Assembly process No.

Welding body (2/2)

C-0060

4. After finishing the welding work, remove the spatters and finish the beads with a grinder.

Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher than 2
or equivalent or equivalent – 3 (m/sec).
AWS ER70S-G and AWS E8016-G and (2) Remove moisture, dust, and paint
equivalent equivalent from surfaces to be welded.
ø 1.2, 1.6 ø 4.0, 5.0 (3) Drying time of arc welding rod
1] Temperature: 150 – 200°C
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 2] Time: 120 minutes
Preheating/Postheating Unnecessary Unnecessary
Gas shielding rate (l/min) 25 – 35 —

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

193
Assembly process No. Welding body instruction (1/2)
C-0070

Welding body instruction (1/2)

Welding instructions
are shown in Proce-
dure for welding body
(2/2) (C-0080)

Weld cross rib Weld cross rib

(inside of chan- (inside of chan-
nel), too. nel), too.

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

194
Assembly process No. Welding body instruction (2/2)
C-0080

Welding body instruction (2/2)

690 ± 1.5

Precautions NTightening torque:

arks

195
Assembly process No. Turn over the body
C-0090

1. Remove the stands (8 pieces) for transportation installed to the bottom plate.
Stand for transportation

2. Reverse the body

(1) Prepare a 50-ton crane and a 20-ton crane. (Set the crane trucks as near the body as possible.)
(2) Insert the lifting pins (ATH-785-006) from inside of the body into the body and install 2-pieces chains (ATH-
465-040) with shackles. (2 places each on right and left sides, 4 pieces in total)
(3) Taking care of the center of gravity, wind in the 50-ton and 25-ton cranes simultaneously. (Secure the
space for reversing the body.)
(4) Taking care of the center of gravity, wind in the 50-ton crane and wind out the 25-ton crane to lay the body
on its side.
(5) Keep holding up the body with the 50-ton crane, remove the sling from the 25-ton crane, move the 25-ton
crane to the opposite side and install the sling to the 25-ton crane.
(6) Taking care of the center of gravity, wind in the 25-ton crane and wind out the 50-ton crane.
(7) After the body becomes horizontal, wind out both cranes simultaneously to lower the body to the ground
and then remove the slings. At this time, put wooden blocks under the front and rear of the bottom plate.
(1) (2) (3)(4) (4)

(5) (6) (7) (7)

Next, weld the inside of the bottom plate.

Connect the welding ground cable to the body securely.
Apply CO2 gas shielded arc welding as standard. If it is difficult to apply CO2 gas shielded arc welding, apply
arc welding.
Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher
or equivalent or equivalent than 2 – 3 (m/sec).
AWS ER70S-G and equivalent AWS E8016-G and equivalent (2) Remove moisture, dust, and
ø 1.2, 1.6 ø 4.0, 5.0 paint from surfaces to be
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 welded.
(3) Drying time of arc welding rod
Preheating/Postheating Unnecessary Unnecessary 1] Temperature: 150 – 200°C
Gas shielding rate (l/min) 25 – 35 — 2] Time: 120 minutes
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty

Other remarks

196
Assembly process No. Welding body protector (1/2)
C-0100

1. Weld the protector.

(1) Place the protector on the tops of the side plate and front plate with a crane.
Capacity of crane: Min. 2 tons
Lift of crane: Min. 7 m
Breaking strength of wire rope, chain, chain block: Min. 2 tons
(2) When positioning the protector, set the protector plate parallel to body side plate.
(3) Cut the front and side plates of the protector with gas so that the top of the body side plate and
will be in parallel with the top of the protector.
Note: Since the protector and front plate are distorted by welding as shown below, the front and
side plates of the protector must be cut with gas so that the clearance will be minimized at the
time of welding. (Reduce the clearance to below 3 mm.)
(4) After positioning, tack-weld the front panel of the protector.
If any plate is used to secure the protector, remove it with a gas cutting device or a grinder.

CO2 gas arc welding Arc welding Remarks

Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher than 2
or equivalent or equivalent – 3 (m/sec).
AWS ER70S-G and AWS E8016-G and (2) Remove moisture, dust, and paint
equivalent equivalent from surfaces to be welded.
ø 1.2, 1.6 ø 4.0, 5.0 (3) Drying time of arc welding rod
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 1] Temperature: 150 – 200°C
Preheating/Postheating Unnecessary Unnecessary 2] Time: 120 minutes
Gas shielding rate (l/min) 25 – 35 —
Precautions Necessary tools Necessary equipment
Name Q'ty Name Q'ty

Other remarks

197
Assembly process No. Welding body protector (2/2)
C-0110

1. Weld the protector.

Welding order: Weld the side plate first.
Welding symbol:
Follow welding instruction drawing below.
Welding condition:
Follow welding condition table below.
Perform welding according to KES04.343, General, 2nd Grade.
2. Tack-weld the right and left triangular plates (Section C-C shown below) and then weld them perma-
nently.

X→

View X

Apply CO2 gas shielded arc welding as standard. If it is difficult to apply, however, apply arc welding.
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher than 2
or equivalent or equivalent – 3 (m/sec).
AWS ER70S-G and AWS E8016-G and (2) Remove moisture, dust, and paint
equivalent equivalent from surfaces to be welded.
ø 1.2, 1.6 ø 4.0, 5.0 (3) Drying time of arc welding rod
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 1] Temperature: 150 – 200°C
2] Time: 120 minutes
Preheating/Postheating Unnecessary Unnecessary
Gas shielding rate (l/min) 25 – 35 —

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

198
Assembly process No. Finishing and painting welded parts of body
C-0120

1. Finishing
Remove the spatters and finish the beads with a grinder. Cut the hanging plate welded to the top of
the body with gas and finish the marks of weld with a grinder.

2. Check the welded parts for defects.

(1) Crack of weld bead (visual check)
(2) Undercut, overlap, and spatter
(3) Leg length of weld for shortage (Insufficient leg length is not permitted.)

3. After cooling, paint the welded parts.

(1) Mix the base and hardener of the paint well at the ratio of 5:1 as specified.
(2) After painting, clean the paint spray gun with paint thinner before the paint is hardened.

Put on mask, goggles, gloves, etc. to protect yourself from paint mist.

[Undercoat paint]
RETAN GP primer
RETAN GP hardener
RETAN GP thinner

[Top coat paint]

NAX MIGHTYLAC G II KB natural yellow
NAX MIGHTYLAC G II KB hardener
NAX MIGHTYLAC G II KB thinner

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

199
Assembly process No. Welding front body mount bracket
C-0130

Weld the front body mount bracket.

1. Install the body to the frame and adjust its dumping posture. (For the method of installing the body,
see Assembly Manual No. 0650 – 0730.)
2. Adjust the distance between the body and frame with shims in advance. (See Assembly Manual No.
0720.)
3. Position the front body and mount bracket properly and weld them. For the welding condition, see
Table 1.
Place bracket (561-46-8A870) on the right of the frame (rear support) and place bracket (561-46-
8A890) on the left and then measure the clearance between the body and bracket at 4 places.
If the clearance is 57 mm or less, cut the lower part of the bracket (hatched part).
(See the following figure.)
4. Position the front body mount bracket properly and weld it.

Zo

A
If less than 57 mm, Left figure shows 561-46-8A890
cut hatched part. (LH), which is symmetrically iden-
tical to 561-46-8A870 (RH).

Detail of A
View Z

Table 1
CO2 gas arc welding Arc welding Remarks
Welding position Flat (F) Flat, vertical (V) (1) Do not apply CO2 gas welding
Welding rod JIS Z3312YGW11 JIS Z3212D5816 when wind velocity is higher than 2
or equivalent or equivalent – 3 (m/sec).
AWS ER70S-G and AWS E8016-G and (2) Remove moisture, dust, and paint
equivalent equivalent from surfaces to be welded.
ø 1.2, 1.6 ø 4.0, 5.0 (3) Drying time of arc welding rod
Welding current (A) 320 – 350, 380 – 420 130 – 160, 220 – 260 1] Temperature: 150 – 200°C
2] Time: 120 minutes
Preheating/Postheating Unnecessary Unnecessary
Gas shielding rate (l/min) 25 – 35 —

Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty

Other remarks

200
 Rev. 01

Machine check sheet for field assembly

HD785-7
Serial number: ( )

Target machine number: 30001 -

* This check sheet contains check items for the parts related to field assembly,
safety-critical parts, and critical parts.

Packing style for shipping at disassembled condition

(1) Chassis assembly

(2) Cab assembly
(3) R.H. platform assembly
(4) Front axle assembly
(5) Rear axle assembly
(6) Tires assembly
(7) Dump body assembly

* After completion of field assembly, perform the field inspection according to this check sheet.

* After finishing the field check, be sure to send this check sheet to "Komatsu Ibaraki Plant,
Quality Assurance Department, Inspection Section".
[PDF data]
Mail address: JP00MB_ibpool@global.komatsu

[Facsimile]
81-29-265-2865

[Attention to]
163-46, Nagasuna, Hitachinaka-shi, Ibaraki, Japan, postl code: 312-0004
 1/7

* Before performing inspection, read the Operation and

Maintenance Manual thoroughly, and understand safety, Check mark list of inspection result
handling, and operation.  Ჴᢘӳ
Good g Ჴɧᢘӳ
No Good
 Ჴૠ͌ᚡλ
W rite down the ᆰഇ Ჴ
Empty No ச౨௹
inspection yet
Service meter Distance meter Ჴᛆ࢘Ƥƣ Ჴᄩᛐɧᙲ
No need to check
Inspection date Inspected by Not applicable
Start End Start End
* If check result is good after the maintenance, circle the above
* * MO MO mark.

Mainte-
No. Inspection item Judgment procedure and standards Check nance Remarks

Record the serial Nos. of the component parts.

1 Cab assembly No. Enter the No. (No. )

* No. is stamped on floor (near left door bottom).

Enter the Nos. (Left: ) (Right: )

2 Front axle Nos. * No. is stamped on front suspension cylinder.

Enter the No. (No. )

3 Rear axle No.
* Nameplate of No. is installed to differential case.

Check the oil and water levels. (Check before starting engine.)

Engine oil level (Check with Level must be between (H) and (H-10 mm).
4 engine stopped) (Check with oil level gauge.)

5 Hydraulic oil level Level must be within inspection window range.

6 Transmission oil level (1) Level must be above (L) of gauge (engine stop position).

7 Brake oil level Level must be in range of brake oil tank gauge.

8 Coolant level The level must be above the midpoint between Full and Low
of the sub-tank.

9 Battery fluid level The fluid level must be 10 – 12 mm above the plates.

10 Windshield washer fluid level The fluid level must be above 2/3 of the tank.

Turn switch ON.

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

12 Function of back buzzer Sound must be proper in volume and must not have beat noise.
(Sensory check)

When wiper switch is turned to [LO] or [HI], wiper must operate.

(Wiping speed must change between LO and HI.)

When wiper switch is turned to [INT], wiper must operate inter-

mittently.

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

13 Function of windshield wiper glass.)

When wiper switch is turned to [OFF], wiper must stop at stop-

ping position automatically. (Wiper must stop at proper position.)

When windshield washer switch is turned to [ON], washing fluid

must be splashed over glass and wiper must operate. (Washing
fluid must be splashed over proper position.)

14 Safety function (1) When key switch is turned to START position while transmission
shift lever is not in N, engine must not start.

When the parking brake switch is ON and the transmission shift

15 Safety function (2) lever is not in N, the centralized warning lamps and alarm buzzer
must be turned ON.

No. Inspection item
Start the engine. (Before starting the engine, check the safety around the truck. Measure each item after warm-up operation.)
16 Abnormal noise from engine
Safety function (3)
17 * Check with engine started and
parking brake turned off.
Safety function (4)
18 * Check after starting engine and
turning parking brake OFF.
Safety function (5)
19 * Check with engine started and
parking brake turned off.
20 Function of engine cooling water
temperature gauge
Function of torque converter oil
21 temperature gauge
Function of brake oil temperature
22 gauge of retarder, bar meter must When brake oil temperature rises because of operation of
move toward High side.
23
Engine speed
* Engine coolant temperature:
In green range
* Engine oil temperature: 70 – 80
24 °C
* Torque converter oil tempera-
ture: 70 – 80 °C
* If method of measuring engine
speed is unknown, see Shop
25
manual, Testing and adjusting,
Measuring engine speed.
26
27 Engine acceleration time (LiL o
Hi), in power mode
28 Engine acceleration time (LiL o
Stall), in power mode
29
30
Function of AISS
31
32 Low idling regulation
33 Exhaust gas color
34 Exhaust gas leakage
2/7
Judgment procedure and standards Check Mainte- Remarks
nance
No abnormal noise must be generated. (Sensory check)
When dump lever is set to any position other than FLOAT and
transmission lever is set to any position other than N position,
centralized warning lamp must light up and centralized alarm
buzzer must sound.
While dump lever is not in FLOAT position, transmission shifts to
D – L but does not shift to R.
When body is not seated and transmission lever is shifted to D –
L, "only 2nd speed must be selected at D and only 1st speed
must be selected at 5 to L"
As cooling water temperature rises while engine is running, bar
meter must move toward High side.
As oil temperature rises while engine is running, bar meter must
move toward High side.
retarder, bar meter must move toward High side.
Measure with parking brake ON, accelerator pedal OFF, and
AISS switch ON.
Standard: 625 – 675 rpm
Low idle speed, Measured value: ( ) rpm
Measure with parking brake ON and body seated (float caution
lamp OFF) in power mode.
Standard: 2,200 – 2,300 rpm
High idle speed, Measured value: ( ) rpm
Engine speed at torque converter stall - Measured value:
( rpm) Power mode standard: 1,735 ± 100 rpm
Engine speed at torque converter stall - Measured value:
( rpm) Economy mode standard: 1,635 ± 100 rpm
Standard value: Max. 3.5 sec, Measured value:
( ) sec
• HD785: LiL o Hi × 0.95 (LiL o 2,100 rpm)
Standard value: Max. 6.0 sec, Measured value:
( ) sec
• HD785: LiL o Hi × 0.95 (LiL o 1,700 rpm)
When AISS switch is turned ON, low idling speed of engine must
be set to LiL (650 rpm).
* Regardless of engine water temperature and operation of
brake.
While AISS switch is turned OFF, if engine water temperature is
below 50 °C, low idling speed of engine must be kept at LiH (945
rpm).
While AISS switch is turned OFF, if engine water temperature is
above 50 °C, low idling speed of engine must be kept at LiL (650
rpm). If parking brake and retarder brake are both turned OFF at
this time, low idling speed of engine must be set to LiH (1,000
rpm).
When truck is steered to end, engine must not stop at low idling
speed. Engine oil pressure caution lamp must not light up.
Exhaust gas color must be proper during sharp acceleration (Li
o Hi). (Sensory check.)
Exhaust gas must not leak from exhaust pipe joint, exhaust shut-
ter, etc.
 3/7

No. Inspection item Judgment procedure and standards Check Mainte- Remarks
nance

Check the lamps.

When the lamp switch is turned ON (1st/2nd stage), both front

35 Function of clearance lamps
lamps and 3 rear lamps (right, center, and left) must light up.

36 Check of head lamp When the lamp switch is turned ON (2nd stage), the head lamps
(1 lamp on each side) must light up.

Check of high beam (Function When the head lamp is turned ON and the dimmer switch is
37 operated, the number of the lamps must change between 2 and
of dimmer switch) 4. The lighting direction must change.)

38 Function of turn signal lamps When the turn signal lever is operated, the front and rear turn
signal lamps in the turning direction must flash.

When the hazard switch is turned ON, both turn signal lamps
39 Function of hazard lamp and pilot (arrow) lamp in the cab must flash.

40 Function of backup lamp When the transmission shift lever is in R, the backup lamp must
light up.

When the brake pedal is pressed, the 3 red brake lamps (Right,
41 center, and left) must light up.
When the retarder lever is pulled, the 2 red brake lamps (Right
42 Function of brake lamp and left) must light up. The center brake lamp must not light up
at this time.
When the lamp switch is turned ON and the brake is used, the
43
brightness of the brake lamp must change (increase).

When emergency brake is pressed while parking brake is ON,

44 Function of emergency brake
brake lamp must not light.

45 Function of room lamp When the switch is turned ON. Must light up when cab door is
open.

Lamp must light up when switch is turned ON (Right and left

46 Function of working lamp sides).

Lamp must light up when switch is turned ON (Right and left

47 Function of fog lamp (If equipped) sides).

Drive and check truck. (Before checking the following items, check the safety around the truck.)

Abnormal noise from transmis-

48 No abnormal noise must be generated. (Sensory check)
sion

49 Abnormal noise from differential No abnormal noise must be generated. (Sensory check)

When engine speed is set to high idling in N-range, truck must

50 Dragging of power train not start.

51 Straight travel of truck While machine is traveling, control of steering wheel is not lost.

When shift lever is set to D with brake turned ON (rear brake

52 Braking mode function
pilot lamp turned ON), gear speed must not change from F2.
(1) When lockup operates and brake is turned ON (rear brake
53 pilot lamp lights up), exhaust brake must operate (regardless of
operation of exhaust brake switch).
Function of exhaust brake (2) When lockup operates and accelerator pedal is turned OFF,
54 (If equipped) exhaust brake must operate (only when exhaust brake switch is
ON).

55 When (1) or (2) occurs, exhaust brake pilot lamp must light up.

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

Heating of rear axles (Both sides) After driving in yard, check by feeling that axle housing and final
57 brake drive cover are normal.
After machine travels in yard, oil of abnormal quantity must not
Drainage through floating seal be drained through seal. * Check with drain plug removed.
58
(All width) (Reference: After 60-minute travel, oil must not be drained more
than 100 cc from each side.)