Field Assembly HD787!7!7001 Up

DUMP TRUCK

Field Assembly InstructionGEN00058-07

HD785-7SERIAL 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 Page0010 Oil, grease, and coolant 160020 Levels of oil, grease, and coolant 170030 Positioning rear axle assembly 180040 Slinging and moving of bare machine 190050 Connection of rod and rear suspension 200060 Positioning bare machine 210070 Connection of rear axle cooling hose 220080 Connection of rear axle brake hose 230085 Connection of rear axle brake hose (ASR specification: If equipped) 240086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped) 250087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped) 260090 Connection and fixing of rear grease piping and supply of grease 270100 Preparation for installing front axle 280110 Installation of front axle 290120 Connection of front axle suspension pressure sensor 300125 Connection of front axle wheel speed sensor (ABS specification: If equipped) 310130 Connection of steering cylinder and tie rod 320140 Connection of front axle brake cooling hoses 330150 Connection of front axle brake hoses 340160 Connection of front axle auto suspension piping 350165 Fixing of front axle auto suspension piping 360166 Fixing of front axle auto grease piping (If equipped: Auto grease specification) 370167 Connection of left front axle auto grease piping (If equipped: Auto grease specification) 380168 Connection of right front axle auto grease piping (If equipped: Auto grease specification) 390170 Installation of bumper and front axle steps 400171 Installation of front axle step (EU specification) 410180 Installation of tire and wheel assembly 420190 Installation of drive shaft 430200 Installation of oil quick charge box (If equipped: Oil quick charge specification) 440260 Installation of fuel tank wiring harness cover 450270 Installation of toolbox and tool kit 460275 Installation of fuel tank step (If equipped) 470280 Installation of rear support 480281 Installation of rear support (Muffler specification: If equipped) 490282 Installation of rear support (ABS specification: If equipped) 500283 Installation of rear support (Sand terrain specification: If equipped) 510290 Installation of muffler 520291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped) 530300 Installation of fire prevention cover 540310 Installation of front support 550315 Installation of front support (Fog lamp specification: If equipped) 560317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped) 570320 Installation of steering valve 580330 Preparation for installing cab 590340 Installation of cab 600345 Connection of ABS piping (If equipped) 610350 Connection of column 620355 Installation of washer tank 630360 Connection of cab piping 640370 Connection of cab wiring 650375 Connection of cab wiring (ASR/ABS specification: If equipped) 660376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification) 670377 Connection and fixing of engine compartment lamp wiring harness (if equipped) 680378 Connection of auto grease harness to cab (If equipped: Auto grease specification) 690379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification) 700380 Installation and fixing of steering hoses 71

CONTENTS

0385 Fixing of air conditioner drain hose 720390 Installation of steering hose cover 730395 Connection of air conditioner and heater hoses 740400 Connection of cab floor wiring 750405 Fixing of ASR/ABS wiring harness (If equipped) 760406 Connection and fixing of ABS wiring harness (ABS specification: If equipped) 770410 Installation of cover under cab 780415 Wiring of front glass with heater wire (If equipped) 790420 Installation of cab seal 800430 Installation of ambient temperature sensor wiring harness 810440 Installation of undercab wiring harness connector 820445 Connection and fixing of rear view camera wiring harness (if equipped) 830450 Installation of R.H platform assembly 840470 Installation of right fender 850472 Installation of right fender (If equipped: Body heating-less muffler specification) 860475 Installation of fuel tank quick charge-less hose (If equipped) 870476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification) 880480 Installation of cab step 890481 Assembly of diagonal ladder (if equipped) 900482 Installation of cab step: Diagonal ladder specification (if equipped) 910483 Installation of diagonal ladder 1 (if equipped) 920484 Installation of diagonal ladder 2 (if equipped) 930485 Installation of diagonal ladder 3 (if equipped) 940486 Installation of diagonal ladder (EU specification) 950487 Installation of diagonal ladder-2 (EU specification) 960488 Installation of diagonal ladder-3 (EU specification) 970490 Installation of L.H underview mirror (If equipped) 980500 Installation of fire extinguisher (If equipped) 990510 Installing radio antenna and fixing its cable 1000520 Installation of L.H fender 1010530 Installation of left side mudguard 1020540 Installation of grille guard 1030550 Installation of left payload lamp (If equipped) 1040555 Installation of left side lamp (If equipped) 1050560 Installation of right payload lamp (If equipped) 1060565 Installation of right side lamp (If equipped) 1070570 Installation of left fender side lamp wiring harness (If equipped) 1080580 Installation of right fender side lamp wiring harness (If equipped) 1090581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification) 1100590 Installation of KOMTRAX (If equipped) 1110595 Fixing of ORBCOMM antenna (If equipped) 1120597 Connection and fixing of harness and hose going to auto grease pump - 1 (If equipped: Auto grease specification) 1130598 Connection and fixing of harness and hose going to auto grease pump - 2 (If equipped: Auto grease specification) 1140600 Removal of hoist cylinder fixing bracket 1150610 Connection of hoist cylinder piping 1160620 Welding of body 1170630 Sticking of body decal 1180640 Supply of oil 1190650 Slinging of body 1200660 Installation of hinge pin 1210670 Connecting hoist cylinder 1220680 Hoist cylinder grease piping 1230685 Fixing of auto grease piping to body (If equipped: Auto grease specification) 1240700 Installation of field welding protection cover 1250710 Installation of body mount 1260720 Procedure for adjusting body mount shim 1270730 Field welding of exhaust tube 128

No. Item Page

CONTENTS

7. Adjustment procedure

8. Welding procedure

AppendixField assembly inspection report

0740 Assembly of body heater cover 1290770 Installation of poke ejector 1300780 Installation of poke ejector storage pin 1310790 Installation of body mudguard 1320800 Installation of body lock pin 1330810 Installation of transmission underguard 1340830 Installation of front handle 1350850 Connection of dump sensor 1360860 Procedure for adjusting dump sensor 1370870 Calibrating dump control 1380880 Adjustment of optical axis of light 1390900 Bleeding air from brake 1400901 Bleeding air from brake of ASR specification (ASR specification: If equipped) 1410905 Bleeding air from ABS circuit (ABS specification: If equipped) 1420910 Adjusting suspension 1430920 Charging air conditioner with refrigerant 1440930 Fitting of floating seal 1450950 Painting 1460960 Touchup 1471000 Sticking of front axle decal 1481020 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification) 1491100 Installation of chocks (If equipped) 1511200 Installation of radiator curtain (If equipped) 1521300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification) 153

No. Item Page

No. Item PageT-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification) 154T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification) 155T-0030 Setting of machine monitor 156T-0040 Selection of machine model 157T-0050 Selection of optional component 158T-0060 Selection of option 159T-0070 Option setting/no-setting selection screen - Saving of change of option selection 160T-0080 OFF setting of corrosion resistor with maintenance monitor 161T-0090 Adjustment of body positioner sensor 162T-0100 Deletion of electrical system fault history (1) 163T-0110 Deletion of electrical system fault history (2) 164

No. Item PageC-0010 Preparation of welding body 165C-0020 Assembly of split body (1/2) 166C-0030 Assembly of split body (2/2) 167C-0040 Tack welding body 168C-0050 Welding body (1/2) 169C-0060 Welding body (2/2) 170C-0070 Welding body instruction (1/2) 171C-0080 Welding body instruction (2/2) 172C-0090 Turn over the body 173C-0100 Welding body protector (1/2) 174C-0110 Welding body protector (2/2) 175C-0120 Finishing and painting welded parts of body 176C-0130 Welding front body mount bracket 177

11. Outline of division (Only main components)

1. Bare machine

3. Front axle assembly

5. Front tire and wheel assembly

2. Dump body (Divided into 3)

4. Rear axle and tire assembly

6. Cab assembly

22. Dimensions of main components

Drawing of bare machine on trailer

Reference

Specifications of completed truck

No. Unit name Weight (kg)Overall length

(mm)Overall width

(mm)Overall height

(mm)

1 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

SpecificationsRelated items

Weight (kg) Overall length (mm) Overall width (mm) Overall height (mm)

In self-propelled

travelHD785-7

64,600(Mass of machine)

10,290(Front bumper

End of body)

5,528 5,047(When empty)

150

2,7806,2003,000

1,680

11,980

530

3,800

G.L.

33. 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.

Compressor parts andtools keeping place

Tire and wheel assembly

Forklift

30M

30M

50-t crane

50-t crane

BodyCAB

Bare machine

Front axle

Rear axle assembly and tire assembly

Light units keeping placePlatform, front support, mudguard, rear

support, fire prevention cover, poke ejec-tor, drive shaft, etc.

44-1. Rough schedule of assembly and weldingDay 1st day

Hour 1 2 3 4 5 6 7 8

Condition of chassis

Rough contents of assem-bly work

Positioning rear axlePositioning chassis

Installing front axleInstalling tires

Crane

490 kN {50 ton} 245 kN {25 ton} 245 kN {25 ton} (98 kN {10 ton})

Forklift

4 ton * Fork length: Approx. 2 m

Number of workers 2

Day 1st day

Hour 1 2 3 4 5 6 7 8

Condition of body

Contents of welding work UnloadingRemoval of stands and fixing partsPositioning and fixing split body

Welding back side

Crane

245 kN {25 ton} 245 kN {25 ton}

Number of workers 3

Approx. 2 m

54-2. Rough schedule of assembly and weldingDay 2nd day

Hour 1 2 3 4 5 6 7 8



Installing supportInstalling cab

Piping and wiring

Crane

490 kN {50 ton} 490 kN {50 ton}

Forklift

Number of workers 2

Day 2nd day

Hour 1 2 3 4 5 6 7 8

Condition of body

Contents of welding work Positioning and fixing split bodyWelding back sideTurning over

Crane

245 kN {25 ton}

Number of workers 3

64-3. Rough schedule of assembly and weldingDay 3rd day

Hour 1 2 3 4 5 6 7 8



Installing platformPainting

Supply of oil and coolantStarting engine

Crane

Forklift

Number of workers 2

Day 3rd day

Hour 1 2 3 4 5 6 7 8

Condition of body

Contents of welding work Welding inside of body Welding protector

Crane

245 kN {25 ton}

Number of workers 3

74-4. Rough schedule of assembly and weldingDay 4th day

Hour 1 2 3 4 5 6 7 8



Mounting bodyAdjusting shimsField welding

Crane

490 kN {50 ton} 245 kN {25 ton} 245 kN {25 ton} (98 kN {10 ton})

Number of workers 2

Day 4th day

Hour 1 2 3 4 5 6 7 8

Condition of body

Contents of welding work

Crane

Number of workers

84-5. Rough schedule of assembly and weldingDay 5th day

Hour 1 2 3 4 5 6 7 8



Installing exterior partsPainting

Maintenance, adjustmentInspection

Crane

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

Number of workers 2

Day 4th day

Hour 1 2 3 4 5 6 7 8

Condition of body

Contents of welding work

Crane

Number of workers

95-1 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

4 Gas cutting machine 1

5 Torch 1220N2 1

6 Acetylene gas 1 For gas cutting machine

7 Oxygen gas 14.7 MPa {150kg/cm} 1 For gas cutting machine

8 Grinder (round) FG50L-1 1

9 Grindstone SCW50 19 10 1

10 Grinder LISG-7S 1 For finishing

11 Grindstone 180 6 22 3

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-auto-matic welding machine 1.2 mm 80kg

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/cm} 1 Injection into suspension

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

32 Wood block 300 mm square, 1 m long 12 * Quantity depends on using condition.

33 Oil jack 5 l 1 For oil injection

34 Oil See Field Assembling Procedures. See Field Assembling Procedures.

35 Oil sump, washing can 2

36 Drained oil can Empty drum can 1

37 Cloth 5kg

38 Diesel fuel See Field Assembling Procedures. For refilling fuel

39 Antifreeze 5 l For adding in subtank (to change mixing ratio depending on local weather)

40 Air hose 6 1m 1 For air bleeding

10

5-2 List of jigs, tools, and consumables for field assembling (2/2) No. Item Specification Q'ty Remarks

41 Sanding machine for scal-ing-off coating 914B 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 m or 7 kg/cm 1

47 Air hose With mouthpiece of 12 5 For impact grinder

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

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 1 Use to bundle harnesses

59 Standard tool (ISO specifi-cation) 700SX 2

60 Bar 1m 1

61 Pointed steel bar 1 For hole alignment

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

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 60 250 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 28 2 For slinging chassis

77 Wire 4m 28 2 For mounting body

78 Wire 5m 28 2 For installing body

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

121

For mounting bodyFor slinging chassisFor slinging separated body

11

List of touch-up coating on body for overseas specifications

No. Part Name Unit Q'ty

1 Retane GP primer 4kg 1

2 Retane GO hardener 0.8kg 1

3 Retane GP thinner 4l 1

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

12

5-3. Tools and consumablesNote: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

Body alignment shaft

Body lifting pin

HEAT TREATMENT

MATERIALSTKM13A

PART NAMEShaft

QTY1

WJ-H46-74001-023

HEAT TREATMENT

MATERIALSS400

PART NAMEBody lifting pin

QTY4

AHT-785-006

13

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

Body assembly lifting tool

HEAT TREATMENTPU-4

MATERIALSS40

PART NAMESPACER

QTY3

ATH-465-027

HEAT TREATMENT

MATERIAL

PART NAMEBody assembly lifting tool

QTY1

ATH-465-039

14

Chassis lifting tool

Dump body lifting tool

HEAT TREATMENT

MATERIAL

PART NAMEChassis lifting tool

QTY2

ATH-465-040

HEAT TREATMENT

MATERIAL

PART NAMESplit dump body lifting tool

QTY1

ATH-465-041

15

Universal lifting tool

Front axle installation guide

HEAT TREATMENT

MATERIAL

PART NAMEUniversal lifting tool

QTY1

ATH-465-042

HEAT TREATMENT

MATERIAL

PART NAMEFront axle installation guide

QTY2

ATH-785-078

16

Assembly process No.

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 0C, always use EOS0W30, or

EOS5W40, even though the temperature goes up to 10C during the daytime. t Coolant

Komatsu genuine super coolant (AF-NAC) is added to the cooling water, so there is no need tochange it for temperatures down to -10C.If the temperature goes below -10C, adjust the density. For details, see CLEANING INSIDE OFCOOLING SYSTEM in the WHEN REQUIRED Section of the Operation and Maintenance Manual.

a For details of the notes (e.g., Note. 1, Note.2 ) in the table, see the Operation and Maintenance Manual.

Oil, grease, and coolant0010

17


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).

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)

Power line oil

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

Final drive case 64 each on right and left sides64 each on right and

left sides

Fuel tank Diesel fuel 1,308

Cooling system Coolant 283 279

Levels of oil, grease, and coolant0020

Precautions Necessary tools Necessary equipmentName Q'ty Name Q'ty

Other remarks

18


Slinging of rear axle1. Sling the rear axle and tire assembly with a 50 ton crane.

Slinging position: Rod mounting portion on differential

Positioning of rear axle1. Position the rear axle. See the following figure.

(Secure the ground clearance under the coupling section so that the rear axle assembly will be hori-zontal.)When positioning the rear axle on the ground, prevent slanting of the machine caused by subsid-ence of the ground.

2. Lock the wheels with chocks to prevent the rear axle from moving.

Weight: 20 ton (Including sling)

Wood block

1,200

Positioning rear axle assembly0030

Precautions Necessary tools Necessary equipmentLock the wheels with chocks to prevent the rear axlefrom moving.

Name Q'ty Name Q'tyNylon sling (250 mm wide 5 m)

1 Crane (50 ton) 1

Other remarks

19


Sling 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 28 wireSlinging position on front side : Frame slinging bracketSlinging 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).

Moving of bare machine1. Move the bare machine to above the rear axle.

Front12.5 ton (Including sling)Crane: 50 ton

Rear10.8 ton (Including sling)Crane: 25 ton

View f rom rear of bare machine

Body lock pin

Slinging positions

Raised upper rod

Slinging and moving of bare machine0040

Precautions Necessary tools Necessary equipmentInsert the body lock pin for slinging the rear side frominside of the machine. (If it is inserted from outside, itcannot be removed after the tire is installed.)

Name Q'ty Name Q'tyCranes (50 ton, 25 ton) 1

eachSling (ATH-465-040) 2Pin (60 250 mm) 2Wire (7 m, 28 ) 2

Other remarks

20


3

Connection of rod and rear suspension0050

Connection of rod and rear suspension

1. Connect A, B and C in order.Remove the pins installed temporarily and the spacers and bolts to be used in step 3.

2. Adjust the pin holes and remove the rod from the pin holes temporarily.3. Put the spacer in the rubber part of the spherical bushing. (See the figure at right.)4. Adjust the pin holes and insert the pin.5. Install the lock bolt and washer.6. Supply grease.

Part No. Part name Q'ty Condition of partsA (1) 561-52-81210 Pin 2 Temporarily installed to rear axle A

(2) 01010-81430 Bolt 2 Temporarily installed to rear axle A(3) 569-40-61710 Washer 2 Temporarily installed to rear axle A

B (4) 561-52-81210 Pin 2 Temporarily installed to frame B(5) 01010-81430 Bolt 2 Temporarily installed to frame B(6) 569-40-61710 Washer 2 Temporarily installed to frame B

C (7) 561-52-81210 Pin 2 Temporarily installed to rear axle C(8) 01010-81425 Bolt 2 Temporarily installed to rear axle C(9) 569-40-61710 Washer 2 Temporarily installed to rear axle C

Tack-weld nylon sling and lever block.(Used to fix lower arm)

* Carry out work simultaneously.

Precautions Necessary tools Necessary equipment1. When adjusting the holes, take care not to catch

your finger.2. If the spacer is installed forcibly, it is deformed. Take

care.3. When hitting the pin, take care not to crash the

grease fitting.4. Clean the pins installed temporarily and parts A, B

and C.


2

Lever block (2 ton, LB020)

2

Other remarks

21


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 thatthe 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.

1,000

Steel plate

Remove chock on front side.

2,800

Wood block

Wood block Sttel plate

Positioning bare machine0060

Precautions Necessary tools Necessary equipmentTake care that the chassis will not move.

Set the bare machine to proper height so that you caninstall the front tires.

Name Q'ty Name Q'tyWood block (300 mm square, 1 m)

6

Steel plate 1

Other remarks

22


Connection of rear axle cooling hose

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.

3. Clean the parts stained with oil.

Part No. Part name Q'ty Condition of parts(1) 07371-21465 Flange 4 Installed parts(2) 07372-21245 Bolt 8 Installed parts(3) 01643-51232 Washer 8 Installed parts(4) 07000-F3048 O-ring 2 Installed parts(5) 07371-32076 Flange 4 Installed parts(6) 07372-21240 Bolt 8 Installed parts(7) 01643-51232 Washer 8 Installed parts(8) 07000-F2060 O-ring 2 Installed parts

Rear axle plug, 4 pieces

Rear axle

Rear axle

Hose plug on machine side, 2 pieces

Connection of rear axle cooling hose0070

Precautions Necessary tools Necessary equipmentWhen connecting each hose, check that no dirt is in thehose and the O-ring is fitted securely.

When removing each plug, set an oil drain case toreceive the leaking oil.

*1. Dimension of plate (See "Fig 1")Large pipe: W = 63 mmSmall pipe: W = 55 mm

Name Q'ty Name Q'tyImpact wrench (For M12 mm)

1

Socket (19 mm) 1

Other remarks

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

Flange Plate

Fig.1

Note) Do not damage the O-ring.

23


Connection of rear axle brake hose

1. Remove the plugs from each part.

2. Connect the 3 hoses.


Caution: Install the hoses horizontally.

a

b

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

View Y

a b c

View Z

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

b c

Connection of rear axle brake hose0080

Precautions Necessary tools Necessary equipment1. Take care extremely not to mistake the connecting

positions.

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

Name Q'ty Name Q'ty

Other remarks

24


a

b

c

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

View Y

a

b c

View Z

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

Connection: CNJ13

ac

dConnection: CNJ12

Connection of rear axle brake hose

1. Remove the plugs from each part.

2. Connect the 3 hoses.

3. Connect connectors "CNJ12" and CNJ13".


Caution: Install the hoses horizontally.

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


positions.

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

Name Q'ty Name Q'ty

Other remarks

25


Connection of valve sub-assembly wiring harness

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-51512 Clip 5 Installed temporarily to machine(2) 01024-81016 Bolt, sems 6 Installed temporarily to machine(3) 08193-21012 Clip 2 Installed temporarily to machine

* 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.

View ZView YRemove clip and bolt and fix wiring harness.

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


Other remarks

26


Connection and fixing of piping going to rear axle

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 416-88-11140 Plate 2 Packed separately (HD785-7-087)(2) 04434-52110 Clip 2 Packed separately (HD785-7-087)(3) 07095-20314 Cushion 2 Packed separately (HD785-7-087)(4) 07283-32236 Clip 2 Packed separately (HD785-7-087)(5) 01643-31032 Washer 4 Packed separately (HD785-7-087)(6) 01580-11008 Nut 4 Packed separately (HD785-7-087)

Rear axle

ASR valveRear axle slack adjuster

Z(190)

(225)

View X

Rear axle

Connection

View Z

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


Other remarks

27


Connection and fixing of rear grease piping and supply of grease

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

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

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

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

5. Supply grease until it flows out of the lubri-cated spherical bushing, seal, or boot lip.

6. Grease must not ooze from the pipe joints

X

Y

View X

FWD

A

a

c

a

b

b c

View Y

FWD

Aa

c

c

b

b

a

Part No. Part name Q'ty Condition of part (Parts list No.)(2) 561-52-82641 Tube 1 Packed separately (HD785-7-090)(4) 421-09-12540 Elbow 2 Packed separately (HD785-7-090)(6) 561-52-82631 Tube 1 Packed separately (HD785-7-090)(8) 04434-50608 Clip 4 Packed separately (HD785-7-090)(9) 01024-80816 Bolt sems 4 Packed separately (HD785-7-090)

Connection and fixing of rear grease piping and supply of grease0090


positions.Name Q'ty Name Q'ty

Other remarks

28


Preparation for installing front axle1. Remove the packing materials for each part.

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

Part No. Part name Q'ty Condition of parts(1) 561-40-61550 Pin 2 Temporarily installed to machine (L = 260 mm)(2) 561-40-61560 Pin 2 Temporarily installed to machine (L = 290 mm)(3) 566-52-41950 Spacer 4 Temporarily installed to machine(4) 01010-81425 Bolt 4 Temporarily installed to machine(5) 569-40-61710 Washer 4 Temporarily installed to machine(6) 561-40-81540 Pin 2 Temporarily installed to machine(7) 566-52-61150 Spacer 4 Temporarily installed to machine(8) 01010-81425 Bolt 2 Temporarily installed to machine(9) 569-40-61710 Washer 2 Temporarily installed to machine

Preparation for installing front axle0100

Precautions Necessary tools Necessary equipment1. Dimensions of pin vary on each portion. Place pins

near relevant locations to install pins in place withease.

2. Adjust sling so that suspension cylinder becomesvertical against ground.Hook slings at suspension cylinder assembly andhub stud portion.

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

Other remarks

29


Lever block

How to sling

Fix with spacer,pin and lock bolt.

Fix with spacer,pin and lock bolt.

Move up.

Move up.

A-arm

GuideATH-785-078

Fix to fuel tankbracket.

Installation of front axle0110

Installation of frontxle

o When installing steering cylinder

o When installing suspension cylinder

1. Move up the A-arm mounting part with a crane.

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 coversof the spherical bushings of the A-arm (4 places on rightand left sides) and then adjust the pin holes again with thelever block. (Adjust the horizontal direction with the leverblock, 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 Necessary tools Necessary equipment1. Check spacer for deviation.2. When making alignment, take care not to catch your

fingers in it.3. Check for O-ring on spherical bushing.

Name Q'ty Name Q'tyNylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1Nylon sling (100 mm wide 3 m) 1Lever block (3/4 ton, LB008) 3Lever block (2 ton, LB020) 1Guide pin (ATH-785-078)

Other remarks

30


A

A2

View Z

Suspension oil pressure sensor (left) CN SUFL

Suspension oil pressure sensor (Right) CN SUFR

Connection of front axle suspension pressure sensor

1. After installing the front axle, connect the suspension oilpressure sensor wiring harness.

2. Fix the suspension oil pressure sensor wiring harness of theleft front axle with clips (1) and bolts (2).

3. Fix the suspension oil pressure sensor wiring harness of theright front axle with clips (1) and bolts (2).

Part No. Part name Q'ty Condition of parts(1) 04434-50810 Clip 3 Temporarily installed to machine(2) 01024-81020 Bolt, sems 3 Temporarily installed to machine

Connection

Suspension oil pressure sensor (Left) CN SUFLSuspension oil pressure sensor (Right) CN SUFR

Z

Connection of front axle suspension pressure sensor0120


Nylon sling (30 mm wide 2 m) 3 Crane (25 ton) 1Nylon sling (100 mm wide 3 m) 1Lever block (3/4 ton, LB008) 3Lever block (2 ton, LB020) 1

Other remarks

Section A-A

31


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.

30

50

Connection: CN WSFLWheel speed sensor (FL)

View Y Fixing with clip (installed to front axle)

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

Left front axle

Connecting: CN WSFRWheel speed sensor (FR)

View Z

Fixing with clip (installed to front axle)

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

Z

Y

Connection of front axle wheel speed sensor (ABS speci-fication: If equipped)0125


Other remarks

32


Connection of steering cylinder and tie rod

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.

Part No. Part name Q'ty Condition of parts(1) 561-40-61531 Pin 2 Temporarily installed to front axle(2) 561-40-61570 Pin 2 Temporarily installed to front axle(3) 01010-81425 Bolt 4 Temporarily installed to front axle(4) 569-40-61710 Washer 4 Temporarily installed to front axle(5) 561-40-61631 Boot 8 Temporarily installed to front axle

L = 260mm

Reconnection

L = 240mm

Reconnection

Connection of steering cylinder and tie rod0130

Precautions Necessary tools Necessary equipment1. Check that the O-rings are fitted to the steering cyl-

inder and tie rod spherical bushing.2. Note that the lengths of the pins are different from

one another.

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

Other remarks

33


Connection of front axle brake cooling hoses

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.)


Part No. Part name Q'ty Condition of parts(1) 07371-21465 Flange 8 Installed parts(2) 07375-21240 Bolt 16 Installed parts(3) 07000-F3048 O-ring 4 Installed parts

Connect front side to front side

Connect rear side torear side.

Connection

Left side

Connection

Connect rear side to rear side.

Connect front side to front side.

Right side

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

Frame seen from front

(Flange face - center of clip width)

(Flange face - center of clip width)

Connection of front axle brake cooling hoses0140

Precautions Necessary tools Necessary equipmentWhen removing each pipe plug, prepare a drain case toreceive the leaking oil.

Name Q'ty Name Q'ty

Other remarks

34


Connection of front axle brake hoses

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.

Connection

Right front axle

Left front axle

Connection

a b

a

b

a

b

ab

a

b

a

b

After connecting hose, reassemble.

After connecting hose, reassemble.

Connection of front axle brake hoses0150


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

Name Q'ty Name Q'ty

Other remarks

35


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

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

Section A-AConnection

Color of SOL A-A band: Yellow

Color of SOL A-B band: Red

Color of SOL B-A band: Black

Color of SOL B-B band: Green

Left front axle

Connection

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

Color of SOL B-A band: Blue

Color of SOL A-A band: Brown

Color of SOL A-B band: White

Color of SOL B-A band: Blue

SOL B-B

Color of SOL A-A band: Brown

Right front axle

Section B-B

Connection of front axle auto suspension piping

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.

Connection of front axle auto suspension piping0160


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

Name Q'ty Name Q'ty

Other remarks

36


View Q

: 3 places

View P

View X: Left axle

: 8 places

View Y: Right axle

420 (Actual length of center of brake hose)




268 (Actual length of center of auto suspension hose)

Left axle seen from rear

532 (Actual length of center of auto suspension hose)

Right axle seen from front

Fixing of front axle auto suspension piping0165


Other remarks

Fixing of front axle auto suspension piping1. Fix the front axle and auto suspension piping. * For the clamp locations, see the following figure.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-53212 Clip 8 Packed separately (HD785-7-165)(2) 04434-53412 Clip 4 Packed separately (HD785-7-165)(3) 07095-00420 Cushion 1 Packed separately (HD785-7-165)(4) 07095-00423 Cushion 3 Packed separately (HD785-7-165)(5) 01024-81025 Bolt, sems 4 Packed separately (HD785-7-165)(6) 01580-11008 Nut 4 Packed separately (HD785-7-165)(7) 01024-81020 Bolt, sems 4 Packed separately (HD785-7-165)(8) 01643-31032 Washer 4 Packed separately (HD785-7-165)

37


View Z


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


300 (Actual length of center of auto grease hose) 600 (Actual length of center of auto grease hose)

View Y: Right axleView X: Left axle

Fixing of front axle auto grease piping

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-52310 Clip 4 Packed separately (HD785-7-166)(2) 04434-53412 Clip 4 Packed separately (HD785-7-166)(3) 07095-00420 Cushion 4 Packed separately (HD785-7-166)(4) 01024-81025 Bolt, sems 4 Packed separately (HD785-7-166)(5) 01643-31032 Washer 4 Packed separately (HD785-7-166)(6) 01580-11008 Nut 4 Packed separately (HD785-7-166)

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


Other remarks

38


Connection of left front axle auto grease piping1. Connect the left front axle and auto grease piping.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-95-63290 Elbow 3 Installed to machine body(2) 04434-51010 Clip 1 Packed separately (HD785-7-167)(3) 01024-81016 Bolt, sems 1 Packed separately (HD785-7-167)

Connect: Band color "Yellow" L2

Connect: Band color "Blue" L3

Connect: Band color "Green" L6

Connect: Band color "Red" L1

Connect: Band color "White" L4

View Y

View W

View Z

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


Other remarks

39


Connection of right front axle auto grease piping

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-95-63290 Elbow 3 Installed to machine body

Connect: Band color "Blue" R3

Connect: Band color "Black" R5

Connect: Band color "White" R4

Connect: Band color "Green" R6

Connect: Band color "Red" R1

View X

View Y

Section A-A

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


Other remarks

40


Installation of bumper step

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

Installation of front axle steps

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 01024-81225 Bolt, sems 8 Installed to bumper(2) 561-54-86871 Step 2 Packed separately (HD785-7-170)(3) 01024-81230 Bolt, sems 8 Packed separately (HD785-7-170)(4) 561-54-31690 Step 2 Packed separately (HD785-7-170)

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-86751 Bracket L. H 2 Packed separately (HD785-7-170)(2) 561-54-86761 Bracket R. H 2 Packed separately (HD785-7-170)(3) 01024-81225 Bolt 8 Packed separately (HD785-7-170)(4) 561-54-86740 Step 2 Packed separately (HD785-7-170)(5) 01024-81030 Bolt 8 Packed separately (HD785-7-170)

Installation of bumper and front axle steps0170

Precautions Necessary tools Necessary equipmentThere are right and left front axles. Since they arestamped as shown below, check the stamps wheninstalling.

Name Q'ty Name Q'ty

Other remarks

"R.H."

41


Installation of front axle step

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-88300 Step assembly, R.H 1 Packed separately (HD785-7-172)(2) 561-54-88400 Step assembly, L.H 1 Packed separately (HD785-7-172)(3) 01024-81225 Bolt 4 Packed separately (HD785-7-172)

Installation of front axle step (EU specification)0171

Precautions Necessary tools Necessary equipmentThe right and left front axles are different. When install-ing them, confirm their part Nos.

Name Q'ty Name Q'ty

Other remarksSale code : 5AC11

42


1,11

2

3

4 6

78

9

10

5

Installed to front axletemporarily

3 : 1,519 -- 1,617 Nm{154.9 -- 164.8 kgm}

Installation of tire and wheel assembly

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 forinflating 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.)

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 569-22-72870 Nut 40 Temporarily installed to front axle(2) 426-09-11520 Washer 40 Temporarily installed to front axle(3) 561-30-80000 Tire assembly 2 Packed separately (HD785-7-180)

Apply chock hitch.

Nylon sling

Weight of tire: 1,500 kg

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

Place wooden blocks underfront axle (under king pin) andplace steel plate under them.

Wood block

Steel plate

Secure tire with wire to prevent tire from falling. 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.

Installation of tire and wheel assembly0180

Precautions Necessary tools Necessary equipment1. When carrying the tire, take care that it will not fall.2 When positioning the tire, take care not to damage

the air valve.

Name Q'ty Name Q'tyTorque wrench QLE21000

1 Crane (50 ton) 1Forklift (4 ton) 1

Nylon sling (100 mm wide 12 m)

1 Wire 1

Socket (1 inch 46 mm) 1

Other remarks

Take care of position of air valve.

43


Installation of drive shaft

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

tightening order, see Fig. 1. Apply LT-2 to the bolts.)5. Tighten the bolt again with the torque wrench.

(Torque wrench: 343 627 Nm {34.9 43.5 kgm})6. Install the guard again.7. Wipe off the grease from the mounting part and

degrease the bolts (coupling).

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-20-72002 Propeller shaft 1 Packed separately (HD785-7-190)(2) 01050-61895 Bolt 8 Packed separately (HD785-7-190)

Apply LT-2.3: 343 -- 427 Nm {34.9 -- 43.5 kgm}

Install larger end to transmission.

Installation of drive shaft0190

Precautions Necessary tools Necessary equipmentInstall drive shaft from the front side and transmissionside for the ease of work. (Tighten the bolts on the frontside temporarily and fit the faucet joint securely.)

When installing the rear side, install a chain block to thedrive shaft to extend.


2 Crane (25 ton) 1

Torque wrench, 2800QL 1

Other remarks

5,1

2

3

4

Bolt (2) tightening torque:343 427Nm{34.9 43.5kgm}Guard tightening torque:1,180 1,470Nm{120 150kgm}

Fig. 1

44


Hydraulic tank

: 5 places

Transmission and brake cooling oil

Brake control oil

Steering and H/T oilEngine oil

Section A-A View Z

Installation of oil quick charge box

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) X251156860 Box, sub assembly 1 Packed separately (HD785-7-200)(2) 01024-81225 Bolt, sems 5 Packed separately (HD785-7-200)

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


Other remarks

45


Installation of fuel tank wiring harness cover1. Install cover (1) with the bolts installed to the fuel tank.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-04-81322 Cover 1 Installed to fuel tank

FUEL TANK

Wiring harness cover

Installation procedure for cover (1)


Other remarks

Installation of fuel tank wiring harness cover0260

46


Installation of toolbox

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).

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-98-86110 Tool box, sab assembly 1 Packed separately (HD785-7-270)(2) 01024-81225 Bolt 4 Temporarily installed to fuel tank(3) 09460-00000 Lock 1 Packed separately (HD785-7-270)

Installation of toolbox and tool kit0270


Other remarks

47


EU specification

EU specification

EU specifica-tion reference drawing

EU specifica-tion reference drawing

Installation of fuel tank step1. 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).

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-8A981 Ladder 1 Packed separately (HD785-7-275)(2) 01024-D1230 Bolt 8 Installed to fuel tank(3) 561-54-8A960 Step 1 Packed separately (HD785-7-275)(4) 01024-D1230 Bolt 4 Packed separately (HD785-7-275)(5) 561-54-8A982 Ladder 1 Packed separately (HD785-7-277)(6) 561-54-8A900 Step 1 Packed separately (HD785-7-277)

Installation of fuel tank step (If equipped)0275


Other remarksSales code: 6HH68-A or 5AC11

48


Z

Installation of rear support1. Remove the bolts and washers installed to the machine body temporarily.2. Install the rear support assembly.

Fixing of air tube1. Fix the air tube.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-46-80200 Rear support LH 18 Packed separately (HD785-7-280)(2) 01010-82475 Bolt 18 Installed to frame(3) 01643-32460 Washer 18 Installed to frame(4) 561-46-81791 Rear support RH 1 Packed separately (HD785-7-280)(5) 01010-81850 Bolt 7 Installed to frame(6) 01643-31845 Washer 7 Installed to frame

Part No. Part name Q'ty Condition of part (Parts list No.)(7) 04434-51210 Clip 18 Packed separately (HD785-7-280)(8) 01024-81020 Bolt 18 Packed separately (HD785-7-280)

Diagonal front view

View Z

Installation of rear support0280



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

* 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 pre-ventive paint from rear support ground face (on machine frame side).

49


Installation of rear support1. Remove the bolts and washers installed to the machine body temporarily.2. Install the rear support assembly.


Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-46-80200 Rear support LH 18 Packed separately (HD785-7-281)(2) 01010-82475 Bolt 18 Installed to frame(3) 01643-32460 Washer 18 Installed to frame(4) 561-84-84391 Rear support RH 1 Packed separately (HD785-7-281)(5) 01010-81850 Bolt 7 Installed to frame(6) 01643-31845 Washer 7 Installed to frame


Diagonal front view

View Z

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

Z

* 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 pre-ventive paint from rear support ground face (on machine frame side).

Mufflerspecification



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

50


View Y

Installation of rear support1. Remove the bolts and washers installed to the machine.2. Install the rear support assembly.

(Before installing the left rear support assembly, install ABS assembly (9) with bolts (10).


Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-46-80300 Rear support LH 18 Packed separately (HD785-7-282)(2) 01010-82475 Bolt 18 Installed to frame(3) 01643-32460 Washer 18 Installed to frame(4) 561-84-84391 Rear support RH 1 Packed separately (HD785-7-282)(5) 01010-81850 Bolt 7 Installed to frame(6) 01643-31845 Washer 7 Installed to frame(9) 561-88-80201 ABS front sub assembly 1 Packed separately (HD785-7-282)

(10) 01024-81230 Bolt, sems 4 Packed separately (HD785-7-282)


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



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

* 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 sur-face (on machine frame side).

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

51


Installation of rear support1. Remove the bolts and washers installed to the machine.2. Install the rear support assembly.


Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-46-80200 Rear support LH 1 Packed separately (HD785-7-283)(2) 01010-82475 Bolt 18 Installed to frame(3) 01643-32460 Washer 18 Installed to frame(4) X250783640 Rear support RH 1 Packed separately (HD785-7-283)(5) 01010-81850 Bolt 7 Installed to frame(6) 01643-31845 Washer 7 Installed to frame

Part No. Part name Q'ty Condition of part (Parts list No.)(7) 04434-51210 Clip 2 Packed separately (HD785-7-283)(8) 04434-51010 Clip 1 Packed separately (HD785-7-283)(9) 01024-81020 Bolt 1 Packed separately (HD785-7-283)

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



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

* Keep bolts (2) and (5) tightened lightly for adjust-ment until the right platform and cab are installed.

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

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

52


ab View X

Installation of muffler

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.

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-02-81210 Tube 1 Packed separately (HD785-7-290)(2) 6502-12-1722 V coupling 1 Packed separately (HD785-7-290)(3) 01024-81235 Bolt 2 Packed separately (HD785-7-290)(4) 561-02-81350 Band 1 Installed to frame(5) 01580-11008 Nut 4 Installed to frame(6) 01643-31032 Washer 2 Installed to frame

Tightening procedure for exhaust pipe band

Z

X

View Z

Fire prevention cover

* Tighten bolts to secure fire prevention cover.

3:8.8 9.8 Nm{0.9 1.0 kgm}

* Before tightening the bolts permanently, install all the parts

Installation of muffler0290


Other remarks

53


8.89.8Nm{0.91kgm}

a: 4 places

Rear view of machine Front view of machine(Sectional view of rear support)

3 :Installation of muffler

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) 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. (Twistingdistance: 3 5 mm)

2. Permanently tighten V-coupling (3) on the frame side.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-84-80101 Muffler sub assembly 1 Packed separately (HD785-7-291)(2) 01024-81230 Bolt, sem 4 Packed separately (HD785-7-291)(3) 6502-12-1722 V coupling 1 Packed separately (HD785-7-291)(4) 561-84-84341 Tube 1 Installed to machine

Assembly procedure for exhaust pipe at muffler connecting part

3369A

A

A-A

Twisting distance to left: 3 5 mmTwisting distance to right: 0 mm

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

0291


1

Other remarks

54


Installation of fire prevention cover

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

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-89-86111 Cover 1 Packed separately (HD785-7-300)(2) 561-89-86120 Cover 1 Packed separately (HD785-7-300)(3) 01024-81230 Bolt, sems 6 Packed separately (HD785-7-300)(4) 01024-81225 Bolt, sems 2 Packed separately (HD785-7-300)

Installation of fire prevention cover0300


Other remarks

55


Installation of front support

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-80301 Front support sub assembly LH 1 Packed separately (HD785-7-310)(2) 01010-82270 Bolt 11 Packed separately (HD785-7-310)(3) 01643-32260 Washer 11 Packed separately (HD785-7-310)(4) 561-54-80401 Front support sub assembly RH 1 Packed separately (HD785-7-310)(5) 01010-82255 Bolt 5 Packed separately (HD785-7-310)(6) 01643-32260 Washer 5 Packed separately (HD785-7-310)

3:662 829 Nm{67.5 84.5 kgm}

3:662 829 Nm{67.5 84.5 kgm}

Connection of headlamp wiring harness

Installation of front support0310



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

56



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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-80100 Front support sub assembly LH Fog 1 Packed separately (HD785-7-315)(2) 01010-82270 Bolt 11 Packed separately (HD785-7-315)(3) 01643-32260 Washer 11 Packed separately (HD785-7-315)(4) 561-54-80200 Front support sub assembly RH Fog 1 Packed separately (HD785-7-315)(5) 01010-82255 Bolt 5 Packed separately (HD785-7-315)(6) 01643-32260 Washer 5 Packed separately (HD785-7-315)

3:662 829 Nm{67.5 84.5 kgm}

3:662 829 Nm{67.5 84.5 kgm}

Connection of headlamp wiring harness

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



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

57



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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-85-80V00 Front support sub assembly LH 1 Packed separately (HD785-7-317)(2) 01010-82270 Bolt 11 Packed separately (HD785-7-317)(3) 01643-32260 Washer 11 Packed separately (HD785-7-317)(4) 561-85-80W00 Front support sub assembly RH 1 Packed separately (HD785-7-317)(5) 01010-82255 Bolt 5 Packed separately (HD785-7-317)(6) 01643-32260 Washer 5 Packed separately (HD785-7-317)

Connection of headlamp harness

3 :

3 :

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

0317



1 Crane (25 ton) 1

Torque wrench 1

Other remarks

58


View Z

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

Installation of steering valve1. Remove the blind plugs and caps from the frame

steering piping (5 places).

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

3. Install the nipple to the steering valve.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-40-83300 Valve,steering 1 Packed separately (HD785-7-320)(2) 561-40-42620 Cushion 4 Packed separately (HD785-7-320)(3) 561-40-42630 Collar 4 Packed separately (HD785-7-320)(4) 561-40-42650 Plate 4 Packed separately (HD785-7-320)(5) 02010-20638 Bolt 4 Packed separately (HD785-7-320)(6) 01643-31032 Washer 4 Packed separately (HD785-7-320)(7) 569-40-83470 Bracket 2 Packed separately (HD785-7-320)(8) 569-40-83480 Seal 1 Packed separately (HD785-7-320)(9) 01024-80616 Bolt, sems 2 Packed separately (HD785-7-320)

(10) 01643-30623 Washer 2 Packed separately (HD785-7-320)(11) 01580-10605 Nut 2 Packed separately (HD785-7-320)

Part No. Part name Q'ty Condition of part (Parts list No.)(12) 02896-21012 O-ring 1 Packed separately (HD785-7-320)(13) 569-61-84770 Nipple 2 Packed separately (HD785-7-320)(14) 437-40-22310 O-ring 2 Packed separately (HD785-7-320)(15) 569-61-84780 Nipple 2 Packed separately (HD785-7-320)(16) 418-62-11620 O-ring 2 Packed separately (HD785-7-320)(17) 02896-21018 O-ring 4 Packed separately (HD785-7-320)

Installation of steering valve0320

Precautions Necessary tools Necessary equipment1. Take care that the O-ring will not be projected. Name Q'ty Name Q'ty

Other remarks

59


Preparation for installing cab1. Adjust the dimensions between the viscous mounts with the left front support and rear support as

shown below.

Slinging of cab1. Sling the cab assembly. (Use a sling having capacity of at least 3 ton.)

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-83200 Cab assembly 1 Packed separately (HD785-7-330)

Dimension measuring method

Preparation for installing cab0330


Nylon sling (Capacity: Min. 3 ton)

1 Crane (50 ton) 1

Other remarks

60


* 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.

Connect

Section B-B

Installation of cab

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.

3. Remove the sling.4. Connect the ground wire to the rear of the cab assembly.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 01010-81645 Bolt 8 Packed separately (HD785-7-340)(2) 01643-31645 Washer 8 Packed separately (HD785-7-340)(4) 561-54-87221 Shim t=1.0 4 Packed separately (HD785-7-340)(5) 01010-82055 Bolt 8 Packed separately (HD785-7-340)(6) 01643-32060 Washer 8 Packed separately (HD785-7-340)(7) 561-54-87231 Shim t=0.5 8 Packed separately (HD785-7-340)(8) 561-54-87241 Shim t=1.0 8 Packed separately (HD785-7-340)(9) 01596-03024 Nut 1 Installed to frame

(10) 01643-33080 Washer 1 Installed to frame

Part No. Part name Q'ty Condition of part (Parts list No.)(12) 08028-45025 Cable 1 Installed to cab assembly(13) 01024-81016 Bolt, sems 2 Packed separately (HD785-7-340)

Installation of cab0340

Cle

aran

ce (A

) adj

uste

d w

ith

shim

(Sta

ndar

d: 0

mm

)

Section A-A

* After cab is installed, if clear-ance (A) is made, insert shims (7) and (8) by necessary quan-tity (up to 8 pieces for each place (t0.5 4, t1.0 4)).No shim may be used as stan-dard.

(1) 3: 245 309 Nm{25 31.5 kgm}

(9) 3: 1,177 1,471 Nm{120 150 kgm}

(5) 3: 490 608 Nm{50 62 kgm}

Precautions Necessary tools Necessary equipment1. If there is clearance between the mount bracket and

cab (clearance to be adjusted with shims), insertshims by necessary quantity (up to 8 pieces for eachplace).

2. The part to connect the ground wire must be freefrom stain or paint.

Name Q'ty Name Q'ty

Other remarks

61


Connection of ABS piping

Connection of ABS piping (If equipped)0345


Other remarks

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.

62


A

ARemove these bolt and washer.

Bolt

Set bolt to this "hollow".

Section A-ASteering valve

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.)

Connection of column0350

Precautions Necessary tools Necessary equipment1. Apply grease (LM-G) to the connecting parts.

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

Name Q'ty Name Q'ty

Other remarks

63


Installation of washer tank

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 569-06-6115A Washer tank 1 Packed together with cab(2) 01024-81020 Bolt, sems 4 Packed together with cab(3) 08034-40521 Band 1 Packed together with cab

Installation of washer tank0355

Precautions Necessary tools Necessary equipment1. When fixing the washer hose, take care not to flatten

it.Name Q'ty Name Q'ty

Other remarks

1. Take washer tank assembly (1) out of thecab and install it to the cab with bolts (2).

2. Fix washer hose (A) coming out of the cabwith washer tank clips (marked with a) at2 places so that it will not be flattened andthen connect it to the washer tank.

3. Connect wiring harness (B) going to thewasher motor to the washer tank. (CNFL04)

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 thecab side) so that the hose will not be flat-tened.

64


Z (View from below cab)

View Z(View from below cab)

A

A

Brake accumulator

Path hoses through notches.

Section A-A

Connection of cab piping

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-89-86241 Bracket 1 Packed separately (HD785-7-360)(2) 561-89-86251 Plate 1 Packed separately (HD785-7-360)(3) 561-89-86232 Rubber 1 Packed separately (HD785-7-360)(4) 424-54-14220 Washer 2 Packed separately (HD785-7-360)(5) 561-89-86262 Bracket 2 Packed separately (HD785-7-360)(6) 01024-81025 Bolt, sems 10 Packed separately (HD785-7-360)

Connection of cab piping0360


Other remarks

65


Connection of cab wiring

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-52711 Clip 3 Packed separately (HD785-7-370)(2) 01024-81020 Bolt, sems 4 Packed separately (HD785-7-370)(3) 08193-21012 Clip 1 Packed separately (HD785-7-370)(4) 01024-81016 Bolt, sems 1 Packed separately (HD785-7-370)(5) 23S-62-25850 Clip 1 Packed separately (HD785-7-370)(6) 6152-51-5520 Spacer 1 Packed separately (HD785-7-370)(7) 01024-81070 Bolt, sems 1 Packed separately (HD785-7-370)(9) 04434-52110 Clip 1 Packed separately (HD785-7-370)(10) 07095-20420 Cushion 1 Packed separately (HD785-7-370)(11) 561-61-65530 Clip 1 Packed separately (HD785-7-370)(12) 561-61-65540 Insulator 1 Packed separately (HD785-7-370)




Procedure for connecting wiring harness

CN LP1: Left platformwiring harness junction

CN J06: Wiring harness junction in cab




CN LP2: Left platform wiring harness junction


CN PMLA: PLM and side lamp wiring harness junction

Connection of cab wiring0370


Other remarks

66


Fix upper wiring harness : : Fix lower wiring harness




Procedure for connecting wiring harness

CN LP1: Left platformwiring harness junction





CN LP2: Left platform wiring harness junction


CN PMLA: PLM and side lamp wiring harness junction


Connection of cab wiring

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-52711 Clip 3 Packed separately (HD785-7-375)(2) 01024-81020 Bolt, sems 3 Packed separately (HD785-7-375)(3) 08193-21012 Clip 4 Packed separately (HD785-7-375)(4) 01024-81016 Bolt, sems 4 Packed separately (HD785-7-375)(5) 23S-62-25850 Clip 1 Packed separately (HD785-7-375)(6) 6152-51-5520 Spacer 1 Packed separately (HD785-7-375)(7) 04434-52110 Clip 1 Packed separately (HD785-7-375)(8) 01024-81070 Bolt, sems 1 Packed separately (HD785-7-375)(9) 04434-52511 Clip 1 Packed separately (HD785-7-375)

(10) 07095-20420 Cushion 1 Packed separately (HD785-7-375)(11) 561-61-65530 Clip 1 Packed separately (HD785-7-375)(12) 561-61-65540 Insulator 1 Packed separately (HD785-7-375)(13) 195-979-5190 Collar 1 Packed separately (HD785-7-375)(14) 04434-53411 Clip 1 Packed separately (HD785-7-375)(15) 07095-20625 Cushion 1 Packed separately (HD785-7-375)(16) 01024-81075 Bolt, sems 1 Packed separately (HD785-7-375)

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


Other remarks

67


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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 6131-22-3750 Boss 1 Packed separately (HD785-7-376)(2) 04434-51210 Clip 1 Packed separately (HD785-7-376)(3) 198-06-53510 Cushion 1 Packed separately (HD785-7-376)(4) 01024-81045 Bolt, sems 1 Packed separately (HD785-7-376)(5) 04434-50810 Clip 3 Packed separately (HD785-7-376)

View Z Section B-BConnect: Cab relay connector PRE4

View X

: Tighten together at 3 places.

View Y: Underside of cabSection A-A

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


Other remarks

68


Pass wiring harness into cab.

Mark a: 4 places (Tighten with clip)

View Z: Cab seen from below

Remove cover in cab.

CAB

Section A-A

Connect: SPARE4

Inside of cab seen from front

Connection and fixing of engine compartmentlamp wiring harness

1. Lay the engine compartment lamp wiring harness from themachine 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 har-ness to connector (SPARE4).

3. Install the cover in the cab again.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-50610 Clip 4 Packed separately (HD785-7-377)

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


Other remarks

69


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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-51210 Clip 1 Packed separately (HD785-7-378)(2) 01024-81020 Bolt, sems 2 Packed separately (HD785-7-378)(3) 561-95-83210 Bracket 1 Packed separately (HD785-7-378)

For other specifications, remove mounting bolt and install with it.

Section A-A

Connect: Harness on cab side

View Y

View Z

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


Other remarks

70


Connection of engine stop harness to cab1. Fix the engine stop harness to the cab and connect it to the harness on the cab side.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-50610 Clip 8 Packed separately (HD785-7-379)(2) 04434-51210 Clip 1 Packed separately (HD785-7-379)(3) 198-06-53510 Cushion 1 Packed separately (HD785-7-379)(4) 01024-81020 Bolt, sems 2 Packed separately (HD785-7-379)(5) 08193-21012 Clip 1 Packed separately (HD785-7-379)

Install together with main harness clip mounting bolt.

View Y

Install together with cab under harness clip mounting bolt.

: 8 places

Section A-ASection 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 placesInstall together with main harness clip mounting bolt.

Connect

View XView Z

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


Other remarks

71


Port P: "2"

Port R: "1"

Port LS

Port LT: "4"

Port RT: "5"

Port P

Port R

Port LS Port LT

Port RT

Installation and fixing of steering hoses1. 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.

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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 02766-00423 Hose 1 Packed separately (HD785-7-380)(2) 561-61-82320 Hose 1 Packed separately (HD785-7-380)(3) 561-61-82350 Hose 1 Packed separately (HD785-7-380)(4) 561-61-82310 Hose 1 Packed separately (HD785-7-380)(5) 561-61-82340 Hose 1 Packed separately (HD785-7-380)

Part No. Part name Q'ty Condition of part (Parts list No.)(6) 561-61-64510 Clamp 6 Packed separately (HD785-7-380)(7) 561-61-64540 Plate 3 Packed separately (HD785-7-380)(8) 561-61-64530 Spacer 6 Packed separately (HD785-7-380)(9) 561-61-64520 Plate 3 Packed separately (HD785-7-380)(10) 01024-81290 Bolt sems 6 Packed separately (HD785-7-380)

Port LSPort P: "2"

Port RT: "5"Port R: "1"

Port LT: "4"

View Z

Installation and fixing of steering hoses0380


Other remarks

72


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.

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-51510 Clip 2 Packed in cab(2) 01024-81016 Bolt, sems 2 Installed to front support LH(3) 04435-51510 Clip 1 Packed in cab(4) 04435-51810 Clip 1 Packed in cab(5) 01024-81290 Bolt, sems 2 Installed in No. 0380

Fixing of air conditioner drain hose0385


Other remarks

73


Installation of steering hose cover

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

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-81490 Cover 1 Packed separately (HD785-7-390)(2) 01024-81220 Bolt, sems 4 Packed separately (HD785-7-390)(3) 561-54-81580 Cover 1 Packed separately (HD785-7-390)(4) 01024-81220 Bolt, sems 4 Packed separately (HD785-7-390)

Installation of steering hose cover0390


Other remarks

74


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).

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 09479-02400 Clamp 2 Installed to hose(2) 01024-81020 Bolt, sems 1 Packed separately (HD785-7-395)

Connection of air conditioner and heater hoses0395


Other remarks

75


View Z

CN HM-21AExhaust temperature sensorconnector (LF)

CN HM-21CExhaust temperature sensorconnector (LR)

CN HM-21DExhaust temperature sensorconnector (RR))

CN HM-21BExhaust temperature sensorconnector (RF)

Inside of cab floor

CN HM-22A

CN HM-22C

CN HM-22B

CN HM-22D

CN HM-23A

CN HM-23C

CN HM-23B

CN HM-23D

Connection

X

View X

Z


Other remarks

Connection of cab floor wiring1. Remove the cover in the cab floor.

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

Part No. Part name Q'ty Condition of parts(1) 561-97-82250 Wiring harness 1 Installed to frame

Inside of cab floor

Connection of cab floor wiring 0400

76


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)

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 04434-51910 Clip 1 Packed separately (HD785-7-405)(2) 01024-81016 Bolt, sems 2 Packed separately (HD785-7-405)(3) 08193-21012 Clip 1 Packed separately (HD785-7-405)

Z

X

CAB

View X

Fixing: CN J11

View Z

CN ABSER: Ground

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


Other remarks

77


Connection and fixing of ABS wiring harness

1. Connect and fix the wiring harness with the installedclip and bolt.

View Z

ABS front box

View X

Wheel speed sensor wiring harness

Section A-A

ABS/ASR wiring harness

FixingConnection and fixing: CN J11

Fixing

Z

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


Other remarks

X

78


Installation of cover under cab

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).

Part No. Part name Q'ty Condition of part (Parts list No.)(1) 561-54-82141 Cover 1 Packed separately (HD785-7-410)(2) 01024-81020 Bolt, sems 9 Packed separately (HD785-7-410)(3) 569-54-82260 Seal 1 Packed separately (HD785-7-410)(4) 569-54-82290 Seal 1 Packed separately (HD785-7-410)(5) 07094-30620 Clamp 2 Packed separately (HD785-7-410)(6) 07095-00628 Cushion 2 Packed separately (HD785-7-410)(7) 01024-81270 Bolt, sems 1 Packed separately (HD785-7-410)

FWDA

B

Section A-A

A

B

View Z

Section B-B

Directed toinside of cover

Directed to inside of cover

Z

Installed position of (5), (6) and (7)

View Z

Installa

Documents

Field Assembly HD787!7!7001 Up