) (5) (6)

Part No. 04434-52310 04434-53412 07095-00420 01024-81025 01643-31032 01580-11008 Precautions

600 (Actual length of center of auto grease hose)

View X: Left axle

Part name Clip Clip Cushion Bolt, sems Washer Nut

Q'ty 4 4 4 4 4 4

View Y: Right axle

Condition of part (Parts list No.) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Packed separately (HD785-7-166) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

37

Assembly process No.

0167

Connection of left front axle auto grease piping (If equipped: Auto grease specification)

Connection of left front axle auto grease piping 1. Connect the left front axle and auto grease piping.

Connect: Band color "Yellow" L2 View Z Connect: Band color "Blue" L3

View W

Connect: Band color "Green" L6

Connect: Band color "Red" L1

Connect: Band color "White" L4 View Y

(1) (2) (3)

Part No. 561-95-63290 04434-51010 01024-81016 Precautions

Part name Elbow Clip Bolt, sems

Q'ty 3 1 1

Condition of part (Parts list No.) Installed to machine body Packed separately (HD785-7-167) Packed separately (HD785-7-167) Necessary tools Name

Other remarks

38

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Connection of right front axle auto grease piping (If equipped: Auto grease specification)

0168

Connection of right front axle auto grease piping 1. Connect the right front axle and auto grease piping.

Connect: Band color "Blue" R3

Section A-A

Connect: Band color "Black" R5

Connect: Band color "White" R4

Connect: Band color "Red" R1 Connect: Band color "Green" R6

View Y

View X

(1)

Part No. 561-95-63290

Precautions

Part name Elbow

Q'ty 3

Condition of part (Parts list No.) Installed to machine body

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

39

Assembly process No.

Installation of bumper and front axle steps

0170 Installation of bumper step

1. Remove bolts (1) from the bumper and install steps (2). 2. Install steps (4) with bolts (3). (1) (2) (3) (4)

Part No. 01024-81225 561-54-86871 01024-81230 561-54-31690

Part name Bolt, sems Step Bolt, sems Step

Q'ty 8 2 8 2

Condition of part (Parts list No.) Installed to bumper Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170)

Installation of front axle steps

1. Install the steps to the right and left front axles. (1) (2) (3) (4) (5)

Part No. 561-54-86751 561-54-86761 01024-81225 561-54-86740 01024-81030

Part name Bracket L. H Bracket R. H Bolt Step Bolt

Precautions There are right and left front axles. Since they are stamped as shown below, check the stamps when installing.

Q'ty 2 2 8 2 8

Condition of part (Parts list No.) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Packed separately (HD785-7-170) Necessary tools Name

"R.H." Other remarks

40

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of front axle step (EU specification)

0171 Installation of front axle step

1. Install the steps to the right and left front axles.

(1) (2) (3)

Part No. 561-54-88300 561-54-88400 01024-81225

Part name Step assembly, R.H Step assembly, L.H Bolt

Precautions The right and left front axles are different. When installing them, confirm their part Nos.

Q'ty 1 1 4

Condition of part (Parts list No.) Packed separately (HD785-7-172) Packed separately (HD785-7-172) Packed separately (HD785-7-172)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sale code : 5AC11

41

Assembly process No.

Installation of tire and wheel assembly

0180 Installation of tire and wheel assembly Apply chock hitch.

Nylon sling

If forklift is available, you can work easily as shown below.

Place wooden blocks under front axle (under king pin) and place steel plate under them.

Weight of tire: 1,500 kg Wood block Steel plate

Secure tire with wire to prevent tire from falling. Installed to front axle temporarily

Note) If the block is projected out too much, it will interfere with the installed tire. Accordingly, set the block inside of the king pin.

3 : 1,519 -- 1,617 Nm

{154.9 -- 164.8 kgm}

(1) (2) (3)

Part No. 569-22-72870 426-09-11520 561-30-80000

Part name Nut Washer Tire assembly

Q'ty 40 40 2

Condition of part (Parts list No.) Temporarily installed to front axle Temporarily installed to front axle Packed separately (HD785-7-180)

1. Remove the nuts and washers installed to the front axle temporarily. 2. Install the tire with the forklift and install the nuts and washers in the order of the numbers shown at right. Note) Take care that the tire will not fall from the forklift. When positioning the tire, take care not to damage the valve for inflating the tire. 3. Tighten the nuts with the impact wrench temporarily. 4. Lift up the front part of the chassis with the crane and remove the wood blocks. 5. Tighten the tire mounting nuts with the torque wrench. (Tightening torque: 1,519 – 1,852 Nm {154.9 – 188.8 kgm}) 6. Touch up the tightened parts (to prevent rusting). (Use the yellow paint used for the body.) Precautions

1,11

Take care of position of air valve.

5

3 9

7

8

10 4

6

2

Necessary tools Necessary equipment Name Q'ty Name Q'ty 1. When carrying the tire, take care that it will not fall. Torque wrench 1 Crane (50 ton) 1 2 When positioning the tire, take care not to damage QLE21000 Forklift (4 ton) 1 the air valve. Nylon sling 1 Wire 1 (100 mm wide × 12 m) Socket (1 inch × 46 mm) 1

Other remarks

42

Assembly process No.

Installation of drive shaft

0190 Installation of drive shaft

Apply LT-2. 3: 343 -- 427 Nm {34.9 -- 43.5 kgm}

Install larger end to transmission.

(1) (2)

Part No. 561-20-72002 01050-61895

Part name Propeller shaft Bolt

Q'ty 1 8

Condition of part (Parts list No.) Packed separately (HD785-7-190) Packed separately (HD785-7-190)

1. Remove the drive shaft from the machine. 2. Sling the drive shaft with the crane and put it between the rear axle and transmission. 3. Lightly hit the drive shaft spider to fit the faucet joint securely. 4. Install and tighten the bolts in the diagonal order. (For the Fig. 1 tightening order, see Fig. 1. Apply LT-2 to the bolts.) 5. Tighten the bolt again with the torque wrench. Bolt (2) tightening torque: (Torque wrench: 343 – 627 Nm {34.9 – 43.5 kgm}) 343 – 427Nm 6. Install the guard again. {34.9 – 43.5kgm} Guard tightening torque: 7. Wipe off the grease from the mounting part and 1,180 – 1,470Nm degrease the bolts (coupling). {120 – 150kgm}

Precautions

Necessary tools Name Install drive shaft from the front side and transmission Nylon sling side for the ease of work. (Tighten the bolts on the front (60 mm wide × 3 m) side temporarily and fit the faucet joint securely.) Torque wrench, 2800QL When installing the rear side, install a chain block to the drive shaft to extend.

4

2

5,1

3

Necessary equipment Q'ty Name Q'ty 2 Crane (25 ton) 1 1

Other remarks

43

Assembly process No.

0200

Installation of oil quick charge box (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 cooling oil

Brake control oil Steering and H/T oil

Engine oil

Section A-A

(1) (2)

View Z

Part No. X251156860 01024-81225

Precautions

Part name Box, sub assembly Bolt, sems

Q'ty 1 5

Condition of part (Parts list No.) Packed separately (HD785-7-200) Packed separately (HD785-7-200)

Necessary tools Name

Other remarks

44

Q'ty

Necessary equipment Name Q'ty

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)

Part No. 561-04-81322

Precautions

Part name Cover

Q'ty 1

Condition of part (Parts list No.) Installed to fuel tank

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

45

Assembly process No.

Installation of toolbox and tool kit

0270 Installation of toolbox

(1) (2) (3)

Part No. 561-98-86110 01024-81225 09460-00000

Part name Tool box, sab assembly Bolt Lock

Q'ty 1 4 1

Condition of part (Parts list No.) Packed separately (HD785-7-270) Temporarily installed to fuel tank 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).

Precautions

Necessary tools Name

Other remarks

46

Q'ty

Necessary equipment Name Q'ty

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 specification

(1) (2) (3) (4) (5) (6)

Part No. 561-54-8A981 01024-D1230 561-54-8A960 01024-D1230 561-54-8A982 561-54-8A900 Precautions

Part name Ladder Bolt Step Bolt Ladder Step

Q'ty 1 8 1 4 1 1

EU specification reference drawing

EU specification reference drawing

Condition of part (Parts list No.) Packed separately (HD785-7-275) Installed to fuel tank Packed separately (HD785-7-275) Packed separately (HD785-7-275) Packed separately (HD785-7-277) Packed separately (HD785-7-277) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 6HH68-A or 5AC11

47

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 preventive paint from rear support ground face (on machine frame side).

* Remove rust preventive paint from rear support ground face (on machine frame side). (1) (2) (3) (4) (5) (6)

Part No. 561-46-80200 01010-82475 01643-32460 561-46-81791 01010-81850 01643-31845

Z

Part name Rear support LH Bolt Washer Rear support RH Bolt Washer

Q'ty 18 18 18 1 7 7

Condition of part (Parts list No.) Packed separately (HD785-7-280) Installed to frame Installed to frame Packed separately (HD785-7-280) Installed to frame Installed to frame

Part name Clip Bolt

Q'ty 18 18

Condition of part (Parts list No.) Packed separately (HD785-7-280) Packed separately (HD785-7-280)

Fixing of air tube 1. Fix the air tube. (7) (8)

Part No. 04434-51210 01024-81020

View Z

Diagonal front view

Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Other remarks

48

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Assembly process No.

0281

Installation of rear support (Muffler specification: If equipped)

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. Muffler specification

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

* Remove rust preventive paint from rear support ground face (on machine frame side). (1) (2) (3) (4) (5) (6)

Part No. 561-46-80200 01010-82475 01643-32460 561-84-84391 01010-81850 01643-31845

Z

Part name Rear support LH Bolt Washer Rear support RH Bolt Washer

Q'ty 18 18 18 1 7 7

Condition of part (Parts list No.) Packed separately (HD785-7-281) Installed to frame Installed to frame Packed separately (HD785-7-281) Installed to frame Installed to frame

Part name Clip Bolt

Q'ty 18 18

Condition of part (Parts list No.) Packed separately (HD785-7-281) Packed separately (HD785-7-281)

Fixing of air tube 1. Fix the air tube. (7) (8)

Part No. 04434-51210 01024-81020

View Z

Diagonal front view

Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Other remarks

49

Assembly process No.

0282

Installation of rear support (ABS specification: If equipped)

* Keep bolts (2) and (5) tightened lightly Installation of rear support for adjustment until the right platform and 1. Remove the bolts and washers installed to the machine. cab are installed. 2. Install the rear support assembly. (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

* Remove rust preventive paint from rear support grounding surface (on machine frame side). (1) (2) (3) (4) (5) (6) (9) (10)

Part No. 561-46-80300 01010-82475 01643-32460 561-84-84391 01010-81850 01643-31845 561-88-80201 01024-81230

Part name Rear support LH Bolt Washer Rear support RH Bolt Washer ABS front sub assembly Bolt, sems

Q'ty 18 18 18 1 7 7 1 4

Condition of part (Parts list No.) Packed separately (HD785-7-282) Installed to frame Installed to frame Packed separately (HD785-7-282) Installed to frame Installed to frame Packed separately (HD785-7-282) Packed separately (HD785-7-282)

Part name Clip Bolt

Q'ty 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-282) Packed separately (HD785-7-282)

Fixing of air tube 1. Fix the air tube. (7) (8)

Part No. 04434-51210 01024-81020

Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Other remarks

50

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Assembly process No.

0283

Installation of rear support (Sand terrain specification: If equipped)

Installation of rear support 1. Remove the bolts and washers installed to the machine. 2. Install the rear support assembly. * Keep bolts (2) and (5) tightened lightly for adjustment until the right platform and cab are installed. * Remove rust preventive paint from rear support grounding surface (on machine frame side).

* Remove rust preventive paint from rear support grounding surface (on machine frame side).

(1) (2) (3) (4) (5) (6)

Part No. 561-46-80200 01010-82475 01643-32460 X250783640 01010-81850 01643-31845

Part name Rear support LH Bolt Washer Rear support RH Bolt Washer

Q'ty 1 18 18 1 7 7

Condition of part (Parts list No.) Packed separately (HD785-7-283) Installed to frame Installed to frame Packed separately (HD785-7-283) Installed to frame Installed to frame

Part name Clip Clip Bolt

Q'ty 2 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-283) Packed separately (HD785-7-283) Packed separately (HD785-7-283)

Fixing of air tube 1. Fix the air tube. (7) (8) (9)

Part No. 04434-51210 04434-51010 01024-81020

Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Other remarks

51

Assembly process No.

Installation of muffler

0290 Installation of muffler Fire prevention cover * Before tightening the bolts permanently, install all the parts

Z

X 3: 8.8 – 9.8 Nm {0.9 – 1.0 kgm}

(1) (2) (3) (4) (5) (6)

Part No. 561-02-81210 6502-12-1722 01024-81235 561-02-81350 01580-11008 01643-31032

Part name Tube V coupling Bolt Band Nut Washer

* Tighten bolts to secure fire prevention cover. Q'ty 1 1 2 1 4 2

View Z

Condition of part (Parts list No.) Packed separately (HD785-7-290) Packed separately (HD785-7-290) Packed separately (HD785-7-290) Installed to frame Installed to frame 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}. 2) Tighten nut "b" to 59 – 74 Nm {6 – 7 kgm} and then return nut "a" slightly. Precautions

Necessary tools Name

Other remarks

52

a b Q'ty

View X Necessary equipment Name Q'ty

Assembly process No.

0291

Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)

Installation of muffler

a: 4 places

3: 8.8–9.8Nm {0.9–1kgm}

Front view of machine (Sectional view of rear support)

Rear view of machine

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) (2) (3) (4)

Part No. 561-84-80101 01024-81230 6502-12-1722 561-84-84341

Part name Muffler sub assembly Bolt, sem V coupling Tube

Q'ty 1 4 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-291) Packed separately (HD785-7-291) Packed separately (HD785-7-291) 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

336±9

A

A-A A

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty 1

Other remarks

53

Assembly process No.

Installation of fire prevention cover

0300 Installation of fire prevention cover

* Install the fire prevention cover before installing the fender (for higher workability).

(1) (2) (3) (4)

Part No. 561-89-86111 561-89-86120 01024-81230 01024-81225

Part name Cover Cover Bolt, sems Bolt, sems

Q'ty 1 1 6 2

Condition of part (Parts list No.) Packed separately (HD785-7-300) Packed separately (HD785-7-300) Packed separately (HD785-7-300) Packed separately (HD785-7-300)

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

Precautions

Necessary tools Name

Other remarks

54

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of front support

0310 Installation of front support

3: 662 – 829 Nm {67.5 – 84.5 kgm}

3: 662 – 829 Nm {67.5 – 84.5 kgm}

Connection of headlamp wiring harness

(1) (2) (3) (4) (5) (6)

Part No. 561-54-80301 01010-82270 01643-32260 561-54-80401 01010-82255 01643-32260

Part name Front support sub assembly LH Bolt Washer Front support sub assembly RH Bolt Washer

Q'ty 1 11 11 1 5 5

Condition of part (Parts list No.) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) Packed separately (HD785-7-310) 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. Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Other remarks

55

Assembly process No.

0315

Installation of front support (Fog lamp specification: If equipped)

Installation of front support

3: 662 – 829 Nm {67.5 – 84.5 kgm}

3: 662 – 829 Nm {67.5 – 84.5 kgm}

Connection of headlamp wiring harness

(1) (2) (3) (4) (5) (6)

Part No. 561-54-80100 01010-82270 01643-32260 561-54-80200 01010-82255 01643-32260

Part name Front support sub assembly LH Fog Bolt Washer Front support sub assembly RH Fog Bolt Washer

Q'ty 1 11 11 1 5 5

Condition of part (Parts list No.) Packed separately (HD785-7-315) Packed separately (HD785-7-315) Packed separately (HD785-7-315) Packed separately (HD785-7-315) Packed separately (HD785-7-315) Packed separately (HD785-7-315)

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. Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Other remarks

56

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Assembly process No.

0317

Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)

Installation of front support

3:

3:

Connection of headlamp harness

(1) (2) (3) (4) (5) (6)

Part No. 561-85-80V00 01010-82270 01643-32260 561-85-80W00 01010-82255 01643-32260

Part name Front support sub assembly LH Bolt Washer Front support sub assembly RH Bolt Washer

Q'ty 1 11 11 1 5 5

Condition of part (Parts list No.) Packed separately (HD785-7-317) Packed separately (HD785-7-317) Packed separately (HD785-7-317) Packed separately (HD785-7-317) Packed separately (HD785-7-317) Packed separately (HD785-7-317)

1. Install front support assemblies (1) and (4) with bolts (2) and (5) and washers (3) and (6). 2. Fix the harness to the clips and connect connectors (CN-RP and CN-LP3). 3. After installing, touch up the damaged surfaces.

Precautions

Necessary tools Name Nylon sling (60 mm wide × 3 m) Torque wrench

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1 1

Other remarks

57

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.

3 : 44.1 -- 58.8 Nm {4.5 -- 6.0 kgm}

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Part No. 561-40-83300 561-40-42620 561-40-42630 561-40-42650 02010-20638 01643-31032 569-40-83470 569-40-83480 01024-80616 01643-30623 01580-10605

Part name Valve,steering Cushion Collar Plate Bolt Washer Bracket Seal Bolt, sems Washer Nut

Q'ty 1 4 4 4 4 4 2 1 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320)

3. Install the nipple to the steering valve.

View Z (12) (13) (14) (15) (16) (17)

Part No. 02896-21012 569-61-84770 437-40-22310 569-61-84780 418-62-11620 02896-21018

Part name O-ring Nipple O-ring Nipple O-ring O-ring

Precautions 1. Take care that the O-ring will not be projected.

Q'ty 1 2 2 2 2 4

Condition of part (Parts list No.) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Packed separately (HD785-7-320) Necessary tools Name

Other remarks

58

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Preparation for installing cab

0330 Preparation for installing cab 1. Adjust the dimensions between the viscous mounts with the left front support and rear support as shown below.

Dimension measuring method

Slinging of cab 1. Sling the cab assembly. (Use a sling having capacity of at least 3 ton.)

(1)

Part No. 561-54-83200 Precautions

Part name Cab assembly

Q'ty 1

Condition of part (Parts list No.) Packed separately (HD785-7-330)

Necessary tools Name Nylon sling (Capacity: Min. 3 ton)

Necessary equipment Q'ty Name Q'ty 1 Crane (50 ton) 1

Other remarks

59

Assembly process No.

Installation of cab

0340

Clearance (A) adjusted with shim (Standard: 0 mm)

Installation of cab

Section A-A

* After cab is installed, if clearance (A) is made, insert shims (7) and (8) by necessary quantity (up to 8 pieces for each place (t0.5 × 4, t1.0 × 4)). No shim may be used as standard.

(5) 3: 490 – 608 Nm {50 – 62 kgm}

* After the cab is mounted, if there is clearance (Standard: 0 mm), insert shims (4) as necessary [Number of shims prepared for each place: 4 (t1.0 x 4)]. No shim may be used as standard.

(1) 3: 245 – 309 Nm {25 – 31.5 kgm} (9) 3: 1,177 – 1,471 Nm {120 – 150 kgm}

Connect

Section B-B

1. Move the cab assembly to above the frame. 2. Remove parts (9) and (10) installed temporarily and then install the cab assembly with the following parts. (1) (2) (4) (5) (6) (7) (8) (9) (10)

Part No. 01010-81645 01643-31645 561-54-87221 01010-82055 01643-32060 561-54-87231 561-54-87241 01596-03024 01643-33080

Part name Bolt Washer Shim t=1.0 Bolt Washer Shim t=0.5 Shim t=1.0 Nut Washer

Q'ty 8 8 4 8 8 8 8 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Packed separately (HD785-7-340) Installed to frame Installed to frame

3. Remove the sling. 4. Connect the ground wire to the rear of the cab assembly. (12) (13)

Part No. 08028-45025 01024-81016

Part name Cable Bolt, sems

Precautions 1. If there is clearance between the mount bracket and cab (clearance to be adjusted with shims), insert shims by necessary quantity (up to 8 pieces for each place). 2. The part to connect the ground wire must be free from stain or paint.

Q'ty 1 2

Condition of part (Parts list No.) Installed to cab assembly Packed separately (HD785-7-340)

Necessary tools Name

Other remarks

60

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Connection of ABS piping (If equipped)

0345 Connection of ABS piping 1. Remove the plugs of each hose and tube. 2. Check that the correct O-ring is fitted to each tube and connect the hose on the ABS front box side.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

61

Assembly process No.

Connection of column

0350 Connection of column 1. Remove the bolt and washer and connect the column shaft to the steering valve. 2. Set the bolt removed in step 1 to the hollow of the steering valve joint and tighten it again. (See section A-A.)

Remove these bolt and washer.

A A

Bolt Set bolt to this "hollow".

Steering valve Section A-A

Precautions 1. Apply grease (LM-G) to the connecting parts.

Necessary tools Name

2. When installing the parts, do not hit them with a hammer etc. or installing them forcibly.

Other remarks

62

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of washer tank

0355 Installation of washer tank

1. Take washer tank assembly (1) out of the cab and install it to the cab with bolts (2). 2. Fix washer hose (A) coming out of the cab with washer tank clips (marked with a) at 2 places so that it will not be flattened and then connect it to the washer tank. 3. Connect wiring harness (B) going to the washer motor to the washer tank. (CN FL04) 4. Fix washer hose (A) and wiring harness (B) going to the washer motor with band (3) at 80 mm from the bracket end (on the cab side) so that the hose will not be flattened.

(1) (2) (3)

Part No. 569-06-6115A 01024-81020 08034-40521

Part name Washer tank Bolt, sems Band

Precautions 1. When fixing the washer hose, take care not to flatten it.

Q'ty 1 4 1

Condition of part (Parts list No.) Packed together with cab Packed together with cab Packed together with cab

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

63

Assembly process No.

Connection of cab piping

0360 Connection of cab piping

Z (View from below cab)

Path hoses through notches. Brake accumulator

A View Z (View from below cab)

1. 2. 3. 4. 5. 6

A

Remove the underside cover of the cab floor. Remove the plugs from each part. Connect the 7 hoses. Pass 5 hoses through the notches of rubber (3). Install the following parts. Clean the parts stained with oil. (1) (2) (3) (4) (5) (6)

Part No. 561-89-86241 561-89-86251 561-89-86232 424-54-14220 561-89-86262 01024-81025

Precautions

Part name Bracket Plate Rubber Washer Bracket Bolt, sems

Q'ty 1 1 1 2 2 10

Section A-A

Condition of part (Parts list No.) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360) Packed separately (HD785-7-360)

Necessary tools Name

Other remarks

64

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Connection of cab wiring

0370 Connection of cab wiring

Procedure for connecting wiring harness

CN LP2: Left platform wiring harness junction

Z (View from below cab) CN LP1: Left platform wiring harness junction

CN J01: Wiring harness junction in cab

CN J06: Wiring harness junction in cab CN J05: Wiring harness junction in cab

CN PMLA: PLM and side lamp wiring harness junction

CN J03: Wiring harness junction in cab CN J02: Wiring harness junction in cab

Z (View from below cab)

(1) (2) (3) (4) (5) (6) (7) (9) (10) (11) (12)

Part No. 04434-52711 01024-81020 08193-21012 01024-81016 23S-62-25850 6152-51-5520 01024-81070 04434-52110 07095-20420 561-61-65530 561-61-65540

Z (View from below cab)

Part name Clip Bolt, sems Clip Bolt, sems Clip Spacer Bolt, sems Clip Cushion Clip Insulator

Q'ty 3 4 1 1 1 1 1 1 1 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370) Packed separately (HD785-7-370)

1. Connect the wiring harness in the cab. 2. Install the cab undercover removed in the previous step. 3. Fix the bracket installed in the previous step. Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

65

Assembly process No.

0375

Connection of cab wiring (ASR/ABS specification: If equipped)

Connection of cab wiring

CN LP2: Left platform wiring harness junction

Procedure for connecting wiring harness

CN J04: Wiring harness junction in cab CN LP1: Left platform wiring harness junction CN J06: Wiring harness junction in cab

Z (View from below cab)

CN J05: Wiring harness junction in cab

CN J01: Wiring harness junction in cab

CN J03: Wiring harness junction in cab

CN PMLA: PLM and side lamp wiring harness junction

CN J02: Wiring harness junction in cab

Z (View from below cab)

Z (View from below cab) : Fix lower wiring harness

Fix upper wiring harness :

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Part No. 04434-52711 01024-81020 08193-21012 01024-81016 23S-62-25850 6152-51-5520 04434-52110 01024-81070 04434-52511 07095-20420 561-61-65530 561-61-65540 195-979-5190 04434-53411 07095-20625 01024-81075

Part name Clip Bolt, sems Clip Bolt, sems Clip Spacer Clip Bolt, sems Clip Cushion Clip Insulator Collar Clip Cushion Bolt, sems

Q'ty 3 3 4 4 1 1 1 1 1 1 1 1 1 1 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375) Packed separately (HD785-7-375)

1. Connect the wiring harness in the cab. 2. Install the cab undercover removed in the previous step. 3. Fix the bracket installed in the previous step. Precautions

Necessary tools Name

Other remarks

66

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0376

Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)

Connection of engine prelubrication harness to cab 1. Fix the engine prelubrication harness to the cab and connect it to the harness on the cab side.

View X

View Z

Section B-B

Connect: Cab relay connector PRE4

: Tighten together at 3 places.

View Y: Underside of cab

Section A-A

(1) (2) (3) (4) (5)

Part No. 6131-22-3750 04434-51210 198-06-53510 01024-81045 04434-50810 Precautions

Part name Boss Clip Cushion Bolt, sems Clip

Q'ty 1 1 1 1 3

Condition of part (Parts list No.) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Packed separately (HD785-7-376) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

67

Assembly process No.

Connection and fixing of engine compartment lamp wiring harness (if equipped)

0377

Connection and fixing of engine compartment lamp wiring harness Pass wiring harness into cab.

Mark a: 4 places (Tighten with clip)

View Z: Cab seen from below

CAB

Remove cover in cab.

Section A-A 1. Lay the engine compartment lamp wiring harness from the machine to under the cab and fix it with clips (1). 2. Pass the engine compartment wiring harness into the cab. Remove the cover in the cab and connect the wiring harness to connector (SPARE4). 3. Install the cover in the cab again.

Connect: SPARE4

Inside of cab seen from front

(1)

Part No. 04434-50610 Precautions

Part name Clip

Q'ty 4

Condition of part (Parts list No.) Packed separately (HD785-7-377) Necessary tools Name

Other remarks

68

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0378

Connection of auto grease harness to cab (If equipped: Auto grease specification)

Connection of auto grease harness to cab 1. Fix the auto grease harness to the cab and connect it to the harness on the cab side. For other specifications, remove mounting bolt and install with it.

Section A-A Connect: Harness on cab side

View Y

View Z

(1) (2) (3)

Part No. 04434-51210 01024-81020 561-95-83210 Precautions

Part name Clip Bolt, sems Bracket

Q'ty 1 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-378) Packed separately (HD785-7-378) Packed separately (HD785-7-378) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

69

Assembly process No.

0379

Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)

Connection of engine stop harness to cab 1. Fix the engine stop harness to the cab and connect it to the harness on the cab side.

Install together with main harness clip mounting bolt.

View Y

Install together with cab under harness clip mounting bolt.

: 8 places

Section A-A

Section B-B Install together with cab under harness clip mounting bolt.

Section C-C

Remove used for standard and install with it.

Section D-D : 2 places Install together with main harness clip mounting bolt.

Connect View Z

View X

(1) (2) (3) (4) (5)

Part No. 04434-50610 04434-51210 198-06-53510 01024-81020 08193-21012 Precautions

Part name Clip Clip Cushion Bolt, sems Clip

Q'ty 8 1 1 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Packed separately (HD785-7-379) Necessary tools Name

Other remarks

70

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation and fixing of steering hoses

0380 Installation and fixing of steering hoses 1. Remove the cover from the front support. Install the 5 hoses to the steering valve. When installing the hoses, match the Nos. printed on them to the following figure. Port P: "2"

Port LS

Port RT: "5" Port R: "1" Port LT: "4"

View Z (1) (2) (3) (4) (5)

Part No. 02766-00423 561-61-82320 561-61-82350 561-61-82310 561-61-82340

Part name Hose Hose Hose Hose Hose

Q'ty 1 1 1 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380)

Port R Port P Port LT

Port LS

Port RT

Port R: "1" Port P: "2" Port LS Port LT: "4" Port RT: "5"

(6) (7) (8) (9) (10)

Part No. 561-61-64510 561-61-64540 561-61-64530 561-61-64520 01024-81290 Precautions

Part name Clamp Plate Spacer Plate Bolt sems

2. Fix the 5 steering hoses to the front support. 3. Connect the hoses to the steering tubes of the frame. 4. Clean the parts stained with oil. Q'ty 6 3 6 3 6

Condition of part (Parts list No.) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Packed separately (HD785-7-380) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

71

Assembly process No.

Fixing of air conditioner drain hose

0385 Fixing of air conditioner drain hose

1. Remove the cab undercover. 2. Remove wiring harness clamping bolts (2) of the front support LH. 3. Install the air conditioner drain hose to the wiring harness clamping position of the front support LH with clip (1) and bolts (2) removed in step 1. 4. Remove bolts (5) installed in field assembly procedure No. 0380. 5. Install the 2 air conditioner drain hoses together with clips (3) and (4) and bolts (5) removed in step 3.

(1) (2) (3) (4) (5)

Part No. 04434-51510 01024-81016 04435-51510 04435-51810 01024-81290 Precautions

Part name Clip Bolt, sems Clip Clip Bolt, sems

Q'ty 2 2 1 1 2

Condition of part (Parts list No.) Packed in cab Installed to front support LH Packed in cab Packed in cab Installed in No. 0380 Necessary tools Name

Other remarks

72

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of steering hose cover

0390 Installation of steering hose cover

1. Install the cover over the steering piping of the left front support

(1) (2) (3) (4)

Part No. 561-54-81490 01024-81220 561-54-81580 01024-81220

Precautions

Part name Cover Bolt, sems Cover Bolt, sems

Q'ty 1 4 1 4

Condition of part (Parts list No.) Packed separately (HD785-7-390) Packed separately (HD785-7-390) Packed separately (HD785-7-390) Packed separately (HD785-7-390)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

73

Assembly process No.

Connection of air conditioner and heater hoses

0395 Connection of air conditioner and heater hoses

1. Connect the 4 hoses to the cab piping. 2. Fix hose (d) going to the engine and hose (c) coming from the engine with clamps (1). (1) (2)

Part No. 09479-02400 01024-81020 Precautions

Part name Clamp Bolt, sems

Q'ty 2 1

Condition of part (Parts list No.) Installed to hose Packed separately (HD785-7-395) Necessary tools Name

Other remarks

74

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Connection of cab floor wiring

0400 Connection of cab floor wiring 1. Remove the cover in the cab floor.

Inside of cab floor

X 2. Connect the wiring coming from the following figure (View Z) inside the cab floor. * Each wiring harness is printed with a connector No. Take care not to connect them wrongly.

Z

CN HM-21B Exhaust temperature sensor connector (RF) CN HM-21A Exhaust temperature sensor connector (LF)

CN HM-21D Exhaust temperature sensor connector (RR))

View Z

(1)

Part No. 561-97-82250

Precautions

View X

CN HM-21C Exhaust temperature sensor connector (LR)

Part name Wiring harness

Connection

CN HM-22A

CN HM-23A

CN HM-22C

CN HM-23C

CN HM-22B

CN HM-23B

CN HM-22D

CN HM-23D

Q'ty 1

Inside of cab floor

Condition of parts Installed to frame

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

75

Assembly process No.

Fixing of ASR/ABS wiring harness (If equipped)

0405 Fixing of ASR/ABS wiring harness 1. Fix ASR/ABS wiring harness (1) to the cab with clip (1) and bolt (2). 2. Fix the connector with clip (3) and bolts (2). (CN J11)

CAB

X

Z

Fixing: CN J11

View X

CN ABSER: Ground

View Z

(1) (2) (3)

Part No. 04434-51910 01024-81016 08193-21012 Precautions

Part name Clip Bolt, sems Clip

Q'ty 1 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-405) Packed separately (HD785-7-405) Packed separately (HD785-7-405) Necessary tools Name

Other remarks

76

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0406

Connection and fixing of ABS wiring harness (If equipped)

Connection and fixing of ABS wiring harness 1. Connect and fix the wiring harness with the installed clip and bolt.

X

ABS front box

View Z Wheel speed sensor wiring harness ABS/ASR wiring harness Fixing Connection and fixing: CN J11 Fixing

Section A-A

Precautions

Z View X

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

77

Assembly process No.

Installation of cover under cab

0410 Installation of cover under cab FWD

A A

B

B

Z View Z

Directed to inside of cover

Directed to inside of cover

Section A-A

Section B-B Installed position of (5), (6) and (7)

View Z

1. Install seals (3) and (4) to cover (1). 2. Install the cover under the cab. 3. Fix the 2 hoses with clamps (5), cushions (6) and bolt (7).

(1) (2) (3) (4) (5) (6) (7)

Part No. 561-54-82141 01024-81020 569-54-82260 569-54-82290 07094-30620 07095-00628 01024-81270

Precautions

Part name Cover Bolt, sems Seal Seal Clamp Cushion Bolt, sems

Q'ty 1 9 1 1 2 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410) Packed separately (HD785-7-410)

Necessary tools Name

Other remarks

78

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Wiring of front glass with heater wire (If equipped)

0415 Installation of cab undercover

a: 3 places

FWD

X

Z : 2 places (1 place: See view X)

: 3 places

CN BR-4 Connection : 2 places

View X

View Z

(Battery)

Connection: Secondary side (BR04)

1. Using clips (1) and bolts (2), connect the glass heater wiring harness coming from the cab. 2. Remove the bolts marked with a (3 places) and fix wiring harness with clips (1), collars (4) and bolts (5). (Discard the removed bolts.) 3. Open the battery box cover and connect the glass heater wiring harness to the battery relay. (View X) 4. Fix the wiring harness with bands (3) and (6).

(1) (2) (3) (4) (5) (6)

Part No. 04434-50610 01024-81016 08034-20823 22D-62-18450 01024-81055 08034-20519 Precautions

Part name Clip Bolt, sems Band Collar Bolt, sems Band

Q'ty 6 3 2 3 3 2

Condition of part (Parts list No.) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Packed separately (HD785-7-415) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

79

Assembly process No.

Installation of cab seal

0420 Installation of cab seal

Z

1. Stick seal (1) to the clearance between the cab and radiator guard. (1) Degrease, clean and dry the seal sticking surface. (2) Thinly apply adhesive (LT-1A) to the seal sticking surface and sticking surface on the right side of the cab. Dry the surfaces coated with the adhesive for 3 - 5 minutes and then stick the seal.

(1)

Part No. 561-54-61290

Precautions

Part name Seal

Q'ty 1

Condition of part (Parts list No.) Packed separately (HD785-7-420)

Necessary tools Name

Other remarks

80

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0430

Installation of ambient temperature sensor wiring harness

Installation of ambient temperature sensor wiring harness

Connection: CN FL06

Front support (Left) Ambient temperature sensor wiring harness

1. Fix the wiring harness under the cab with clips (2) and bolts (3). 2. Fix the connector with clip (1) and bolts (3) and connect CN FL06. * Bolts (3) are those used in Assembly procedure No. 0480, however. Use them to fix the cab step, too.

(1) (2) (3)

Part No. 08193-21012 04434-50612 01024-81230

Precautions

Part name Clip Clip Bolt, sems

Q'ty 1 2 3

Condition of part (Parts list No.) Packed separately (HD785-7-430) Packed in cab Bolt (2) used in No. 0480

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 6HF55K (VHMS + PLM + ORB, overseas)

81

Assembly process No.

Installation of undercab wiring harness connector

0440 Installation of undercab wiring harness connector

Front support (Left)

1. Fix the wiring harness under the cab with clip (2) and bolts (3). 2. Fix the wiring harness with clip (1) and bolts (3) and connect connector (4) to its end. * Bolts (3) are those used in Assembly procedure No. 0480, however. Use them to fix the cab step, too.

(1) (2) (3) (4)

Part No. 08193-21012 04434-50612 01024-81225 08192-23830

Precautions

Part name Clip Clip Bolt, sems Connector

Q'ty 1 2 3 1

Condition of part (Parts list No.) Packed separately (HD785-7-440) Packed in cab Bolt (2) used in No. 0480 Packed separately (HD785-7-440)

Necessary tools Name

Other remarks

82

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0445

Connection and fixing of rear view camera wiring harness (if equipped)

Connection and fixing of rear view camera wiring harness Camera cable

Wiring harness rail

2-stage connection 1) Tighten the connector with the fingers. 2) Using 2 17mm spanner wrench, rotate the outer ring 180 degrees. Tighten to about 245 Nm {25 kgm} securely.

View X

Connect

View Y

Pass through backup lamp mounting hole and fix together with junction connector. Section A-A

Section B-B

Section C-C

Mark a: 9 places Mark u: 11 places

View Z

(1) (2) (3) (4)

Part No. 120-54-42430 04434-50610 01024-81050 08034-20823

Part name Spacer Clip Bolt, sems Band

Q'ty 9 9 9 11

Condition of part (Parts list No.) Installed temporarily to machine Installed temporarily to machine Installed temporarily to machine Packed separately (HD785-7-445)

1. Pull the camera cable out of the cab. (See view Z.) 2. Remove the wire harness rail cover and fix the camera cable with clips (2) installed temporarily. 3. Connect the rear view camera and camera cable and fix the wire harness with bands (4). Precautions

Necessary tools Name 17mm spanner wrench

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

83

Assembly process No.

Installation of R.H platform assembly

0450 Installation of R.H platform assembly

3 : 319 – 608 Nm {32.5 – 62 kgm} Target : 460 Nm {47 kgm}

1. Remove bolts (2) installed temporarily. 2. Sling the right platform and install it with bolts (2) and (3). Install caps (5). Part No. 561-54-80602 01024-81235 01010-82045 01643-32060 09415-05016

(1) (2) (3) (4) (5)

Part name R.H platform assembly Bolt Bolt Washer Cap

Q'ty 1 8 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-450) Temporarily installed to machine body Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450)

Installation of R.H platform mirror 1. Install the mirror and underview mirror to the handrail. (See view Z) 2. Adjust the angle of the mirror.

Z

: 59 -- 74 Nm {6 -- 7.5 kgm}

: 59 -- 74 Nm {6 -- 7.5 kgm}

View Z

(1) (2) (3) (4) (6) (7) (8) (9) (10) (11)

Part No. 561-54-80900 07283-33442 01643-31032 01597-01009 07283-32236 07283-52232 01597-01009 01643-31032 23W-P86-2890 561-54-81871

Part name Mirror & rail assembly Clip Washer Nut Clip Seat Nut Washer Mirror Stay

Q'ty 2 4 8 8 2 2 4 4 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450) Packed separately (HD785-7-450)

Precautions

Necessary tools Name Tighten the mounting bolts of rear support No. 0280 perNylon sling manently. (250 mm wide × 5 m) (2) 3: 824 – 1,030 Nm {84 – 105} kgm (5) 3: 343 – 427 Nm {35 – 43.5} kgm

Other remarks

84

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1

Assembly process No.

Installation of right fender

0470 Installation of right fender

Set glossy side toward front of machine.

1. Install the right fender. 2. Install the guard to the right fender.

(1) (2) (3)

Part No. X251043130 01024-81230 561-54-87420

Part name Fender R.H Bolt sems Guard

Precautions Install guard (3) with its glossy side toward the front of the machine.

• Remove guard mounting plate and bolts installed to fender assembly. • Install the guard with the removed plate and bolts. 3 : 29.4 – 49.0 Nm {3 – 5 kgm}

Q'ty 1 6 1

Condition of part (Parts list No.) Packed separately (HD785-7-470) Packed separately (HD785-7-470) Packed separately (HD785-7-470)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

85

Assembly process No.

0472

Installation of right fender (If equipped: Body heating-less muffler specification)

Installation of right fender

: 6 places

• Remove the plate and bolts for the guard installed to the fender assembly temporarily. • Install the right fender with the removed plate and bolts. Tightening torque: 29.4 - 49.0 Nm {3 - 5 kgm} • Install the fender with the glossy side toward front of machine.

(1) (2) (3) (4)

Part No. X251039700 01024-81225 01024-81225 561-54-87420

Precautions

Part name Fender R, H Bolt, sems Bolt, sems Guard

Q'ty 1 6 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-472) Installed to fender Packed separately (HD785-7-472) Packed separately (HD785-7-472)

Necessary tools Name

Other remarks

86

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0475

Installation of fuel tank quick charge-less hose (If equipped)

Installation of fuel tank quick charge-less hose Right fender

View X

Fuel tank

Fire prevention cover View Z

* To be installed to fire prevention cover.

: 3 places

Detail of part P

1. Fix bracket (1) to the fire prevention cover with bolts (2) installed to the fire prevention cover. (2 places) 2. Fix the hose going to the fuel tank breather to the bracket with clips (4) and bolts (5). (2 places) 3. Install cover (3) to the fire prevention cover with bolts (6). 4. Fix the hose going to the fuel tank breather to cover (3) with clip (4) and bolt (5). (1 place) (1) (2) (3) (4) (5) (6) (7)

Part No. 561-04-81530 01024-81020 561-04-81540 04434-51210 01024-81020 01024-81040 01024-81016 Precautions

Part name Bracket Bolt, sems Cover Clip Bolt, sems Bolt, sems Bolt, sems

Q'ty 2 4 1 5 3 2 2

Condition of parts Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Packed separately (HD785-7-475) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

87

Assembly process No.

0476

Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)

Installation of fuel tank quick chargeless hose

Rear support

Right fender

Fuel tank

View X

View Y

* To be installed to rear support. L-plate

Detail of part Q

View Z

View P

Bolt

Bolt

1. Remove the L-plate and 2 bolts. (See view P.) 2. Install cover (1) and the hose going together to the fuel tank breather to rear support (1) with clips (2) and bolts (3). (See views Y and Q.) 3. Fix the hose going to the fuel tank breather with clips (7) and bolts (8). (3 places. See views X and Z.) 4. Install cover (4) with bolts (5) and (6). (See view Y.) (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 561-04-81550 04434-51212 01024-81260 561-04-81560 01024-81045 01024-81035 04434-51210 01024-81016 Precautions

Part name Cover Clip Bolt, sems Cover Bolt, sems Bolt, sems Clip Bolt, sems

Q'ty 1 2 2 1 1 1 3 3

Condition of part (Parts list No.) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Packed separately (HD785-7-476) Necessary tools Name

Other remarks

88

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of cab step

0480 Only machine equipped with radio

Detailed assembly of (7), (8) and (9) Scrape paint off ground part for radio antenna (Scrape paint off on left platform side, too).

CAB

Peel off masking tape.

Installation of front cab step 1. Install the step assembly to the front side of the cab. (1) (2)

Part No. 561-54-80103 01024-81230

Part name Front cab step assembly Bolt

Q'ty 1 12

Condition of part (Parts list No.) Packed separately (HD785-7-480) Packed separately (HD785-7-480)

Installation of side cab step 1. Install the step assembly to the front side of the cab. (3) (4) (5) (6) (7) (8) (9)

Part No. 561-54-80203 01024-81225 01024-81230 01024-81250 01024-81245 01643-31232 01580-11210 Precautions

Part name Side cab step assembly Bolt Bolt Bolt Bolt Washer Nut

Q'ty 1 8 2 2 1 1 1

Condition of parts Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480) Packed separately (HD785-7-480)

Necessary tools Name Nylon sling (250 mm wide × 5 m)

Necessary equipment Q'ty Name Q'ty 1 Crane (25 ton) 1

Other remarks

89

Assembly process No.

Assembly of diagonal ladder (if equipped)

0481 Assembly of diagonal ladder

Fig. 1

Up

Set edge side up.

1. Install the handrail to the platform. * When installing clamp (9), see "Fig. 1".

Set rear side down. Photo of clamp (9)

Weight: 125 kg

Weight: 45 kg (1) (2) (5) (6) (7) (8) (9) (10) (11)

Part No. 561-89-85810 561-89-85850 561-89-85831 561-89-85861 561-89-85821 561-89-85870 561-54-61910 01643-31645 01010-81635

Precautions

Weight: 75 kg Part name Step Guard Step Guard Step Guard Clamp Washer Bolt

Q'ty 1 1 1 1 1 1 8 16 16

Necessary tools Name

Other remarks

90

Condition of part (Parts list No.) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481) Packed separately (HD785-7-481)

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0482

Installation of cab step: Diagonal ladder specification (if equipped)

Installation of cab step 1. Install the step assembly to the left side of the cab. Only machine equipped with radio

EU specification

Remove paint from radio antenna ground part (Remove paint from ground part on left platform side, too). Remove masking tape.

(1) (2)

Part No. 561-54-80203 01024-81225

Part name Side cab step assembly Bolt

Q'ty 1 8

Condition of part (Parts list No.) Packed separately (HD785-7-482) Packed separately (HD785-7-482)

Installation of cab step 1. Install the step assembly to the front side of the cab.

(3) (4) (5) (6) (7) (8) (9) (10)

Part No. Part name 561-89-80100 Step assembly 01024-81230 Bolt, sems 01024-81250 Bolt, sems 01024-81245 Bolt, sems 01643-31232 Washer 01580-11210 Nut X251271380 Front cab step sub A., kal X251271400 Side cab step sub A., kal Precautions

Q'ty Condition of part (Parts list No.) 1 Packed separately (HD785-7-481) 14 Packed separately (HD785-7-482) 2 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-482) 1 Packed separately (HD785-7-487) 1 Packed separately (HD785-7-489) Necessary tools Necessary equipment Name Q'ty Name Q'ty Nylon sling 1 Crane (25t) 1 (250 mm wide * 5 m)

Other remarks Sales code: 6HB55 or 5AC11

91

Assembly process No.

Installation of diagonal ladder 1 (if equipped)

0483 Installation of diagonal ladder 1 1. Install the step assembly to the front side of the cab. 2. Install the rod.

Tightening torque (10):490 – 608 Nm {50 – 62 kgm}

*2 places

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

*2 places

Section A-A

Part No. 561-89-8583A 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 01643-32060 01580-02016 01597-02016 01583-12012 561-89-6A970 Precautions

Other than rod (11) Part name Step assembly Bolt Plate Plate Cushion Bushing Washer Nut Nut Nut Rod

Q'ty 1 2 2 8 8 4 6 2 2 4 1

Section B-B

Condition of part (Parts list No.) See field assembly procedure No. 0481. Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483) Packed separately (HD785-7-483)

Necessary tools Name Nylon sling (250 mm wide * 5 m)

Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1

Other remarks Sales code: 6HB55 or 5AC11

92

Assembly process No.

Installation of diagonal ladder 2 (if equipped)

0484 Installation of diagonal ladder 2 1. Install the step assembly to the front side of the cab. * 2 places

Detail of part A

(1) (2) (3) (4) (5)

Part No. 561-89-8581A 01024-81230 01024-81245 01643-31232 01580-11210

Precautions

Part name Step assembly Bolt, sems Bolt, sems Washer Nut

Q'ty 1 6 2 2 2

Condition of part (Parts list No.) See field assembly procedure No. 0481. Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484)

Necessary tools Name Nylon sling (250 mm wide * 5 m)

Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1

Other remarks

93

Assembly process No.

Installation of diagonal ladder 3 (if equipped)

0485 Installation of diagonal ladder 3 1. Install the step assembly to the front side of the cab. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Part No. 561-89-8582A 01024-81230 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 0643-32060 01580-12016 09415-03614

Part name Step assembly Bolt, sems Bolt Plate Plate Cushion Bushing Washer Nut Cap

Q'ty 1 6 2 2 4 4 2 2 2 2

Condition of part (Parts list No.) See field assembly procedure No. 0481. Installed temporarily to machine Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Packed separately (HD785-7-485)

* 2 places

Section A-A

Installation of step 1. Install the step assembly to the front side of the cab. (11) (12)

Part No. 561-54-6A151 01024-81235 Precautions

Part name Step Bolt, sems

Q'ty 1 4

Necessary tools Name Nylon sling (250 mm wide * 5 m)

Other remarks

94

Condition of part (Parts list No.) Packed separately (HD785-7-485) Packed separately (HD785-7-485) Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1

Assembly process No.

Installation of diagonal ladder (EU specification)

0486 Installation of diagonal ladder 1. Install the handrails to the ladder and platform. * When installing clamp (7), see "Fig. 1".

Fig. 1

Up

Set edged end up

Set round end down Clamp figure

Weight: 125 kg

mark: 8 place

Weight: 45 kg

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 561-89-85810 561-89-85850 561-89-85831 561-89-85861 561-89-86820 561-89-86870 561-54-61910 01643-31645 01010-81635 Precautions

Weight: 75 kg

Part name Step Guard Step Guard Step Guard Clamp Washer Bolt

Q'ty 1 1 1 1 1 1 8 16 16

Condition of part (Parts list No.) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487) Packed separately (HD785-7-487)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 5AC11

95

Assembly process No.

Installation of diagonal ladder-2 (EU specification)

0487 Installation of ladder-2 1. Install the step assembly to the front side of the cab.

* 2 places

Detail A

(1) (2) (3) (4) (5)

Part No. 561-89-8581A 01024-81230 01024-81245 01643-31232 01580-11210

Precautions

Part name Step assembly Bolt, sems Bolt, sems Washer Nut

Q'ty 1 6 2 2 2

Condition of part (Parts list No.) See Field assembly manual No. 0486. Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484) Packed separately (HD785-7-484)

Necessary tools Name Nylon sling (250 mm wide x 5 m)

Other remarks Sales code: 5AC11

96

Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1

Assembly process No.

Installation of diagonal ladder-3 (EU specification)

0488 Installation of ladder-3 1. Install the step assembly to the front side of the cab. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Part No. 561-89-8682A 01024-81230 01011-82015 566-54-21931 566-54-21920 566-54-12212 566-54-21910 01643-32060 01580-12016 09415-03614

Part name Step assembly Bolt, sems Bolt Plate Plate Cushion Bushing Washer Nut Cap

Q'ty 1 6 2 2 4 4 2 2 2 2

Condition of part (Parts list No.) See Field assembly manual No. 0486. Temporarily Installed to machine Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488) Packed separately (HD785-7-488)

* 2 places

Section A-A

Installation of step 1. Install the step to the step assembly on the front side of the cab. (11) (12)

Part No. 561-54-88200 01024-81235 Precautions

Part name Step Bolt, sems

Q'ty 1 4

Condition of part (Parts list No.) Packed separately (HD785-7-488) Packed separately (HD785-7-488)

Necessary tools Name Nylon sling (250 mm wide x 5 m)

Necessary equipment Q'ty Name Q'ty 1 Crane (25t) 1

Other remarks Sales code: 5AC11

97

Assembly process No.

Installation of L.H underview mirror (If equipped)

0490 Installation of L.H underview mirror

3:

59 -- 74 Nm {6 -- 7.5 kgm}

1. Install the underview mirror to the cab step. 2. Adjust the angle of the mirror. (2) (3) (4) (5) (7) (8)

Part No. 07283-32236 07283-52232 01597-01009 01643-31032 23W-P86-2890 561-54-81871

Precautions

Part name Clip Seat Nut Washer Mirror Stay

Q'ty 2 2 4 4 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490) Packed separately (HD785-7-490)

Necessary tools Name

Other remarks

98

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of fire extinguisher (If equipped)

0500 Installation of fire extinguisher (If equipped)

1. Remove the temporarily installed bolts and install fire extinguisher (1) with bolts (2). (1) (2)

Part No. 09495-00000 01435-00616

Precautions

Part name Extinguisher Bolt

Q'ty 1 4

Condition of part (Parts list No.) Packed separately (HD785-7-500) Packed separately (HD785-7-500)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 6ZZ01

99

Assembly process No.

Installing radio antenna and fixing its cable

0510 Perform this work only when the radio is installed.

View Z

Bind connector and cable

L.H.platform assembly

Conection

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Part No. 561-54-87480 01225-40412 01023-10414 07270-51514 04434-51910 01435-01016 08037-11825 561-54-86941 01435-01016 08037-01008 08210-00610

Part name Antenna assembly Screw Screw Tube Clip Bolt Grommet Cover Bolt Grommet Spairal tube

Q'ty 1 1 1 1 6 6 1 1 2 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510) Packed separately (HD785-7-510)

1. Install antenna (1) to the handrail installed to the L.H platform assembly as shown in the above figure. 2. Connect the antenna cable coming from the cab to the cable coming from the antenna. 3. Fix the cable with the other parts as shown in the above figure. Precautions

Necessary tools Name

Other remarks

100

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of L.H fender

0520 Installation of L.H fender

Installed to

Set glossy side toward front of machine.

(1) (2) (3)

Part No. X251042740 01024-81230 561-54-87410

Part name Fender L.H Bolt sems Guard

Q'ty 1 6 1

Condition of part (Parts list No.) Packed separately (HD785-7-520) Packed separately (HD785-7-520) Packed separately (HD785-7-520)

1. Install the left fender. 2. Remove the bolts and plate installed temporarily to the left fender. 3. Install the guard with the bolts and plate removed in 2. (Install the guard with its glossy side toward the front of the machine.) 4. Tighten the guard mounting bolts to 29.4 – 49.0 Nm {3 – 5 kgm}.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

101

Assembly process No.

Installation of left side mudguard

0530 Installation of left side mudguard

View from inside of cab

Z

3 : 29.4 -- 49.0 Nm {3 -- 5 kgm} r: 3 places

a: 6 places

View Z

(1) (2) (3) (4) (5) (6) (7) (8)

Part No. 561-54-86670 01024-D1025 561-54-86820 01024-D1220 569-54-81571 01024-D1030 417-43-16210 283-54-11470

Part name Bracket Bolt, sems Bracket Bolt, sems Guard Bolt, sems Washer Plate

Q'ty 1 2 1 3 1 6 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530) Packed separately (HD785-7-530)

1. Install the left side mudguard. Precautions

Necessary tools Name

Other remarks

102

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of grille guard

0540 Installation of grille guard

(1)

Part No. 561-54-81763

Part name Guard

Q'ty 1

Condition of part (Parts list No.) Packed separately (HD785-7-540)

1. Remove the bolts installed temporarily to the grille. 2. Sling and move the guard over the grille. 3. Install the guard with the removed bolts.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

103

Assembly process No.

Installation of left payload lamp (If equipped)

0550 Installation of left payload lamp 1. Install the payload lamp wiring harness to the rear of the cab. 2. Fix the wiring harness to the bottom of the cab. 3. Connect the payload lamp wiring harness to the frame wiring harness 4. If the side lamp is not installed, bind and fix the wiring harness with band (13).

Cab seen from rear

View Z Fix together with main wiring harness. Connection: CN.PMLA

Cab seen from below

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (12) (13)

Part No. 561-86-80100 569-86-87321 01024-81020 421-62-23710 421-62-18550 175-54-34170 01010-81235 561-86-87522 04434-50810 04434-51010 01024-81016 08034-20834 Precautions

Part name PLM lamp sub assembly L.H Bracket Bolt, sems Cushion Cushion Washer Bolt Wiring harness Clip Clip Bolt, sems Band

Q'ty 1 1 3 4 4 4 4 1 5 1 4 1

Necessary tools Name

Other remarks

104

Condition of part (Parts list No.) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Packed separately (HD785-7-550) Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of left side lamp (If equipped)

0555 Installation of left side lamp 1. Install side lamp wiring harness (1) to the rear of the cab. 2. Fix the wiring harness to the rear and underside of the cab. 3. Connect the wiring harness to the main wiring harness. (Connection: PMLA)

Fix together with main wiring harness.

Connection: CN. PMLA

Bottom view

(1) (2) (3)

Part No. 561-85-81211 04434-50810 01024-81016

Precautions

Part name Wiring harness Clip Bolt, sems

Q'ty 1 5 3

Condition of part (Parts list No.) Packed separately (HD785-7-555) Packed separately (HD785-7-555) Packed separately (HD785-7-555)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 5AC11 (EC Regulations)

105

Assembly process No.

Installation of right payload lamp (If equipped)

0560 Installation of right payload lamp 1. Install the payload lamp wiring harness to the right platform. 2. Remove the bolts marked with a on the right platform (3 places) and fix the wiring harness with them. Fix the other parts of the wiring harness, too. 3. Connect the payload lamp wiring harness to the frame wiring harness 4. If the side lamp is not installed, bind and fix the wiring harness with band (10).

Red

Orange

Green

View Y

Right platform seen from rear

3 : 59 -- 74 Nm

{6 -- 7.5 kgm} Connection: CN.PMRA

View Z

Right platform see from above

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

Part No. 561-86-80201 421-62-23710 421-62-18550 175-54-34170 01010-81235 561-86-87531 01024-81016 04434-50810 08193-21012 08034-20834 561-54-86541 01024-81025 07283-33442 01643-31032 01597-01009 Precautions

Part name PLM lamp sub assembly R.H Cushion Cushion Washer Bolt Wiring harness Bolt, sems Clip Clip Band Cover Bolt, sems Clip Washer Nut

Q'ty 1 4 4 4 4 1 2 7 1 1 1 3 2 4 4

Necessary tools Name

Other remarks

106

Condition of part (Parts list No.) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Packed separately (HD785-7-560) Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of right side lamp (If equipped)

0565 Installation of right side lamp

3 : 59 -- 74 Nm {6 -- 7 kgm}

1. Connect side lamp wiring harness (1). (Connection: PMRA) 2. Fix wiring harness (1) with clip (3) and bolt (2). 3. Fix cover (6) and wiring harness (1) together with clip (3) and bolt (4). 4. Fix cover (6) and guard with clip (7), washer (8) and nut (9).

Right platform

Connection: CN-PMRA

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 561-85-81220 01024-81016 04434-50810 01024-81025 08193-21012 561-54-86541 07283-33442 01643-31032 01597-01009

Precautions

Part name Wiring harness Bolt, sems Clip Bolt, sems Clip Cover Clip Washer Nut

Q'ty 1 1 4 3 1 1 2 4 4

Condition of part (Parts list No.) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565) Packed separately (HD785-7-565)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 5AC11 (EC Regulations)

107

Assembly process No.

0570

Installation of left fender side lamp wiring harness (If equipped)

Installation of left fender side lamp wiring harness 1. Remove the cover installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLL) 3. Fix the side lamp wiring harness with the clips and bolts installed to the fender temporarily. 4. Install the cover removed in steps 1 and 2 again.

Fix with clips and bolts installed temporarily.

Connection: SLL

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 5AC11 (EC Regulations)

108

Assembly process No.

0580

Installation of right fender side lamp wiring harness (If equipped)

Installation of right fender

Z (1) (2) (3) (4) (5) (6)

Part No. 04434-50810 01024-81016 561-85-81170 01024-81020 561-85-81180 01024-81035

Part name Clip Bolt, sems Cover Bolt, sems Cover Bolt, sems

Q'ty 2 2 1 2 1 2

1. Remove the cover installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLR) 3. Fix the side lamp wiring harness with the clips and bolts installed to the fender temporarily and clips (1) and bolts (2). 4. Install cover (5) with bolts (6). 5. Install the covers removed in steps 1 and 2 again.

Condition of part (Parts list No.) Packed separately (HD785-7-580) Packed separately (HD785-7-580) Installed temporarily to right fender Installed temporarily to right fender Packed separately (HD785-7-580) Packed separately (HD785-7-580)

View Z

Connection: SLR

Fix with clips and bolts installed temporarily.

Reinstallation of cover Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks Sales code: 5AC11 (EC Regulations)

109

Assembly process No.

0581

Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)

Installation of right fender

Z (1) (2) (3) (4) (5)

Part No. 561-84-81250 561-84-84250 04434-50810 01024-81016 01024-81045

Part name Cover Cover Clip Bolt, sems Bolt, sems

Q'ty 1 4 4 2 4

1. Remove the cover, clips and bolts installed to the fender temporarily. 2. Remove the lamp cover and connect the wiring harness. (Side lamp wiring harness: CN. SLR) 3. Pass clips 3 through the side lamp wiring harness. Fix the wiring harness with the clips and bolts removed in step 1. 4. Install cover (1) and clips together with bolts (5). 5. Install cover (2) with bolts (5). 6. Install the cover removed in steps 1 again together with the clips.

Precautions

Condition of part (Parts list No.) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581) Packed separately (HD785-7-581)

Connection: SLR

View Z

Reinstallation of cover

View Z

Necessary tools Name

Other remarks

110

Fix with clips and bolts installed temporarily.

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of KOMTRAX (If equipped)

0590 Installation of KOMTRAX 3 : 59 -- 74 Nm {6 -- 7 kgm}

3 : 59 -- 74 Nm Apply LT-2 to threaded part.

{6 -- 7 kgm}

Right handrail

Cable supplied with cab (561-97-62250)

= 5 places

Z

Detail of assembly of antenna

3 : 59 -- 74 Nm {6 -- 7 kgm}

Right platform

Detail of fixing of pole (2 places)

View Z 1. Install the KOMTRAX antenna as shown above. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Part No. 561-97-82141 01010-81635 01643-31645 8A13-10-2100 561-97-62250 561-97-62150 07283-33442 07283-36155 01597-01009 01643-31032 04434-50610 01024-81016

Part name Pole Bolt Washer Antenna. sat Antenna cable Plate Clip Clip Nut Washer Clip Bolt, sems

Q'ty 1 2 2 1 1 2 4 2 12 12 5 5

Precautions

Condition of part (Parts list No.) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Packed separately (HD785-7-590) Necessary tools Name

LT-2

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

111

Assembly process No.

Fixing of ORBCOMM antenna (If equipped)

0595 Fixing of ORBCOMM antenna

= 20 places

View Z

View Y

= 7 places

= 2 places

= 4 places

View X

Bind excessive part of antenna cable together with electrical intake air heater wiring harness.

1. Fix the wiring harnesses with clips (1) in the order of the above numbers. Fix them together at places where bolts (2) are not used. Fix Nos. 6 – 12 with spacers (5) and bolts (6) and (7). 2. After fixing the wiring harness, bind it with bands (3) and (4). 3. Bind the excessive part of the antenna cable together with electrical intake air heater wiring harness between Nos. 19 and 20. (1) (2) (3) (4) (5) (6) (7)

Part No. 04434-50610 01024-81016 08034-20823 08034-20519 175-79-83760 01024-81045 01024-81040 Precautions

Part name Clip Bolt, sems Band Band Spacer Bolt, sems Bolt, sems

Q'ty 20 4 1 3 8 7 1

Condition of part (Parts list No.) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Packed separately (HD785-7-595) Necessary tools Name

Other remarks

112

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

0597

Connection and fixing of harness and hose going to auto grease pump - 1 (If equipped: Auto grease specification)

Connection and fixing of harness and hose going to auto grease pump - 1 1. Fix the harness and hose going to the auto grease pump with the parts installed temporarily to the right platform.

View Y

(When ORBCOMM antenna is installed) (When payload meter and ORBCOMM antenna are installed)

(When payload meter and ORBCOMM antenna are installed)

(When ORBCOMM antenna is installed)

(When payload meter is installed)

Section CA-CA Section BM-BM

(1) (2) (3) (4) (5) (6) (7)

Part No. 04434-51210 01024-81075 154-06-34790 01024-81095 175-79-83760 04434-52712 07095-20420

: 5 places

Part name Clip Bolt, sems Spacer Bolt, sems Spacer Clip Cushion

Q'ty 6 6 6 6 6 5 5

Precautions

(When payload meter is installed)

Condition of part (Parts list No.) Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Necessary tools Name

LT-2

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

113

Assembly process No.

Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification)

0598

Connection and fixing of harness and hose going to auto grease pump - 2 1. Fix the harness and hose going to the auto grease pump with the parts installed temporarily to the right platform. 2. Connect the auto grease hose to the pump.

View WW

Connect

View Y

(When ORBCOMM antenna is installed)

(When payload meter and ORBCOMM antenna are installed)

Connect: GREASE PUMP A CONNECTOR

Connect:

PRESSURE SWITCH CONNECTOR

Section CD-CD Section CC-CC (When payload meter is installed)

Section CB-CB

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Part No. 04434-51210 01024-81075 154-06-34790 01024-81085 561-46-43390 04434-52712 07095-20420 01024-81016 02896-21012 Precautions

Part name Clip Bolt, sems Spacer Bolt, sems Spacer Clip Cushion Bolt, sems O-ring

Q'ty 2 1 1 1 1 1 1 1 1

Condition of part (Parts list No.) Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Installed to right platform Packed separately (HD785-7-598) Necessary tools Name

Other remarks

114

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Removal of hoist cylinder fixing bracket

0600 Removal of hoist cylinder fixing bracket

Hoist cylinder fixing jig Hoist cylinder

Right side of machine

Hoist cylinder

Hoist cylinder fixing jig

Left side of machine

1. Remove the right and left hoist cylinder fixing jigs and secure them with lever blocks. 2. Discard the jigs removed in step 1 above.

Precautions

Necessary tools Name Torque wrench

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

115

Assembly process No.

Connection of hoist cylinder piping

0610 Connection of hoist cylinder piping 1. Remove hoist cylinder mounting bolts A and B and remove the parts marked with A. Since the parts marked with A are not used any more, discard them.

Hoist cylinder

A

A Reused

A

B (1) (2) (3) (4) (5)

Reused

Part No. 07372-21035 07000-F3038 01024-80845 07000-F3030 01643-51032

Part name Bolt O-ring Bolt O-ring Washer

Q'ty 8 2 8 2 8

Condition of part (Parts list No.) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610) Packed separately (HD785-7-610)

2. Using bolt (1) and washer (5) instead of bolt (A) and using bolt (3) instead of bolt B, reconnect the hose. When reconnecting the hose, use O-rings (2) and (4) supplied loose. Precautions 1. When installing the piping, take care that O-ring will not be caught. 2. If the engine is started after this process is completed, the cylinder is extended automatically.

Necessary tools Name

Other remarks

116

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Welding of body

0620 Welding of body

*) For details of welding of body, see the separate manual.

(1)

Part No. 561-74-81102

Precautions

Part name Body U., assembly

Q'ty 1

Condition of part (Parts list No.) Packed separately (HD785-7-620)

Necessary tools Name Port power (300 mm for 10 ton) Hydraulic jack (10 ton) Hydraulic jack (5 ton)

Necessary equipment Q'ty Name Q'ty 1 Cranes (50 ton, 25 ton) Each one 1 1

Other remarks

117

Assembly process No.

Sticking of body decal

0630 Sticking of body decal

Left side of body

Right side of body 1. Stick the decals to the body. (1) (2) (3)

Part No. 561-93-81320 561-93-81310 561-93-81360

Part name Mark Mark Mark

Precautions 1. Eliminate blisters and fit each decal perfectly. 2. Remove all the oil and dust from the surfaces to stick the decals. 3. Stick the decal before installing the body.

Q'ty 2 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-630) Packed separately (HD785-7-630) Packed separately (HD785-7-630)

Necessary tools Name

Other remarks

118

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Supply of oil

0640 Supply of oil *) Referring to No. 0010, check the types of oil and supply proper oil. *) Before starting the engine, be sure to check the oil level in the brake oil tank. If the level is low, add new oil.

1. Before starting the engine, add oil through the filler tube of the transmission case to the H level and then add oil through the oil filler of the brake oil tank to the top (36 liters). 2. After starting the engine, run the engine at low idle and add oil until the oil pressure gauge indicates the maximum. 3. Bleed air from the brake system. Then, run the engine at low idle and adjust the oil level again. (Do not use the oil discharged during the air bleeding operation.) For details, see the Operation and Maintenance Manual. Retightening of hose clamps *) After starting the engine, retighten the clamps of the low-pressure hoses.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

119

Assembly process No.

Slinging of body

0650 Slinging of body Body sling pin (ATH-785-006) Shackle BC40 for 10 ton

Chain sling (ATH-465-039) or ø28 wire

Inserting direction of body sling pin (ATH-785-006): Insert from outside of body.

1. Set the body sling pins from outside of the body side plate (4 pieces to holes of body). 2. Set the shackles and sling. 3. Check the center and sling the body.

Precautions

Necessary tools Name

Other remarks

120

Q'ty

Necessary equipment Name Q'ty Sling (ATH-465-039) 1 Sling (ATH-785-006) 4 Pin (BC40) 4 Crane (50 ton) 1

Assembly process No.

Installation of hinge pin

0660 Installation of hinge pin

A A

3:

245 -- 309 Nm {25 -- 31.5 kgm}

Clearance: Max. 1 mm Clearance: Max. 1 mm

Section A-A (1) (2) (3) (4) (5) (6) (7) (8)

Part No. 568-74-12650 568-74-11421 568-74-12660 568-74-12670 561-74-61740 01010-81635 01643-31645 421-70-11280

Part name Shim t = 6.0 Shim t = 2.3 Shim t = 1.0 Shim t = 4.5 Pin Bolt Washer Washer

Q'ty 2 8 8 2 2 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660) Packed separately (HD785-7-660)

1. Operate the crane to set the pin holes of the frame to those of the body. 2. Insert shims to even the clearance and reduced to 1 mm or less and then insert pins (5). 3. Fix the pins with the lock bolts. Precautions

Necessary tools Name Q'ty Torque wrench (2800QL) 1

Necessary equipment Name Q'ty

Other remarks

121

Assembly process No.

Connecting hoist cylinder

0670 Connecting hoist cylinder

3

Hoist cylinder

:157 -- 196 Nm {16 -- 20 kgm}

Main frame

(1) (2) (3)

1. 2. 3. 4.

Part No. 561-52-61211 01010-81430 569-40-61710

Part name Pin Bolt Washer

Q'ty 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-670) Packed separately (HD785-7-670) Packed separately (HD785-7-670)

Match the hoist cylinder rod hole to the pin hole of the body mounting part. Insert pin (1) and fix it. Tighten set bolts (2) and (3). Install plug (4).

Precautions

Necessary tools Name

Other remarks

122

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Hoist cylinder grease piping

0680 Hoist cylinder grease piping

Install fitting (7) outward.

(1) (2) (3) (4) (5) (6) (7)

Part No. 421-09-12540 423-09-12110 561-52-82610 01024-80816 04434-50608 07042-20108 07020-00000

Part name Elbow Connector Tube Bolt, sems Clip Plug Fitting

Q'ty 2 2 2 2 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680) Packed separately (HD785-7-680)

1. Install the grease tubes to the hoist cylinder. (Install the right and left tubes similarly.) 2. Supply grease.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

123

Assembly process No.

0685

Fixing of auto grease piping to body (If equipped: Auto grease specification)

Fixing of auto grease piping to body 1.Fix the auto grease piping to the body.

: 9 places

Section A-A

View X

Section B-B Detail of part P

(1) (2) (3) (4)

Part No. 561-95-83250 04434-51010 01024-81020 01024-81016 Precautions

Part name Bracket Clip Bolt, sems Bolt, sems

Q'ty 1 11 3 9

Condition of part (Parts list No.) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Packed separately (HD785-7-685) Necessary tools Name

Other remarks

124

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of field welding protection cover

0700 Installation of field welding protection cover

Part welded in field

Part welded in field

Part welded in field

1. Install the protection cover around each "part welded in field" shown in the above figure.

Precautions

Necessary tools Name Fireproof cloth (1 m × 10 m)

Q'ty 1

Necessary equipment Name Q'ty

Other remarks

125

Assembly process No.

Installation of body mount

0710 Installation of body mount 1. Install the body mount. 2. For the adjustment procedure, see the following section. 3 : (8) (12) 245 – 309 Nm {24.9 – 31.5 kgm}

Welded to frame For welding procedure, see C-0130. Welded to frame For welding procedure, see C-0130.

(1) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

Part No. 561-74-61531 561-83-69540 561-83-69550 561-83-69560 561-83-69570 561-74-61511 01010-81645 01643-31645 561-74-61521 561-74-61540 01010-81660 01643-31645 561-46-8A890 561-46-8A870

Part name Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Shim t = 1.0 Pad Bolt Washer Pad Shim t = 1.0 Bolt Washer Bracket (LH) Bracket (RH)

Precautions After welding in the field, touch up the welded parts.

Q'ty 70 8 8 8 8 8 32 32 2 18 8 8 1 1

Condition of part (Parts list No.) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Packed separately (HD785-7-710) Necessary tools Name

Other remarks

126

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Procedure for adjusting body mount shim

0720 Procedure for adjusting body mount shim

1. Procedure for adjusting shim for body mount Adjust the shim according to the following procedure. (1) Bottom mounts (Rubber mounts of body bottom plate) 1. Insert a spacer 43 mm thick (dimension marked with a) in the body end. 2. Measure distance b between the center of the body mount and the frame top (8 places on both sides). 3. Insert (b1 - 35), (b2 - 35), (b3 - 35) and (b4 - 35) pieces of shims (561-74-61531) in the points of b1, b2, b3 and b4 respectively. Omit the figures after the decimal fractions. 4. Install the bottom mounts and remove the spacers. 5. Lower the body and check that all of the 8 bottom mounts are in contact with the frame top. If not, adjust the shims. 6. Finish adjustment of the bottom mounts. * Before installing the frame temporarily, remove the paint from the grounding surface. (2) Front mounts (Rubber mounts of body front plate) 1. After the above adjustment of the bottom mounts, place and tack-weld brackets 561-468A890 and 561-46-8A870 on the frame so that the clearance between the body and bracket will be 57 mm. (See Fig. 1) 2. Raise the body and weld the brackets permanently. 3. Insert 7 shims 561-74-61540 7 mm in total and install rubber pad 561-74-61521. 4. Lower the body and check that the total thickness of the rubber pad is 50 mm. If it is not 50 mm, set it to 50 mm by adjusting the shim. 5. Finish adjustment of the front mounts. 2. After the body is assembled, the discrepancy between the protector and cab must be 59 ± 30 mm. If the discrepancy is not 59 ± 30 mm, adjust the shim of hinge pin (561-7461740) (See A-A).

Fig. 1

127

Assembly process No.

Field welding of exhaust tube

0730 1.

Field welding of exhaust tube

2.

Make the hook (part P) and weld it as shown in the figure. After finishing the work, cut the welded hook with gas and finish the cut surface smoothly with a grinder and the paint it yellow. Must be aligned.

Section A-A Procedure for assembling body exhaust inlet portion 1. Carry out the following work after adjusting the body mount. 2. Install spring (581-02-31360) and seal (582-02-11210) between tube (561-02-81170) and flange (561-02-61150) and then lock nut (0158011411) to dimension A shown in the figure. (4 places) 3. Fix the tube and flange with the jigs so that the distance between them will be the dimension show in the figure (188). 4. While the parts are fixed as explained in 2 and (3), insert plate (582-0211230) in the tube and insert them in the body exhaust inlet portion. 5. Align tube (561-02-81210) with flange (561-02-61150) at the flange mating face and then weld the plate and tube (561-02-81170). (Runout must be 3 mm or less.) 6. After steps 2 - 5 above, remove the jigs used in step 3. 7. Tighten the bolts according to KES 04.123.1.

(1) (2)

Part No. 561-74-80100 582-02-11230

Part name Exhaust box, sub assembly Plate

Precautions Runout must be 3 mm or less.

Q'ty 1 1

Necessary tools Name

Carry out the above work after adjusting the body mount shim.

Other remarks

128

Condition of part (Parts list No.) Packed separately (HD785-7-730) Packed separately (HD785-7-730) Q'ty

Necessary equipment Name Q'ty Spacer (ATH-465-027) 3

Assembly process No.

Assembly of body heater cover

0740 Assembly of body heater cover

3:

54 – 123 Nm

{5.5 – 12.5 kgm} 1. Install the heater cover to the body.

(1) (2)

Part No. 561-74-81470 01024-81220

Precautions

Part name Cover Bolt, sems

Q'ty 1 6

Condition of part (Parts list No.) Packed separately (HD785-7-740) Packed separately (HD785-7-740)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

129

Assembly process No.

Installation of poke ejector

0770 Installation of poke ejector

Weight: 40.4 kg

Bend end of pin. View from inside

(1) (2) (3)

Part No. 561-74-81620 581-74-11360 04050-18055

Part name Bar Pin Pin

Q'ty 2 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-770) Packed separately (HD785-7-770) Packed separately (HD785-7-770)

1. Install the poke ejector to the body.

Precautions

Necessary tools Name

Other remarks

130

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of poke ejector storage pin

0780 Installation of body lock pin

(1) (2)

Part No. 04205-11650 04052-11664

Part name Pin Pin

Q'ty 2 2

Condition of part (Parts list No.) Packed separately (HD785-7-780) Packed separately (HD785-7-780)

1. Install the poke ejector storage pin to the body.

Precautions

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

131

Assembly process No.

Installation of body mudguard

0790 Installation of body mudguard 1. Install the mudguard to the body.

Caution for installing guard

is curved, install it with * Since guard toward the rear of the machine. 3:

3:

29.4 -- 49.0 Nm {3.0 -- 5.0 kgm}

29.4 -- 49.0 Nm {3.0 -- 5.0 kgm}

Bolt between support and body

3:

29.4 -- 49.0 Nm

{3.0 -- 5.0 kgm} Guard fixing bolt

Set glossy side toward rear of machine.

Set glossy side toward rear of machine.

(1) (2) (3) (4) (5) (6) (7) (8)

Part No. 561-74-61631 561-74-61641 01010-81225 01643-31232 561-74-61661 561-74-61651 01010-81230 01643-31232 Precautions

Part name Support (L) Support (R) Bolt Washer Guard Plate Bolt Washer

Q'ty 1 1 14 14 2 2 16 16

Condition of part (Parts list No.) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Packed separately (HD785-7-790) Necessary tools Name

Other remarks

132

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of body lock pin

0800 Installation of body lock pin 1. Store the hoist stopper pin in the axle housing.

View from rear of frame

(1)

Part No. 561-86-68141

Precautions

Part name Pin

Q'ty 2

Condition of part (Parts list No.) Packed separately (HD785-7-800)

Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

133

Assembly process No.

Installation of transmission underguard

0810 Installation of transmission underguard 1. Install the transmission underguard.

A

Thickness 1

Thickness 1

A

Section A-A

(1) (2) (3) (4) (5) (6)

Part No. 561-54-86201 561-54-66250 01010-82080 01580-12016 01643-32060 01010-82055

Precautions

Part name Guard sub assembly Collar Bolt Nut Washer Bolt

(Weight: 120 kg)

Q'ty 1 2 2 2 6 2

Condition of part (Parts list No.) Packed separately (HD785-7-810) Packed separately (HD785-7-810) Packed separately (HD785-7-810) Packed separately (HD785-7-810) Packed separately (HD785-7-810) Packed separately (HD785-7-810)

Necessary tools Name

Other remarks

134

View Z

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Installation of front handle

0830 Installation of front handle 1. Install the handle to the front axle cooling piping. (Install to the right and left similarly.)

3:

59 -- 74 Nm

{6.0 -- 7.5 kgm}

Front axle on right side of frame

Front axle on left side of frame

(1) (2) (3) (4) (5)

Part No. 561-54-86811 07283-34949 07283-34346 01597-01009 01643-31032 Precautions

Part name Grip Clip Clip Nut Washer

Q'ty 2 2 2 8 8

Condition of part (Parts list No.) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Packed separately (HD785-7-830) Necessary tools Name

Q'ty

Necessary equipment Name Q'ty

Other remarks

135

Assembly process No.

Connection of dump sensor

0850 Connection of dump sensor

(1) (2) (3)

1. 2. 3. 4.

Part No. 01010-81035 566-40-11560 04245-4102A

Part name Bolt Washer Rod assembly

Q'ty 1 2 1

Condition of part (Parts list No.) Packed separately (HD785-7-850) Packed separately (HD785-7-850) Packed separately (HD785-7-850)

Install the rod. Check that the distance between the rod end centers is 484 mm (If not, adjust). Fix the dump sensor to the body with bolt (1). Adjust the dump sensor according to "Procedure for adjusting dump sensor" on the next page.

Precautions

Necessary tools Name

Other remarks

136

Q'ty

Necessary equipment Name Q'ty

Assembly process No.

Procedure for adjusting dump sensor

0860 Procedure for adjusting dump sensor Note) Be sure to perform the following adjustment after adjusting the shim of the body mount. 1. Seat the dump body. 2. Check that the difference between the centers of the lever hole and potentiometer hole (Positioning hole marked with a: ø 5) is below 1 mm. Caution) If the misalignment is larger than 1 mm, adjust it to 1 mm or less. If the adjustment dimension of the rod is reduced to 480 mm or less at this time, the potentiometer may be broken. Accordingly, never reduce it so. 3. Check the value of the "Body position" on the real-time monitor in the cab. Standard value of "Body position" when dump body is seated: 0.46 – 0.54 V Procedure for using real-time monitor (1). Press the "t" and "" and "" and "