Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Trucks HD785, HD985, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Dump Trucks HD785-3, HD785-5, HD785-7, HD985-5, HD985-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN01274-23 – Dump Truck HD785-7 Shop Manual.pdf
SEN01274-28 – Dump Truck HD785-7 Shop Manual.pdf
SEN05900-01 – Dump Truck HD785-7 Shop Manual.pdf
CEBM019012 – Dump Truck HD785-7 Shop Manual.pdf
SEBM013917 – Dump Truck HD785-5, HD985-5 Shop Manual.pdf
SEBM05610311 – Dump Truck HD785-3, HD985-3 Shop Manual.pdf
CEAM018608 – Dump Truck HD785-7 Operation & Maintenance Manual.pdf
CEAW004806 – Dump Truck HD785-7 Field Assembly Manual.pdf
GEN00027-03 – Dump Truck HD785-5 Field Assembly Instruction.pdf
GEN00058-08 – Dump Truck HD785-7 Field Assembly Instruction.pdf
GEN00119-01 – Dump Truck HD785-7 Field Assembly Instruction.pdf
SEAM003601 – Dump Truck HD785-3 Operation & Maintenance Manual.pdf
SEAM020406T – Dump Truck HD785-5 Operation & Maintenance Manual.pdf
SEAM05610302 – Dump Truck HD785-3 Operation & Maintenance Manual.pdf
TEN00042-05 – Dump Truck HD785-5 Operation & Maintenance Manual.pdf
TEN00164-08 – Dump Truck HD785-7 Operation & Maintenance Manual.pdf
TEN00371-03 – Dump Truck HD785-7 Operation & Maintenance Manual.pdf
TEN00440-08 – Dump Truck HD785-7 Operation & Maintenance Manual.pdf
TEN00598-02 – Dump Truck HD785-7 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 13,903 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
CEAM018608 – Dump Truck HD785-7 Operation & Maintenance Manual…2
COVER…2
FOREWORD…6
BEFORE READING THIS MANUAL…7
SAFETY INFORMATION…8
INTENDED USE…9
USE OF MACHINE…9
DIRECTIONS OF MACHINE…9
VISIBILITY FROM OPERATOR'S SEAT…10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…11
EPA REGULATIONS, ENGINE NUMBER PLATE…11
SERVICE METER POSITION…12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12
CONTENTS…13
SAFETY…18
SAFETY…19
SAFETY LABELS…22
POSITION FOR ATTACHING SAFETY LABELS…23
SAFETY LABELS…24
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…28
PRECAUTIONS BEFORE STARTING OPERATION…28
PREPARATIONS FOR SAFE OPERATION…28
FIRE PREVENTION…30
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…31
DO NOT GET CAUGHT IN DUMP BODY…33
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…33
UNAUTHORIZED MODIFICATION…33
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…34
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…34
PRECAUTIONS FOR OPERATION…35
PRECAUTIONS FOR JOBSITE…35
STARTING ENGINE…37
OPERATION…39
TRANSPORTATION…43
TOWING…44
PRECAUTIONS FOR MAINTENANCE…45
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…45
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…49
TIRES…54
OPERATION…56
GENERAL VIEW…57
GENERAL VIEW OF MACHINE…57
GENERAL VIEW OF CONTROLS AND GAUGES…58
EXPLANATION OF COMPONENTS…60
MACHINE MONITOR…60
OTHER FUNCTIONS OF MACHINE MONITOR…82
SWITCHES…87
CONTROL LEVERS AND PEDALS…96
BODY PIVOT PIN…101
LOCATION OF FIRE EXTINGUISHER…101
DUST INDICATOR…102
FUSES…103
CAR RADIO…106
CAR STEREO…112
AIR CONDITIONER…121
HANDLING MACHINES EQUIPPED WITH VHMS…126
OPERATION…128
CHECK BEFORE STARTING ENGINE…128
STARTING ENGINE…150
BREAKING-IN THE MACHINE…152
OPERATIONS, CHECKS AFTER STARTING ENGINE…152
STOPPING ENGINE…153
CHECKS AFTER STOPPING ENGINE…153
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…154
SHIFTING GEAR…159
TRAVELING DOWNHILL…161
STEERING THE MACHINE…175
LOADING OPERATIONS…175
DUMP OPERATIONS…176
PRECAUTIONS FOR OPERATION…178
PARKING MACHINE…179
CHECKS AFTER COMPLETION OF WORK…180
LOCKING…180
HANDLING TIRES…181
DETERMINING AND MAINTAINING TRAVEL ROAD…184
DETERMINING TRAVEL ROAD…184
MAINTAINING TRAVEL ROAD…184
TRANSPORTATION…185
PRECAUTIONS WHEN TRANSPORTING…185
STEPS FOR TRANSPORTATION…185
METHOD OF SECURING MACHINE…185
METHOD OF LIFTING MACHINE…186
COLD WEATHER OPERATION…189
PRECAUTIONS FOR LOW TEMPERATURE…189
PRECAUTIONS AFTER COMPLETION OF WORK…190
AFTER COLD WEATHER…191
LONG-TERM STORAGE…192
BEFORE STORAGE…192
DURING STORAGE…192
AFTER STORAGE…192
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…192
TROUBLESHOOTING…193
AFTER RUNNING OUT OF FUEL…193
IF TRANSMISSION HAS TROUBLE…194
METHOD OF LOWERING DUMP BODY IN EMERGENCY…194
METHOD OF TOWING MACHINE…195
IF BATTERY IS DISCHARGED…199
OTHER TROUBLE…203
MAINTENANCE…210
GUIDES TO MAINTENANCE…211
OUTLINE OF SERVICE…215
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…215
OUTLINE OF ELECTRIC SYSTEM…219
WEAR PARTS…220
WEAR PARTS LIST…220
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…221
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…222
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…223
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…224
TORQUE LIST…224
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…225
SAFETY CRITICAL PARTS…226
MAINTENANCE SCHEDULE CHART…233
MAINTENANCE SCHEDULE CHART…233
SERVICE PROCEDURE…235
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…235
WHEN REQUIRED…236
CHECK BEFORE STARTING…263
EVERY 250 HOURS SERVICE…264
EVERY 500 HOURS SERVICE…278
EVERY 1000 HOURS SERVICE…282
EVERY 2000 HOURS SERVICE…296
EVERY 4000 HOURS SERVICE…299
EVERY 8000 HOURS SERVICE…303
EVERY 15000 HOURS SERVICE…304
SPECIFICATIONS…306
SPECIFICATIONS…307
ATTACHMENTS, OPTIONS…308
SELECTING DUMP BODY…309
HANDLING AIR SUSPENSION SEAT…310
SEAT ADJUSTMENT…310
REMOVAL AND INSTALLATION OF HEADREST…312
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…313
EXPLANATION OF COMPONENTS…313
ACTUATION OF ASR SYSTEM…314
PRECAUTIONS WHEN USING…314
TROUBLESHOOTING…315
BLEEDING AIR FROM ASR CIRCUIT…316
HANDLING ABS…317
EXPLANATION OF COMPONENTS…317
ABS SYSTEM CHECK AFTER STARTING ENGINE…319
OPERATION OF ABS…319
PRECAUTIONS WHEN USING…320
TROUBLESHOOTING…321
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…323
OUTLINE OF SYSTEM…323
NORMAL OPERATION DISPLAY…325
EXTERNAL DISPLAY LAMPS…326
PERFORMING CALIBRATION…327
DATA STORED IN PAYLOAD METER…329
PROCEDURE WHEN DOWNLOADING…329
METHOD OF SETTING MACHINE ID, OPEN ID…333
PAYLOAD (CYCLE DATA ITEM)…335
SERVICE FUNCTIONS…335
OTHERS…335
HANDLING AUTO-GREASING SYSTEM…336
METHOD OF OPERATING AUTO-GREASING SYSTEM…336
METHOD OF SETTING TIMER…337
BLEEDING AIR FROM GREASE CIRCUIT…338
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR…338
CHECKING OPERATION OF INJECTOR…339
METHOD OF CHARGING WITH GREASE…340
USE OF REAR VIEW MONITOR…341
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…341
SETTING OF REAR VIEW MONITOR…344
CAUTIONS WHEN USING REAR VIEW MONITOR…344
HANDLING DUMPING COUNTER…345
HANDLING BATTERY ISOLATOR…346
HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE)…348
PRECAUTIONS WHEN USING…348
INDEX…350
CEAW004806 – Dump Truck HD785-7 Field Assembly Manual…354
COVER…354
CONTENTS…356
1. Outline of division (Only main components)…360
2. Dimensions of main components…361
3. Layout of work space…362
4. Rough schedule of assembly and welding…363
5. List of jigs, tools, and consumables for field assembling…368
6. Assembly process No…375
0010 Oil, grease, and coolant…375
0020 Levels of oil, grease, and coolant…376
0030 Positioning rear axle assembly…377
0040 Slinging and moving of bare machine…378
0050 Connection of rod and rear suspension…379
0060 Positioning bare machine…380
0070 Connection of rear axle cooling hose…381
0080 Connection of rear axle brake hose…382
0085 Connection of rear axle brake hose (ASR specification: If equipped)…383
0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped)…384
0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)…385
0090 Connection and fixing of rear grease piping and supply of grease…386
0100 Preparation for installing front axle…387
0110 Installation of front axle…388
0120 Connection of front axle suspension pressure sensor…389
0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)…390
0130 Connection of steering cylinder and tie rod…391
0140 Connection of front axle brake cooling hoses…392
0150 Connection of front axle brake hoses…393
0160 Connection of front axle auto suspension piping…394
0165 Fixing of front axle auto suspension piping…395
0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification)…396
0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)…397
0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)…398
0170 Installation of bumper and front axle steps…399
0171 Installation of front axle step (EU specification)…400
0180 Installation of tire and wheel assembly…401
0190 Installation of drive shaft…402
0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)…403
0260 Installation of fuel tank wiring harness cover…404
0270 Installation of toolbox and tool kit…405
0275 Installation of fuel tank step (If equipped)…406
0280 Installation of rear support…407
0281 Installation of rear support (Muffler specification: If equipped)…408
0282 Installation of rear support (ABS specification: If equipped)…409
0283 Installation of rear support (Sand terrain specification: If equipped)…410
0290 Installation of muffler…411
0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)…412
0300 Installation of fire prevention cover…413
0310 Installation of front support…414
0315 Installation of front support (Fog lamp specification: If equipped)…415
0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)…416
0320 Installation of steering valve…417
0330 Preparation for installing cab…418
0340 Installation of cab…419
0345 Connection of ABS piping (If equipped)…420
0350 Connection of column…421
0355 Installation of washer tank…422
0360 Connection of cab piping…423
0370 Connection of cab wiring…424
0375 Connection of cab wiring (ASR/ABS specification: If equipped)…425
0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)…426
0377 Connection and fixing of engine compartment lamp wiring harness (if equipped)…427
0378 Connection of auto grease harness to cab (If equipped: Auto grease specification)…428
0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)…429
0380 Installation and fixing of steering hoses…430
0385 Fixing of air conditioner drain hose…431
0390 Installation of steering hose cover…432
0395 Connection of air conditioner and heater hoses…433
0400 Connection of cab floor wiring…434
0405 Fixing of ASR/ABS wiring harness (If equipped)…435
0406 Connection and fixing of ABS wiring harness (If equipped)…436
0410 Installation of cover under cab…437
0415 Wiring of front glass with heater wire (If equipped)…438
0420 Installation of cab seal…439
0430 Installation of ambient temperature sensor wiring harness…440
0440 Installation of undercab wiring harness connector…441
0445 Connection and fixing of rear view camera wiring harness (if equipped)…442
0450 Installation of R.H platform assembly…443
0470 Installation of right fender…444
0472 Installation of right fender (If equipped: Body heating-less muffler specification)…445
0475 Installation of fuel tank quick charge-less hose (If equipped)…446
0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)…447
0480 Installation of cab step…448
0481 Assembly of diagonal ladder (if equipped)…449
0482 Installation of cab step: Diagonal ladder specification (if equipped)…450
0483 Installation of diagonal ladder 1 (if equipped)…451
0484 Installation of diagonal ladder 2 (if equipped)…452
0485 Installation of diagonal ladder 3 (if equipped)…453
0486 Installation of diagonal ladder (EU specification)…454
0487 Installation of diagonal ladder-2 (EU specification)…455
0488 Installation of diagonal ladder-3 (EU specification)…456
0490 Installation of L.H underview mirror (If equipped)…457
0500 Installation of fire extinguisher (If equipped)…458
0510 Installing radio antenna and fixing its cable…459
0520 Installation of L.H fender…460
0530 Installation of left side mudguard…461
0540 Installation of grille guard…462
0550 Installation of left payload lamp (If equipped)…463
0555 Installation of left side lamp (If equipped)…464
0560 Installation of right payload lamp (If equipped)…465
0565 Installation of right side lamp (If equipped)…466
0570 Installation of left fender side lamp wiring harness (If equipped)…467
0580 Installation of right fender side lamp wiring harness (If equipped)…468
0581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)…469
0590 Installation of KOMTRAX (If equipped)…470
0595 Fixing of ORBCOMM antenna (If equipped)…471
0597 Connection and fixing of harness and hose going to auto grease pump – 1 (If equipped: Auto grease specification)…472
0598 Connection and fixing of harness and hose going to auto grease pump – 2 (If equipped: Auto grease specification)…473
0600 Removal of hoist cylinder fixing bracket…474
0610 Connection of hoist cylinder piping…475
0620 Welding of body…476
0630 Sticking of body decal…477
0640 Supply of oil…478
0650 Slinging of body…479
0660 Installation of hinge pin…480
0670 Connecting hoist cylinder…481
0680 Hoist cylinder grease piping…482
0685 Fixing of auto grease piping to body (If equipped: Auto grease specification)…483
0700 Installation of field welding protection cover…484
0710 Installation of body mount…485
0720 Procedure for adjusting body mount shim…486
0730 Field welding of exhaust tube…487
0740 Assembly of body heater cover…488
0770 Installation of poke ejector…489
0780 Installation of poke ejector storage pin…490
0790 Installation of body mudguard…491
0800 Installation of body lock pin…492
0810 Installation of transmission underguard…493
0830 Installation of front handle…494
0850 Connection of dump sensor…495
0860 Procedure for adjusting dump sensor…496
0870 Calibrating dump control…497
0880 Adjustment of optical axis of light…498
0900 Bleeding air from brake…499
0901 Bleeding air from brake of ASR specification (ASR specification: If equipped)…500
0905 Bleeding air from ABS circuit (ABS specification: If equipped)…501
0910 Adjusting suspension…502
0920 Charging air conditioner with refrigerant…503
0930 Fitting of floating seal…504
0950 Painting…505
0960 Touchup…506
1000 Sticking of front axle decal…507
1020 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)…508
1100 Installation of chocks (If equipped)…510
1200 Installation of radiator curtain (If equipped)…511
1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)…512
7. Adjustment procedure…513
T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)…513
T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)…514
T-0030 Setting of machine monitor…515
T-0040 Selection of machine model…516
T-0050 Selection of optional component…517
T-0060 Selection of option…518
T-0070 Option setting/no-setting selection screen – Saving of change of option selection…519
T-0080 OFF setting of corrosion resistor with maintenance monitor…520
T-0090 Adjustment of body positioner sensor…521
T-0100 Deletion of electrical system fault history (1)…522
T-0110 Deletion of electrical system fault history (2)…523
8. Welding procedure…524
C-0010 Preparation of welding body…524
C-0020 Assembly of split body (1/2)…525
C-0030 Assembly of split body (2/2)…526
C-0040 Tack welding body…527
C-0050 Welding body (1/2)…528
C-0060 Welding body (2/2)…529
C-0070 Welding body instruction (1/2)…530
C-0080 Welding body instruction (2/2)…531
C-0090 Turn over the body…532
C-0100 Welding body protector (1/2)…533
C-0110 Welding body protector (2/2)…534
C-0120 Finishing and painting welded parts of body…535
C-0130 Welding front body mount bracket…536
Field assembly inspection report…538
CEBM019012 – Dump Truck HD785-7 Shop Manual…556
COVER…556
00 Index and foreword…558
Index…558
Composition of shop manual…559
Table of contents…561
Foreword and general information…578
Safety notice…579
How to read the shop manual…584
Explanation of terms for maintenance standard…586
Handling of electric equipment and hydraulic component…588
Handling of connectors newly used for engines…597
How to read electric wire code…600
Precautions when carrying out operation…603
Method of disassembling and connecting push-pull type coupler…606
Standard tightening torque table…609
Conversion table…613
01 Specification…620
Specification and technical data…620
Specification drawing…621
Specifications…623
Weight table…626
Fuel, coolant and lubricants…627
10 Structure, function and maintenance standard…632
Engine and cooling system…632
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler…633
Fuel system…635
Power train, Part 1…638
Power train skeleton…639
Output shaft…641
Drive shaft…643
Torque converter and transmission hydraulic piping…645
Brake cooling oil control valve (BCV)…647
Torque converter…648
Torque converter valve…656
Transmission…659
Transmission control valve…687
ECMV…689
Lubricating oil amount selector valve…696
Power train, Part 2…700
Axle…701
Differential…703
Final drive…704
Wheels…705
Steering system…708
Steering column…709
Steering linkage…710
Brake system…714
Brake piping…715
Brake valve…717
Secondary brake valve…720
Accumulator charge valve…721
Accumulator…725
Slack adjuster…727
Brake, parking brake…731
Parking brake solenoid…737
Retarder control valve…738
Exhaust brake…739
Undercarriage and frame…742
Suspension…743
Suspension cylinder…745
Rear axle support…753
Hydraulic system…756
Steering and hoist hydraulic piping…757
Steering, hoist filter (high pressure circuit)…759
Dump body control…761
Hydraulic tank…763
Steering valve…764
Crossover relief valve…768
Steering cylinder…769
Steering control valve…770
Hoist valve…779
Dump control valve (EPC valve)…785
Hydraulic pump…789
Work equipment (Body)…794
Auto greasing system…795
Hoist cylinder…806
Cab and its attachments…808
ROPS cab…809
Air conditioner…810
Rear view monitor…819
Controller related…822
Electrical system, Part 1…824
Machine monitor system…825
Electrical system, Part 2…850
Automatic shift control system…851
Automatic emergency steering system…871
Automatic suspension system…875
Retarder control system…878
Battery disconnector switch…891
Dump control lever…895
Electrical system, Part 3…900
VHMS controller related…901
ABS/ASR system…927
Altitude setting function…945
Electrical system, Part 4…950
Sensors, switches…951
20 Standard value table…970
Standard service value table…970
Standard value table for engine…971
Standard value table for machine…973
30 Testing and adjusting…986
Testing and adjusting, Part 1…986
Testing and adjusting tools list…988
Testing engine speed…994
Testing air supply pressure (boost pressure)…995
Testing exhaust temperature…997
Testing exhaust gas color…999
Adjustment of valve clearance…1001
Testing compression pressure…1003
Testing blow-by pressure…1005
Testing engine oil pressure…1006
Handling of fuel system devices…1007
Releasing residual pressure from fuel system…1007
Testing fuel pressure…1008
Reduced cylinder mode operation…1009
No-injection cranking…1009
Testing leakage-from pressure limiter and return rate from injector…1010
Bleeding air from fuel circuit (Standard spec.)…1013
Bleeding air from fuel circuit (Extra low-grade fuel spec.)…1015
Testing the fuel circuit for leakage…1017
Replacement and adjustment of fan belt…1018
Testing and adjusting alternator belt tension…1019
Testing and adjusting air conditioner compressor belt…1020
Testing and adjusting, Part 2…1022
Testing torque converter stall speed…1024
Testing power train oil pressure…1026
Adjusting transmission speed sensor…1034
Testing and adjusting brake oil pressure…1035
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…1038
Testing brake performance…1042
Bleeding air from brake circuit…1044
Bleeding air from ASR circuit (if equipped)…1046
Testing wear of front brake disc…1047
Testing wear of rear brake disc…1048
Method of releasing parking brake in an emergency…1049
Testing and adjusting front suspension cylinder…1050
Testing and adjusting rear suspension cylinder…1054
Testing and adjusting front suspension cylinder (Automatic suspension specification)…1058
Testing and adjusting hydraulic pressure in steering, hoist circuit…1059
Testing and adjusting oil pressure in dump EPC circuit…1062
Air bleeding from steering cylinder…1063
Procedure for raising dump body in emergency…1064
Adjusting body positioner sensor…1065
Handling of high voltage circuit of engine controller…1067
Adjusting transmission controller…1067
Method for emergency escape at electrical system failure…1068
Testing and adjusting, Part 3…1074
Setting and adjusting of devices…1075
Testing and adjusting, Part 4…1088
Special functions of machine monitor (EMMS)…1089
Testing and adjusting, Part 5…1158
Opening ORBCOMM terminal…1159
VHMS controller initial setting procedure…1161
Precautions for replacing VHMS controller…1186
Pm Clinic check sheet…1192
Initial setting of payload meter…1196
Setting of payload meter built in VHMS…1197
40 Troubleshooting…1206
Failure code table and fuse locations…1206
Failure codes table…1207
Fuse locations…1223
General information on troubleshooting…1230
Points to remember when troubleshooting…1231
Sequence of events in troubleshooting…1232
Check before troubleshooting…1233
Classification and procedures for troubleshooting…1234
Contents of troubleshooting table…1235
Connection table for connector pin numbers…1237
T- branch box and T- branch adapter table…1273
Troubleshooting by failure code, Part 1…1278
…
H-7 Time lag is excessive when starting or shifting gear…2057
H-8 Torque converter oil temperature is high…2059
H-9 Torque converter oil pressure is low…2060
H-10 Front brake is ineffective…2061
H-11 Rear brake is ineffective…2062
H-12 Steering wheel is heavy…2063
H-13 Steering wheel does not work…2064
H-14 Steering wheel vibrates…2065
H-15 Dump body lifting speed is slow…2066
H-16 Dump body does not work…2067
H-17 Excessive hydraulic drift of dump body…2068
Troubleshooting of engine (S-mode)…2070
Method of using troubleshooting charts…2072
S-1 Starting performance is poor…2075
S-2 Engine does not start…2076
S-3 Engine does not pick up smoothly…2079
S-4 Engine stops during operations…2080
S-5 Engine does not rotate smoothly…2081
S-6 Engine lacks output (or lacks power)…2082
S-7 Exhaust smoke is black (incomplete combustion)…2084
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2085
S-9 Oil becomes contaminated quickly…2086
S-10 Fuel consumption is excessive…2087
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2088
S-12 Oil pressure drops…2089
S-13 Oil level rises (Entry of coolant or fuel)…2090
S-14 Coolant temperature becomes too high (overheating)…2091
S-15 Abnormal noise is made…2092
S-16 Vibration is excessive…2093
50 Disassembly and assembly…2096
General information on disassembly and assembly…2096
How to read this manual…2097
Coating materials list…2099
Special tool list…2102
Sketches of special tools…2105
Engine and cooling system…2112
Removal and installation of fuel supply pump assembly…2113
Removal and installation of fuel injector assembly…2115
Removal and installation of cylinder head assembly…2116
Removal and installation of engine hood assembly…2129
Removal and installation of radiator assembly…2130
Removal and installation of engine assembly…2139
Removal and installation of engine front oil seal…2144
Removal and installation of engine rear oil seal…2147
Power train, Part 1…2152
Removal and installation of front drive shaft…2153
Removal and installation of rear drive shaft…2155
Removal and installation of output shaft assembly…2156
Disassembly and assembly of damper assembly…2161
Removal and installation of torque converter and transmission assembly…2163
Disconnection and connection of torque converter assembly and transmission assembly…2166
Disassembly and assembly of torque converter PTO assembly…2173
Disassembly and assembly of transmission assembly…2186
Power train, Part 2…2220
Removal and installation of final drive carrier assembly…2221
Disassembly and assembly of final drive carrier assembly…2223
Removal and installation of differential assembly…2225
Disassembly and assembly of differential assembly…2228
Steering system…2242
Removal and installation of steering cylinder assembly…2243
Disassembly and assembly of steering cylinder assembly…2244
Removal and installation of steering valve assembly…2248
Disassembly and assembly of steering valve assembly…2249
Brake system…2262
Removal and installation of front wheel hub and brake assembly…2263
Disassembly and assembly of front wheel hub and brake assembly…2267
Removal and installation of final drive and rear brake assembly…2275
Disassembly and assembly of final drive and rear brake assembly…2277
Undercarriage and frame…2292
Removal and installation of front wheel assembly…2293
Removal and installation of rear wheel assembly…2295
Removal and installation of front suspension cylinder assembly…2297
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)…2299
Removal and installation of king pin…2302
Removal and installation of rear suspension cylinder assembly…2304
Disassembly and assembly of rear suspension cylinder assembly…2305
Hydraulic system…2310
Removal and installation of hoist valve assembly…2311
Disassembly and assembly of hoist valve assembly…2312
Disassembly and assembly of hoist cylinder assembly…2314
Body…2318
Removal and installation of body assembly…2319
Cab and its attachments…2324
Disassembly and assembly of operator’s seat assembly…2325
Removal and installation of air conditioner unit assembly…2335
Electrical system…2338
Removal and installation of engine controller assembly…2339
Removal and installation of transmission controller assembly…2339
Removal and installation of retarder controller assembly…2340
Removal and installation of ABS controller assembly…2340
Removal and installation of VHMS controller assembly…2341
90 Diagrams and drawings…2344
Hydraulic diagrams and drawings…2344
Power train hydraulic circuit diagram…2346
Steering and hoist hydraulic circuit diagram…2347
Brake hydraulic circuit diagram…2348
Brake hydraulic circuit diagram (ASR specification)…2349
Brake hydraulic circuit diagram (ABS specification)…2350
Brake hydraulic circuit diagram (ASR and ABS specification)…2351
Electrical diagrams and drawings…2354
Electrical circuit diagram for outside cab (1/3)…2356
Electrical circuit diagram for outside cab (2/3)…2357
Electrical circuit diagram for outside cab (3/3)…2358
Electrical circuit diagram for inside cab (1/3)…2359
Electrical circuit diagram for inside cab (2/3)…2360
Electrical circuit diagram for inside cab (3/3)…2361
Electrical circuit diagram for VHMS (If equipped)…2362
Electrical circuit diagram for ABS (Outside cab) (If equipped)…2363
Electrical circuit diagram for ABS (Inside cab) (If equipped)…2364
Electrical circuit diagram for ASR (If equipped)…2365
Air conditioner electrical circuit diagram (If equipped)…2366
Electrical circuit diagram for auto greasing (If equipped)…2367
Connectors table and arrangement drawing…2369
GEN00027-03 – Dump Truck HD785-5 Field Assembly Instruction…2373
COVER…2373
CONTENTS…2374
Front Axle, F/T, Chassis, HD785-5 (common to all specifi cations)…2376
Tire Assembly (including Tires), Rear Axle, HD785-5…2377
R.H. Platform, Cabin, HD785-5…2378
Body Assembly (Including Body), HD785-5…2379
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (1/3)…2380
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (2/3)…2381
LIST OF JIGS, TOOLS, AND CONSUMABLES FOR FIELD ASSEMBLING (3/3)…2382
LIST OF TOUCH-UP COATING ON BODY FOR OVERSEAS SPECIFICATIONS…2382
SKETCHES OF SPECIAL TOOLS…2383
MAN-HOURS, WORKERS NEEDED FOR LOCAL ASSEMBLY…2387
ASSEMBLING PROCEDURES ON SITE…2389
1. LIFTING AND MOUNTING REAR AXLE ASSEMBLY…2389
2. LIFTING CHASSIS ASSEMBLY…2391
3. TRANSFERRING CHASSIS ASSEMBLY ONTO REAR AXLE ASSEMBLY…2393
4. CONNECTING RODS TO REAR AXLE SUSPENSION…2395
5. PLACING MOUNT FOR FRONT SIDE…2397
6. CONNECTING REAR AXLE AND PARKING BRAKE LINE…2398
7. LIFTING FRONT AXLE ASSEMBLY…2399
8. ASSEMBLING FRONT AXLE…2401
9. CONNECTING TIE ROD OF STEERING CYLINDER…2403
10. CONNECTING FRONT AXLE HOSES…2405
11. INSTALLING STEPS ON A-SHAPED ARM AND BUMPER…2407
12. INSTALLING FRONT TIRES…2409
13. INSTALLING PROPELLER SHAFT…2411
14. INSTALLING FUEL TANK (1/2)…2413
15. INSTALLING FUEL TANK (2/2)…2415
16. INSTALLING LEFT- AND RIGHTHAND STAYS OF FRAME…2417
17. INSTALLING LEFT- AND RIGHTHAND FENDERS…2419
18. INSTALLING FRONT SUPPORTS…2421
19. INSTALLATION OF FRONT SUPPORT (-40 °C SPECIFICATION FOR POLYUS)…2423
20. INSTALLATION OF FRONT SUPPORT (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2425
21. INSTALLATION OF AIR CLEANER ASSEMBLY INDICATOR HOSES (LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2427
22. INSTALLATION OF RIGHT FRONT SUPPORT AIR CLEANER ASSEMBLY (LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2429
23. CONNECTING STEERING OIL LINE…2431
24. CONNECTION OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2433
25. REMOVING ENGINE HOOD…2435
26. INSTALLING RIGHT-HAND PLATFORM HANDRAIL…2436
27. INSTALLING RIGHT-HAND PLATFORM…2437
28. FIXING OF AIR CLEANER PIPING (LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2439
29. WIRING ALONG RIGHT-HAND PLATFORM SIDE…2441
30. WIRING IN BATTERY BOX…2443
31. INSTALLATION OF DIAGONAL LADDER (1/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2445
32. INSTALLATION OF DIAGONAL LADDER (2/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2447
33. INSTALLATION OF DIAGONAL LADDER (3/3) (DIAGONAL LADDER + LARGE-CAPACITY AIR CLEANER SPECIFICATION)…2449
34. REPLACING SIDE BRACKET OF CABIN…2451
35. INSTALLING HANDRAIL OF CABIN…2452
36. INSTALLING CABIN…2453
37. CONNECTING STEERING COLUMN…2455
38. CLAMPING DRAIN HOSE OF AIR CONDITIONER…2457
39. INSTALLING ROPS AND PAYLOAD LAMP…2458
40. CONNECTING DUMP CONTROL…2459
41. INSTALLING AIR INTAKE (1/2)…2461
42. INSTALLING AIR INTAKE (2/2)…2462
43. INSTALLING AIR INTAKE (1/2) (FRONT AIR INTAKE SPECIFICATION)…2463
44. INSTALLING EXHAUST PIPE…2464
45. DRAWING HARNESS INTO INSIDE OF CABIN…2465
46. CONNECTING HARNESSES INSIDE CABIN (1/2)…2466
47. CONNECTING HARNESSES INSIDE CABIN (2/2)…2467
48. CONNECTING AIR CONDITIONER HOSES…2469
49. INSTALLING WASHER TANK…2470
50. INSTALLING AND CONNECTING AIR HORN…2471
51. WIRING AROUND CABIN (1/2)…2472
52. WIRING AROUND CABIN (2/2)…2473
53. INSTALLATION AND CONNECTION OF FUEL FILTER (-40 °C SPECIFICATION FOR POLYUS)…2475
54. CONNECTING RIGHT-HAND FRONT BRAKE AND RADIATOR SURGE TANK…2477
55. WIRING FOR HEAD LAMP…2479
56. CONNECTING AIR CHARGE LINE…2481
57. AIR PIPING…2483
58. CONNECTING LEFT-HAND FRONT BRAKE…2485
59. INSTALLING PARTS AROUND HOOD…2486
60. CHECKING FOR OIL AND COOLING WATER…2487
61. FILLING GAS INTO AIR CONDITIONER…2488
62. BLEEDING AIR FROM BRAKE…2489
63. REMOVING PARTS FROM HOST CYLINDER AFTER TRANSPORTATION…2491
64. EQUIPPING MACHINE BODY…2493
65. INSTALLING GREASE TUBES ON HOIST CYLINDER…2495
66. ADJUSTMENT OF BODY BOTTOM MOUNT…2497
67. ADJUSTMENT OF BODY POSITIONER…2499
68. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (BODY FRONT MOUNT)…2501
69. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (SWING PREVENTION OF BODY)…2503
70. WELDING BY DETERMINING DIMENSIONS WITH ACTUAL PARTS (EXHAUST FLANGE)…2504
71. INSTALLING BODY SEATING SWITCH…2505
72. INSTALLING BODY ACCESSORIES…2506
73. PAINTING…2507
74. BODY STOPPER PINS…2509
75. ADJUSTMENT OF SUSPENSION…2510
76. SMOOTHING OF FLOATING SEAL…2511
PROCEDURE FOR WELDING AND ASSEMBLING THREE SEPARATED BODY PARTS…2512
WORK PROCEDURES FOR TURNING OVER THE BODY…2527
2900 mm transportation posture (If equipped)…2530
FIELD ASSEMBLY INSPECTION REPORT…2560
GEN00058-08 – Dump Truck HD785-7 Field Assembly Instruction…2577
COVER…2577
CONTENTS…2578
1. Outline of division (Only main components)…2584
2. Dimensions of main components…2585
3. Layout of work space…2586
4. Rough schedule of assembly and welding…0
4-1. Rough schedule of assembly and welding (1st day)…2587
4-2. Rough schedule of assembly and welding (2nd day)…2588
4-3. Rough schedule of assembly and welding (3rd day)…2589
4-4. Rough schedule of assembly and welding (4th day)…2590
4-5. Rough schedule of assembly and welding (5th day)…2591
5. List of jigs, tools, and consumables for field assembling…0
5-1 List of jigs, tools, and consumables for field assembling (1/2)…2592
5-2 List of jigs, tools, and consumables for field assembling (2/2)…2593
5-3. Tools and consumables…2595
6. Assembly process…0
0010 Oil, grease, and coolant…2599
0020 Levels of oil, grease, and coolant…2600
0030 Positioning rear axle assembly…2601
0040 Slinging and moving of bare machine…2602
0050 Connection of rod and rear suspension…2603
0060 Positioning bare machine…2604
0070 Connection of rear axle cooling hose…2605
0080 Connection of rear axle brake hose…2606
0085 Connection of rear axle brake hose (ASR specification: If equipped)…2607
0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped)…2608
0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)…2609
0090 Connection and fixing of rear grease piping and supply of grease…2610
0100 Preparation for installing front axle…2611
0110 Installation of front axle…2612
0120 Connection of front axle suspension pressure sensor…2613
0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)…2614
0130 Connection of steering cylinder and tie rod…2615
0140 Connection of front axle brake cooling hoses…2616
0150 Connection of front axle brake hoses…2617
0160 Connection of front axle auto suspension piping…2618
0165 Fixing of front axle auto suspension piping…2619
0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification)…2620
0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)…2621
0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)…2622
0170 Installation of bumper and front axle steps…2623
0171 Installation of front axle step (EU specification)…2624
0180 Installation of tire and wheel assembly…2625
0190 Installation of drive shaft…2626
0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)…2627
0260 Installation of fuel tank wiring harness cover…2628
0270 Installation of toolbox and tool kit…2629
0275 Installation of fuel tank step (If equipped)…2630
0280 Installation of rear support…2631
0281 Installation of rear support (Muffler specification: If equipped)…2632
0282 Installation of rear support (ABS specification: If equipped)…2633
0283 Installation of rear support (Sand terrain specification: If equipped)…2634
0290 Installation of muffler…2635
0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)…2636
0300 Installation of fire prevention cover…2637
0310 Installation of front support…2638
0315 Installation of front support (Fog lamp specification: If equipped)…2639
0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)…2640
0320 Installation of steering valve…2641
0330 Preparation for installing cab…2642
0340 Installation of cab…2643
0345 Connection of ABS piping (If equipped)…2644
0350 Connection of column…2645
0355 Installation of washer tank…2646
0370 Connection of cab wiring…2647
0375 Connection of cab wiring (ASR/ABS specification: If equipped)…2648
0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)…2649
0377 Connection and fixing of engine compartment lamp wiring harness (if equipped)…2650
0378 Connection of auto grease harness to cab (If equipped: Auto grease specification)…2651
0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)…2652
0380 Installation and fixing of steering hoses…2653
0385 Fixing of air conditioner drain hose…2654
0390 Installation of steering hose cover…2655
0395 Connection of air conditioner and heater hoses…2656
0400 Connection of cab floor wiring…2657
0405 Fixing of ASR/ABS wiring harness (If equipped)…2658
0406 Connection and fixing of ABS wiring harness (ABS specification: If equipped)…2659
0410 Installation of cover under cab…2660
0415 Wiring of front glass with heater wire (If equipped)…2661
0420 Installation of cab seal…2662
0430 Installation of ambient temperature sensor wiring harness…2663
0440 Installation of undercab wiring harness connector…2664
0445 Connection and fixing of rear view camera wiring harness (if equipped)…2665
0450 Installation of R.H platform assembly…2666
0470 Installation of right fender…2667
0472 Installation of right fender (If equipped: Body heating-less muffler specification)…2668
0475 Installation of fuel tank quick charge-less hose (If equipped)…2669
0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)…2670
0480 Installation of cab step…2671
0481 Assembly of diagonal ladder (if equipped)…2672
0482 Installation of cab step: Diagonal ladder specification (if equipped)…2673
0483 Installation of diagonal ladder 1 (if equipped)…2674
0484 Installation of diagonal ladder 2 (if equipped)…2675
0485 Installation of diagonal ladder 3 (if equipped)…2676
0486 Installation of diagonal ladder (EU specification)…2677
0487 Installation of diagonal ladder-2 (EU specification)…2678
0488 Installation of diagonal ladder-3 (EU specification)…2679
0490 Installation of L.H underview mirror (If equipped)…2680
0500 Installation of fire extinguisher (If equipped)…2681
0510 Installing radio antenna and fixing its cable…2682
0520 Installation of L.H fender…2683
0530 Installation of left side mudguard…2684
0540 Installation of grille guard…2685
0550 Installation of left payload lamp (If equipped)…2686
0555 Installation of left side lamp (If equipped)…2687
0560 Installation of right payload lamp (If equipped)…2688
0565 Installation of right side lamp (If equipped)…2689
0570 Installation of left fender side lamp wiring harness (If equipped)…2690
0580 Installation of right fender side lamp wiring harness (If equipped)…2691
0581 Installation of right fender side lamp wiring harness (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)…2692
0590 Installation of KOMTRAX (If equipped)…2693
0595 Fixing of ORBCOMM antenna (If equipped)…2694
0597 Connection and fixing of harness and hose going to auto grease pump – 1 (If equipped: Auto grease specification)…2695
0598 Connection and fixing of harness and hose going to auto grease pump – 2 (If equipped: Auto grease specification)…2696
0600 Removal of hoist cylinder fixing bracket…2697
0610 Connection of hoist cylinder piping…2698
0620 Welding of body…2699
0630 Sticking of body decal…2700
0640 Supply of oil…2701
0650 Slinging of body…2702
0660 Installation of hinge pin…2703
0670 Connecting hoist cylinder…2704
0680 Hoist cylinder grease piping…2705
0685 Fixing of auto grease piping to body (If equipped: Auto grease specification)…2706
0700 Installation of field welding protection cover…2707
0710 Installation of body mount…2708
0720 Procedure for adjusting body mount shim…2709
0730 Field welding of exhaust tube…2710
0740 Assembly of body heater cover…2711
0770 Installation of poke ejector…2712
0780 Installation of poke ejector storage pin…2713
0790 Installation of body mudguard…2714
0800 Installation of body lock pin…2715
0810 Installation of transmission underguard…2716
0830 Installation of front handle…2717
0850 Connection of dump sensor…2718
0860 Procedure for adjusting dump sensor…2719
0870 Calibrating dump control…2720
0880 Adjustment of optical axis of light…2721
0900 Bleeding air from brake…2722
0901 Bleeding air from brake of ASR specification (ASR specification: If equipped)…2723
0905 Bleeding air from ABS circuit (ABS specification: If equipped)…2724
0910 Adjusting suspension…2725
0920 Charging air conditioner with refrigerant…2726
0930 Fitting of floating seal…2727
0950 Painting…2728
0960 Touchup…2729
1000 Sticking of front axle decal…2730
1020-1 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)…2731
1020-2 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)…2732
1100 Installation of chocks (If equipped)…2733
1200 Installation of radiator curtain (If equipped)…2734
1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)…2735
1400 Assembly of power ladder step -1 (If equipped)…2736
1410 Assembly of power ladder step -2 (If equipped)…2737
1420 Assembly of power ladder step -3 (If equipped)…2738
1430 Assembly of power ladder main part -1 (If equipped)…2739
1440 Assembly of power ladder main part -2 (If equipped)…2740
1450 Assembly of power ladder main part -3 (If equipped)…2741
1460 Assembly of power ladder main part -4 (If equipped)…2742
1470 Assembly of power ladder main part -5 (If equipped)…2743
1480 Assembly of power ladder main part -6 (If equipped)…2744
1490 Assembly of power ladder main part -7 (If equipped)…2745
1500 Assembly of power ladder main part -8 (If equipped)…2746
1510 Assembly of power ladder main part -9 (If equipped)…2747
1520 Assembly of power ladder main part -10 (If equipped)…2748
1530 Assembly of power ladder main part -11 (If equipped)…2749
1540 Assembly of power ladder main part -12 (If equipped)…2750
1550 Assembly of power ladder main part -13 (If equipped)…2751
1560 Assembly of power ladder main part -14 (If equipped)…2752
1570 Assembly of power ladder main part -15 (If equipped)…2753
1580 Assembly of power ladder main part -16 (If equipped)…2754
1590 Refilling power ladder with oil…2755
1600 Adjustment of power ladder operating time…2756
1610 Installation of additional under-view mirror…2757
7. Adjustment procedure…0
T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)…2758
T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)…2759
T-0030 Setting of machine monitor…2760
T-0040 Selection of machine model…2761
T-0050 Selection of optional component…2762
T-0060 Selection of option…2763
T-0070 Option setting/no-setting selection screen – Saving of change of option selection…2764
T-0080 OFF setting of corrosion resistor with maintenance monitor…2765
T-0090 Adjustment of body positioner sensor…2766
T-0100 Deletion of electrical system fault history (1)…2767
T-0110 Deletion of electrical system fault history (2)…2768
8. Welding procedure…0
C-0010 Preparation of welding body…2769
C-0020 Assembly of split body (1/2)…2770
C-0030 Assembly of split body (2/2)…2771
C-0040 Tack welding body…2772
C-0050 Welding body (1/2)…2773
C-0060 Welding body (2/2)…2774
C-0070 Welding body instruction (1/2)…2775
C-0080 Welding body instruction (2/2)…2776
C-0090 Turn over the body…2777
C-0100 Welding body protector (1/2)…2778
C-0110 Welding body protector (2/2)…2779
C-0120 Finishing and painting welded parts of body…2780
C-0130 Welding front body mount bracket…2781
Appendix…0
Field assembly inspection report…2782
GEN00119-01 – Dump Truck HD785-7 Field Assembly Instruction…2798
COVER…2798
CONTENTS…2799
1. Outline of division (Only main components)…2805
2. Dimensions of main components…2806
3. Layout of work space…2807
4. Rough schedule of assembly and welding…2808
5. List of jigs, tools, and consumables for field assembling…2813
6. Assembly process No…0
No. 0010 Oil, grease, and coolant…2820
No. 0020 Levels of oil, grease, and coolant…2821
No. 0030 Positioning rear axle assembly…2822
No. 0040 Slinging and moving of bare machine…2823
No. 0050 Connection of rod and rear suspension…2824
No. 0060 Positioning bare machine…2825
No. 0070 Connection of rear axle cooling hose…2826
No. 0080 Connection of rear axle brake hose…2827
No. 0085 Connection of rear axle brake hose (ASR specification: If equipped)…2828
No. 0086 Connection of valve sub-assembly wiring harness (ASR specification: If equipped)…2829
No. 0087 Connection and fixing of piping going to rear axle (Sand terrain/ASR specification: If equipped)…2830
No. 0090 Connection and fixing of rear grease piping and supply of grease…2831
No. 0100 Preparation for installing front axle…2832
No. 0110 Installation of front axle…2833
No. 0120 Connection of front axle suspension pressure sensor…2834
No. 0125 Connection of front axle wheel speed sensor (ABS specification: If equipped)…2835
No. 0130 Connection of steering cylinder and tie rod…2836
No. 0140 Connection of front axle brake cooling hoses…2837
No. 0150 Connection of front axle brake hoses…2838
No. 0160 Connection of front axle auto suspension piping…2839
No. 0165 Fixing of front axle auto suspension piping…2840
No. 0166 Fixing of front axle auto grease piping (If equipped: Auto grease specification)…2841
No. 0167 Connection of left front axle auto grease piping (If equipped: Auto grease specification)…2842
No. 0168 Connection of right front axle auto grease piping (If equipped: Auto grease specification)…2843
No. 0170 Installation of bumper and front axle steps…2844
No. 0171 Installation of front axle step (EU specification)…2845
No. 0173 Installation of front axle step…2846
No. 0174 Installation of front axle step: Diagonal ladder specification (If equipped)…2847
No. 0180 Installation of tire and wheel assembly…2848
No. 0190 Installation of drive shaft…2849
No. 0200 Installation of oil quick charge box (If equipped: Oil quick charge specification)…2850
No. 0260 Installation of fuel tank wiring harness cover…2851
No. 0270 Installation of toolbox and tool kit…2852
No. 0275 Installation of fuel tank step (If equipped)…2853
No. 0280 Installation of rear support…2854
No. 0281 Installation of rear support (Muffler specification: If equipped)…2855
No. 0282 Installation of rear support (ABS specification: If equipped)…2856
No. 0283 Installation of rear support (Sand terrain specification: If equipped)…2857
No. 0290 Installation of muffler…2858
No. 0291 Installation of muffler (Body heating-less/Exhaust selector box specification: If equipped)…2859
No. 0300 Installation of fire prevention cover…2860
No. 0310 Installation of front support…2861
No. 0315 Installation of front support (Fog lamp specification: If equipped)…2862
No. 0317 Installation of front support (Fog lamp, beacon lamp, HID headlamp specification: If equipped)…2863
No. 0320 Installation of steering valve…2864
No. 0330 Preparation for installing cab…2865
No. 0340 Installation of cab…2866
No. 0345 Connection of ABS piping (If equipped)…2867
No. 0350 Connection of column…2868
No. 0355 Installation of washer tank…2869
No. 0370 Connection of cab wiring…2870
No. 0375 Connection of cab wiring (ASR/ABS specification: If equipped)…2871
No. 0376 Connection of engine prelubrication harness to cab (If equipped: Engine prelubrication specification)…2872
No. 0377 Connection and fixing of engine compartment lamp wiring harness (If equipped)…2873
No. 0378 Connection of auto grease harness to cab (If equipped: Auto grease specification)…2874
No. 0379 Connection of engine stop harness to cab (If equipped: Engine emergency stop specification)…2875
No. 0380 Installation and fixing of steering hoses…2876
No. 0385 Fixing of air conditioner drain hose…2877
No. 0390 Installation of steering hose cover…2878
No. 0395 Connection of air conditioner and heater hoses…2879
No. 0400 Connection of cab floor wiring…2880
No. 0405 Fixing of ASR/ABS wiring harness (If equipped)…2881
No. 0406 Connection and fixing of ABS wiring harness (ABS specification: If equipped)…2882
No. 0410 Installation of cover under cab…2883
No. 0415 Wiring of front glass with heater wire (If equipped)…2884
No. 0420 Installation of cab seal…2885
No. 0430 Installation of ambient temperature sensor wiring harness…2886
No. 0440 Installation of undercab wiring harness connector…2887
No. 0445 Connection and fixing of rear view camera wiring harness (if equipped)…2888
No. 0451 Installation of hand rail and mirror to the R.H. platform assembly…2889
No. 0470 Installation of right fender…2890
No. 0472 Installation of right fender (If equipped: Body heating-less muffler specification)…2891
No. 0475 Installation of fuel tank quick charge-less hose (If equipped)…2892
No. 0476 Installation of fuel tank quick chargeless hose: Muffler specification (If equipped: muffler specification)…2893
No. 0481 Assembly of diagonal ladder (if equipped)…2894
No. 0482 Installation of cab step: Diagonal ladder specification (if equipped)…2895
No. 0483 Installation of diagonal ladder 1 (if equipped)…2896
No. 0484 Installation of diagonal ladder 2 (if equipped)…2897
No. 0485 Installation of diagonal ladder 3 (if equipped)…2898
No. 0489 Installation of cab step…2899
No. 0491 Installation of L.H. under view mirror (If equipped)…2900
No. 0500 Installation of fire extinguisher (If equipped)…2901
No. 0511 Installing radio antenna and fixing its cable…2902
No. 0520 Installation of L.H. fender…2903
No. 0530 Installation of left side mudguard…2904
No. 0540 Installation of grille guard…2905
No. 0550 Installation of left payload lamp (If equipped)…2906
No. 0555 Installation of left side lamp (If equipped)…2907
No. 0560 Installation of right payload lamp (If equipped)…2908
No. 0565 Installation of right side lamp (If equipped)…2909
No. 0570 Installation of left fender side lamp wiring harness (If equipped)…2910
No. 0580 Installation of right fender side lamp wiring harness (If equipped)…2911
No. 0581 Installation of right fender side lamp wiring harness. (If equipped: Body heating-less muffler, exhaust gas selector box muffler specification)…2912
No. 0590 Installation of KOMTRAX (If equipped)…2913
No. 0595 Fixing of ORBCOMM antenna (If equipped)…2914
No. 0597 Connection and fixing of harness and hose going to auto grease pump -1 (If equipped: Auto grease specification)…2915
No. 0598 Connection and fixing of harness and hose going to auto grease pump – 2 (If equipped: Auto grease specification)…2916
No. 0600 Removal of hoist cylinder fixing bracket…2917
No. 0610 Connection of hoist cylinder piping…2918
No. 0620 Welding of body…2919
No. 0630 Sticking of body decal…2920
No. 0640 Supply of oil…2921
No. 0650 Slinging of body…2922
No. 0660 Installation of hinge pin…2923
No. 0670 Connecting hoist cylinder…2924
No. 0680 Hoist cylinder grease piping…2925
No. 0685 Fixing of auto grease piping to body (If equipped: Auto grease specification)…2926
No. 0700 Installation of field welding protection cover…2927
No. 0710 Installation of body mount…2928
No. 0720 Procedure for adjusting body mount shim…2929
No. 0730 Field welding of exhaust tube…2930
No. 0740 Assembly of body heater cover…2931
No. 0770 Installation of poke ejector…2932
No. 0780 Installation of poke ejector storage pin…2933
No. 0790 Installation of body mudguard…2934
No. 0800 Installation of body lock pin…2935
No. 0810 Installation of transmission underguard…2936
No. 0830 Installation of front handle…2937
No. 0850 Connection of dump sensor…2938
No. 0860 Procedure for adjusting dump sensor…2939
No. 0870 Calibrating dump control…2940
No. 0880 Adjustment of optical axis of light…2941
No. 0900 Bleeding air from brake…2942
No. 0901 Bleeding air from brake of ASR specification (ASR specification: If equipped)…2943
No. 0905 Bleeding air from ABS circuit (ABS specification: If equipped)…2944
No. 0910 Adjusting suspension…2945
No. 0920 Charging air conditioner with refrigerant…2946
No. 0930 Fitting of floating seal…2947
No. 0950 Painting…2948
No. 0960 Touchup…2949
No. 1000 Sticking of front axle decal…2950
No. 1020-1 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)…2951
No. 1020-2 Operating procedure of prelubrication system (If equipped: Engine prelubrication specification)…2952
No. 1100 Installation of chocks (If equipped)…2953
No. 1200 Installation of radiator curtain (If equipped)…2954
No. 1300 Installation and connection of beacon lamp (If equipped: Yellow beacon lamp specification)…2955
No. 1400 Assembly of power ladder step -1 (If equipped)…2956
No. 1410 Assembly of power ladder step -2 (If equipped)…2957
No. 1420 Assembly of power ladder step -3 (If equipped)…2958
No. 1430 Assembly of power ladder main part -1 (If equipped)…2959
No. 1440 Assembly of power ladder main part -2 (If equipped)…2960
No. 1450 Assembly of power ladder main part -3 (If equipped)…2961
No. 1460 Assembly of power ladder main part -4 (If equipped)…2962
No. 1470 Assembly of power ladder main part -5 (If equipped)…2963
No. 1480 Assembly of power ladder main part -6 (If equipped)…2964
No. 1490 Assembly of power ladder main part -7 (If equipped)…2965
No. 1500 Assembly of power ladder main part -8 (If equipped)…2966
No. 1510 Assembly of power ladder main part -9 (If equipped)…2967
No. 1520 Assembly of power ladder main part -10 (If equipped)…2968
No. 1530 Assembly of power ladder main part -11 (If equipped)…2969
No. 1540 Assembly of power ladder main part -12 (If equipped)…2970
No. 1550 Assembly of power ladder main part -13 (If equipped)…2971
No. 1560 Assembly of power ladder main part -14 (If equipped)…2972
No. 1570 Assembly of power ladder main part -15 (If equipped)…2973
No. 1580 Assembly of power ladder main part -16 (If equipped)…2974
No. 1590 Refilling power ladder with oil…2975
No. 1600 Adjustment of power ladder operating time…2976
No. 1610 Installation of additional under view mirror…2977
No. 7. Adjustment procedure…0
No. T-0010 Bleeding air from fuel circuit 1 (If equipped: Extra low-grade fuel specification)…2978
No. T-0020 Bleeding air from fuel circuit 2 (If equipped: Extra low-grade fuel specification)…2979
No. T-0030 Setting of machine monitor…2980
No. T-0040 Selection of machine model…2981
No. T-0050 Selection of optional component…2982
No. T-0060 Selection of option…2983
No. T-0070 Option setting/no-setting selection screen – Saving of change of option selection…2984
No. T-0080 OFF setting of corrosion resistor with maintenance monitor…2985
No. T-0090 Adjustment of body positioner sensor…2986
No. T-0100 Deletion of electrical system fault history (1)…2987
No. T-0110 Deletion of electrical system fault history (2)…2988
No. 8. Welding procedure…0
No. C-0010 Preparation of welding body…2989
No. C-0020 Assembly of split body (1/2)…2990
No. C-0030 Assembly of split body (2/2)…2991
No. C-0040 Tack welding body…2992
No. C-0050 Welding body (1/2)…2993
No. C-0060 Welding body (2/2)…2994
No. C-0070 Welding body instruction (1/2)…2995
No. C-0080 Welding body instruction (2/2)…2996
No. C-0090 Turn over the body…2997
No. C-0100 Welding body protector (1/2)…2998
No. C-0110 Welding body protector (2/2)…2999
No. C-0120 Finishing and painting welded parts of body…3000
No. C-0130 Welding front body mount bracket…3001
Appendix…0
Field assembly inspection report…3003
SEAM003601 – Dump Truck HD785-3 Operation & Maintenance Manual…3019
COVER PAGE…3019
1. FOREWORD…3020
2. SAFETY INFORMATION…3021
3. INTRODUCTION…3022
3.1 FEATURES…3022
3.1.1 A HARD-WORKING MACHINE…3022
3.1.2 THE MACHINE THAT ANYONE CAN DRIVE AND EVERYONE WANTS TO DRIVE…3022
3.1.3 TROUBLE-FREE MACHINE…3022
3.2 BREAKING IN THE MACHINE…3022
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR…3023
4.1 MACHINE SERIAL NO. PLATE POSITION…3023
4.2 ENGINE SERIAL NO. PLATE POSITION…3023
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…3023
5. CONTENTS…3024
SAFETY…3028
6. GENERAL PRECAUTIONS…3029
7. PRECAUTIONS DURING OPERATION…3034
7.1 BEFORE STARTING ENGINE…3034
7.2 OPERATING MACHINE…3036
7.3 BATTERY…3040
7.4 TOWING…3041
8. PRECAUTIONS FOR MAINTENANCE…3042
8.1 BEFORE CARRYING OUT MAINTENANCE…3042
8.2 DURING MAINTENANCE…3044
8.3 TIRES…3048
9. POSITION FOR ATTACHING SAFETY LABELS…3050
9.1 POSITION FOR ATTACHING SAFETY LABELS…3050
9.2 PLACE FOR STORING MANUAL…3053
OPERATION…3054
10. GENERAL VIEW…3055
10.1 GENERAL VIEW OF MACHINE…3055
10.2 GENERAL VIEW OF CONTROL AND GAUGES…3056
11. EXPLANATION OF COMPONENTS…3057
11.1 MACHINE MONITOR…3057
11.2 SWITCHES…3075
11.3 CONTROL LEVERS AND PEDALS…3082
11.4 MECHATRONICS EQUIPMENT CONTROLLER…3086
11.5 SAFETY PIN…3086
11.6 FUSES…3087
11.7 CAR STEREO…3089
11.8 AIR CONDITIONER…3095
11.9 CAR HEATER…3098
11.10 LOCATION OF FIRE EXTINGUISHER…3099
11.11 LOCATIONOF FIRST AID BOX…3099
12. OPERATION…3100
12.1 CHECK BEFORE STARTING ENGINE…3100
12.2 STARTING ENGINE…3117
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…3119
12.4 MOVING MACHINE OFF…3120
12.5 SHIFTING GEAR…3122
12.6 TRAVELING DOWNHILL…3123
12.7 TRAVELING IN REVERSE…3132
12.8 STEERING THE MACHINE…3133
12.9 STOPPING THE MACHINE…3134
12.10 OPERATING DUMP BODY…3136
12.11 PRECAUTIONS FOR OPERATION…3138
12.12 PARKING MACHINE…3139
12.13 CHECKS AFTER COMPLETION OF WORK…3140
12.14 STOPPING ENGINE…3140
12.15 CHECKS AFTER STOPPING ENGINE…3140
12.16 LOCKING…3141
12.17 HANDLING TIRES…3142
13. DETERMINING AND MAINTAINING TRAVEL ROAD…3145
13.1 DETERMINING TRAVEL ROAD…3145
13.2 MAINTAINING TRAVEL ROAD…3146
14. COLD WEATHER OPERATION…3147
14.1 PRECAUTIONS FOR LOW TEMPERATURE…3147
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…3149
14.3 AFTER COLD WEATHER…3149
15. LONG-TERM STORAGE…3150
15.1 BEFORE STORAGE…3150
15.2 DURING STORAGE…3150
15.3 AFTER STORAGE…3151
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…3151
16. TROUBLESHOOTING…3152
16.1 AFTER RUNNING OUT OF FUEL…3152
16.2 TOWING MACHINE…3152
16.3 IF BATTERY IS DISCHARGED…3156
16.4 OTHER TROUBLE…3160
MAINTENANCE…3169
17. GUIDES TO MAINTENANCE…3170
18. OUTLINES OF SERVICE…3173
18.1 OUTLINE OF OIL, FUEL, COOLANT…3173
18.2 OUTLINE OF ELECTRIC SYSTEM…3176
19. WEAR PARTS LIST…3177
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…3178
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3182
21.1 INTRODUCTION OF NECESSARY TOOLS…3182
21.2 TORQUE LIST…3183
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3184
23. MAINTENANCE SCHEDULE CHART…3186
24. SERVICE PROCEDURE…3191
24.1 INITIAL 250 HOURS SERVICE…3191
24.2 WHEN REQUIRED…3192
24.3 CHECK BEFORE STARTING…3205
24.4 EVERY 250 HOURS SERVICE…3215
24.5 EVERY 500 HOURS SERVICE…3225
24.6 EVERY 1000 HOURS SERVICE…3230
24.7 EVERY 2000 HOURS SERVICE…3235
24.8 EVERY 4000 HOURS SERVICE…3241
24.9 EVERY 3 YEARS SERVICE…3242
SPECIFICATIONS…3243
25. SPECIFICATIONS…3244
OPTIONS, ATTACHMENTS…3246
26. HANDLING PAYLOAD METER…3247
26.1 NAME OF PARTS…3247
26.2 EXTERNAL DISPLAY LAMPS…3247
26.3 OPERATING PAYLOAD METER…3249
27. OPTIONS AND ATTACHMENTS…3258
28. TACHOGRAPH (TCO 15-6)…3259
28.1 EXPLANATION OF COMPONENTS…3259
28.2 METHOD OF USING KEY…3261
28.3 METHOD OF USE…3262
29. REVO TACHOGRAPH (TCO 15-7)…3264
29.1 EXPLANATION OF COMPONENTS…3264
29.2 METHOD OF USE…3267
SEAM020406T – Dump Truck HD785-5 Operation & Maintenance Manual…3270
COVER…3270
1.FOREWORD…3271
2.SAFETY INFORMATION…3274
3.INTRODUCTION…3275
3.1 FEATURES…3275
3.2 BREAKING IN THE MACHINE…3275
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR…3276
4.1 MACHINE SERIAL NO.PLATE POSITION…3276
4.2 ENGINE SERIAL NO.PLATE POSITION…3276
4.3 TABEL TO ENTER SERIAL NO.AND DISTRIBUTOR…3276
5.CONTENTS…3277
SAFETY…3281
6.GENERAL PRECAUTIONS…3282
7.PRECAUTIONS DURING OPERATION…3288
7.1 BEFORE STARTING ENGINE…3288
7.2 AFTER STARTING ENGINE…3290
7.3 SHIPPING…3298
7.4 BATTERY…3299
7.5 TOWING…3301
8.PRECAUTIONS FOR MAINTENANCE…3302
8.1 BEFORE CARRYING OUT MAINTENANCE…3302
8.2 DURING MAINTENANCE…3308
8.3 TIRES…3315
9.POSITION FOR ATTACHING SAFETY LABELS…3317
9.1 POSITION FOR ATTACHING SAFETY LABELS…3317
OPERATION…3321
10.GENERAL VIEW…3322
10.1 GENERAL VIEW OF MACHINE…3322
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…3323
11.EXPLANATION OF COMPONENTS…3324
11.1 MACHINE MONITOR…3324
11.2 SWITCHES…3338
11.3 CONTROL LEVERS AND PEDALS…3345
11.4 MECHATRONICS EQUIPMENT CONTROLLER…3349
11.5 SAFETY PIN…3349
11.6 DUST INDICATOR…3350
11.7 FUSES…3350
11.8 LOCATION OF MANUAL BOX…3351
11.9 CAR STEREO…3352
11.10 AIR CONDITIONER…3358
11.11 CAR HEATER…3362
11.12 LOCATION OF FIRE EXTINGUISHER…3363
11.13 LOCATION OF FIRST AID BOX…3363
12.OPERATION…3364
12.1 CHECK BEFORE STARTING ENGINE…3364
12.2 STARTING ENGINE…3381
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…3383
12.4 MOVING MACHINE OFF…3384
12.5 SHIFTING GEAR…3386
12.6 TRAVELING DOWNHILL…3387
12.7 TRAVELING IN REVERSE…3393
12.8 STEERING THE MACHINE…3394
12.9 STOPPING THE MACHINE…3395
12.10 OPERATING DUMP BODY…3397
12.11 PRECAUTIONS FOR OPERATION…3399
12.12 PARKING MACHINE…3400
12.13 CHECKS AFTER COMPLETION OF WORK…3401
12.14 STOPPING ENGINE…3401
12.15 CHECKS AFTER STOPPING ENGINE…3401
12.16 LOCKING…3402
12.17 HANDLING TIRES…3403
13.DETERMINING AND MAINTAINING TRAVEL ROAD…3406
13.1 DETERMINING TRAVEL ROAD…3406
13.2 MAINTAINING TRAVEL ROAD…3407
14.COLD WEATHER OPERATION…3408
14.1 PRECAUTIONS FOR LOW TEMPERATURE…3408
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…3410
14.3 AFTER COLD WEATHER…3410
15.LONG-TERM STORAGE…3411
15.1 BEFORE STORAGE…3411
15.2 DURING STORAGE…3411
15.3 AFTER STORAGE…3412
15.4 PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…3412
16.TROUBLESHOOTING…3413
16.1 AFTER RUNNING OUT OF FUEL…3413
16.2 TOWING MACHINE…3413
16.3 IF BATTERY IS DISCHARGED…3416
16.4 OTHER TROBLE…3420
MAINTENANCE …3437
17.GUIDES TO MAINTENANCE…3438
18.OUTLINES OF SERVICE…3441
18.1 OUTLINE OF OIL,FUEL,COOLANT…3441
18.2 OUTLINE OF ELECTRIC SYSTEM…3444
19.WEAR PARTS LIST…3445
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…3446
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3450
21.1 INTRODUCTION OF NECESSARY TOOLS…3450
21.2 TORQUE LIST…3451
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3452
23.MAINTENANCE SCHEDULE CHART…3454
24.SERVICE PROCEDURE…3459
24.1 INITIAL 250 HOURS SERVICE…3459
24.2 WHEN REQUIRED…3460
24.3 CHECK BEFORE STARTING…3475
24.4 EVERY 250 HOURS SERVICE…3485
24.5 EVERY 500 HOURS SERVICE…3493
24.6 EVERY 1000 HOURS SERVICE…3500
24.7 EVERY 2000 HOURS SERVICE…3505
24.8 EVERY 4000 HOURS SERVICE…3511
24.9 EVERY 3 YEARS SERVICE…3512
SPECIFICATIONS…3513
25.SPECIFICATIONS…3514
OPTIONS,ATTACHMENTS…3516
26.HANDLING PAYLOAD METER…3517
26.1 NAME OF PARTS…3517
26.2 EXTERNAL DISPLAY LAMPS…3517
26.3 OPERATING PAYLOAD METER…3519
27.OPTIONS AND ATTACHMENTS…3528
28.TACHOGRAPH (TCO 15-6)…3529
28.1 EXPLANATION OF COMPONENTS…3529
28.2 METHOD OF USING KEY…3531
28.3 METHOD OF USE…3532
29.REVO TACHOGRAPH (TCO 15-7)…3534
29.1 EXPLANATION OF COMPONENTS…3534
29.2 METHOD OF USE…3537
30.USING DIFFERENTIAL LOCK…3539
30.1 DIFFERENTIAL LOCK PEDAL…3539
30.2 PRECAUTIONS AND METHOD OF USE…3540
31.OPERATION OF ABS AND ABS/ASR…3541
31.1 EXPLANATION OF COMPONENTS…3541
31.2 OPERATION METHOD…3542
31.3 PRECAUTION FOR USE…3543
31.4 TROUBLESHOOTING…3544
32.ARSC(AUTOMATIC RETARD SPEED CONTROL)…3545
32.1 EXPLANATION OF COMPONENTS…3545
32.2 METHOD OF OPERATION…3547
32.3 TROUBLESHOOTING…3549
33.PMC(POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE)…3552
33.1 CHECK BEFORE STARTING…3552
33.2 ABNORMALITY DISPLAYED DURING OPERATION…3552
33.3 HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS…3552
33.4 MESSAGE FOR OPERATION AND MAINTENANCE(MOM)…3553
34.ASRII(AUTOMATIC SPIN REGULATOR II)…3558
34.1 EXPLANATION OF COMPONENTS…3558
34.2 ACTUATION OF ASRII SYSTEM…3559
34.3 TROUBLESHOOTING…3560
SEAM05610302 – Dump Truck HD785-3 Operation & Maintenance Manual…3564
COVER…3564
CONTENTS…3567
OPERATION…3568
GENERAL LOCATIONS AND SPECIFICATIONS…3568
INSTRUMENTS AND CONTROLS…3569
CHECK BEFORE STARTING…3598
OPERATING YOUR MACHINE…3610
OPERATING DUMP BODY…3628
METHOD OF RELEASING PARKING BRAKE AND EMERGENCY BRAKE WHEN ACTUATED IN AN EMERGENCY…3630
INSTRUCTION FOR TOWING THE MACHINE…3632
HANDLING THE TIRES…3633
HANDLING PAYLOAD METER…3636
COLD WEATHER OPERATION…3644
MAINTENANCE…3649
PERIODIC MAINTENANCE…3649
PERIODIC REPLACEMENT OF SAFETY PARTS…3650
MAINTENANCE TABLE…3652
OIL FILLER AND LEVEL GAUGE POSITIONS…3656
EVERY 250 HOURS SERVICE…3657
EVERY 500 HOURS SERVICE…3666
EVERY 1000 HOURS SERVICE…3669
EVERY 2000 HOURS SERVICE…3673
EVERY 4000 HOURS SERVICE…3679
WHEN REQUIRED…3680
ADJUSTMENT…3688
TROUBLESHOOTING GUIDE…3693
SERVICE METER…3700
MACHINE AND ENGINE SERIAL NUMBERS…3701
FUEL, COOLANT AND LUBRICANTS…3702
EQUIPPED WITH A MONITOR PANEL…3704
SAFETY AND OPERATION…3777
CONTENTS…3778
SAFETY HINTS…3779
PRECAUTIONS FOR MAINTENANCE…3791
CAR STEREO…3799
OPERATING THE AIR CONDITIONER…3802
OPERATING THE CAR HEATER…3806
TACHOGRAPH (TCO 15-6)…3807
REVO TACHOGRAPH (TCO 15-7)…3811
HANDLING OF BATTERY…3815
STORAGE…3818
COOLANT AND LUBRICANTS…3820
SEBM013917 – Dump Truck HD785-5, HD985-5 Shop Manual…3824
COVER…3824
CONTENTS…3825
01 GENERAL…3852
GENERAL ASSEMBLY DRAWING…3853
SPECIFICATIONS…3855
WEIGHT TABLE…3858
LIST OF LUBRICANT AND COOLANT…3859
10 STRUCTURE AND FUNCTION…3860
RADIATOR, TORQUE CONVERTER COOLER…3863
BRAKE OIL COOLER…3864
POWER TRAIN SKELETON…3865
OUTPUT SHAFT (HD785-5)…3866
OUTPUT SHAFT (HD985-5)…3867
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…3868
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM…3869
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS…3870
TORQUE CONVERTER…3871
TORQUE CONVERTER VLAVE…3873
LOCKUP SOLENOID VALVE…3877
TRANSMISSION…3878
TRANSMISSION VALVE…3881
ECMV…3882
LUBRICATION RELIEF VALVE…3887
FRONT AXLE (HD785-5)…3888
FRONT AXLE (HD985-5)…3889
REAR AXLE (HD785-5)…3891
REAR AXLE (HD985-5)…3894
DIFFERENTIAL…3895
DIFFERENTIAL LOCK CONTROL…3897
DIFFERENTIAL LOCK SOLENOID VALVE…3899
FINAL DRIVE (HD785-5)…3900
FINAL DRIVE (HD985-5)…3902
FRONT BRAKE…3903
REAR BRAKE…3904
PARKING BRAKE…3908
WHEELS (HD785-5)…3909
WHEELS (HD985-5)…3910
AXLE SUPPORT (HD785-5)…3911
AXLE SUPPORT (HD985-5)…3912
STEERING SYSTEM…3913
STEERING WHEEL (HD785-5)…3914
STEERING WHEEL (HD985-5)…3915
STEERING LINKAGE…3916
SUSPENSION SYSTEM…3918
SUSPENSION CYLINDER…3920
REAR SUSPENSION CYLINDER…3923
AIR PIPING…3925
AIR CIRCUIT DIAGRAM…3927
DESICCANT TYPE AIR DRIER (IF EQUIPPED)…3929
AIR GOVERNOR…3930
SAFETY VALVE…3930
CHECK VALVE…3931
DOUBLE CHECK VALVE…3931
AUTO DRAIN VALVE…3932
HAND BRAKE VALVE…3933
BRAKE VALVE…3934
EMERGENCY BRAKE CONTROL VALVE…3935
PARKING BRAKE CONTROL VALVE…3938
PARKING BRAKE PILOT VALVE…3939
RELAY VLAVE…3940
PARKING BRAKE RELAY VALVE…3943
QUICK-RELEASE VALVE…3945
PARKING BRAKE CHAMBER…3945
RATIO VALVE (FOR FRONT BRAKE)…3946
FRONT BRAKE CHAMBER…3947
BRAKE CHAMBER…3948
SLACK ADJUSTER…3951
AIR DRIER (DESICCANT TYPE) (IF EQUIPPED)…3952
HYDRAULIC PIPING…3954
HYDRALUIC CIRCUIT DIAGRAM…3956
DUMP BODY CONTROL…3957
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5)…3958
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5)…3959
BRAKE COOLING OIL CONTROL VALVE (BCV)…3960
STEERING VALVE…3961
DEMAND VALVE…3965
HOIST VALVE…3969
CROSSOVER RELIEF VALVE…3971
STEERING CYLINDER…3972
HOIST CYLINDER…3972
ELECTRICAL CIRCUIT DIAGRAM…3973
STOP LAMP SWITCH…3976
EXHAUST BRAKE SWITCH…3976
TILT SWITCH…3976
FRONT BRAKE CUT-OFF VALVE…3977
OVERRUN PREVENTION VALVE…3978
EXHAUST BRAKE VALVE…3978
HORN VALVE…3979
PARKING BRAKE SWITCH…3979
AIR CONDITIONER…3980
PIPING DIAGRAM…3980
ELECTRICAL CIRCUIT DIAGRAM…3981
REFRIGERANT CIRCUIT DIAGRAM…3983
UNIT…3984
RECEIVER DRYER…3984
CONDENSER…3985
COMPRESSOR…3985
ENGINE CONTROL SYSTEM…3986
SYSTEM DRAWING…3986
ELECTRICAL CIRCUIT DIAGRAM…3988
FUEL INJECTION PUMP ELECTRIC GOVERNOR…3989
HYDRAULIC CIRCUIT DIAGRAM…3990
AISS…3990
SENSOR, SWITCHES…3991
EXHAUST BRAKE…3992
SYSTEM DIAGRAM…3992
SYSTEM DIAGRAM…3993
AUTOMATIC SHIFT CONTROL SYSTEM…3995
SYSTEM DIAGRAM…3995
ELECTRICAL CIRCUIT DIAGRAM…3997
TRANSMISSION CONTROLLER…3998
CONNECTOR SIGNALS…3999
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES…4000
AUTOMATIC GEAR SHIFTING LINE GRAPH…4001
SHIFT LEVER SWITCH…4003
SENSORS, SWITCHES…4004
TRANSMISSION OIL TEMPERATURE SENSOR…4004
FILL SWITCH…4005
ACCELERATOR SENSOR…4006
SHIFT LIMIT SWITCH…4007
MODE SELECTOR SWITCH…4007
SELF-DIAGNOSTIC FUNCTION…4008
AUTOMATIC EMERGENCY STEERING SYSTEM…4009
SYSTEM DIAGRAM…4009
ELECTRIC CIRCUIT DIAGRAM…4010
FLOW SWITCH…4011
RELAY TIMER…4013
AUTOMATIC SUSPENSION SYSTEM…4014
SYSTEM DIAGRAM…4014
STRUCTURE OF SYSTEM…4015
SYSTEM CIRCUIT DIAGRAM…4016
AUTOMATIC SUSPENSION MODE SELECTION CONTROL…4017
SUSPENSION CONTROLLER…4018
SENSOR, SWITCHES…4019
STEERING ANGLE SENSOR…4019
PRESSURE SENSOR…4019
SELF-DIAGNOSTIC FUNCTION…4020
PAYLOAD METER (PRINTER TYPE) (OP)…4021
STRUCTURE OF SYSTEM…4021
ELECTRICAL CIRCUIT DIAGRAM…4022
PAYLOAD METER BLOCK DIAGRAM…4022
PRINCIPLE OF CALCULATION…4023
FEATURES OF EQUIPMENT…4025
1. PAYLOAD METER…4025
2. PRESSURE SENSOR…4028
3. CLINOMETER…4029
4. LAMP DRIVE RELAY…4029
SELF-DIAGNOSTIC FUNCTION…4030
PAYLOAD METER Ⅱ (CARD TYPE) (OP)…4031
STRUCTURE OF SYSTEM…4031
ELECTRICAL CIRCUIT DIAGRAM…4032
PAYLOAD METER BLOCK DIAGRAM…4032
PRINCIPLE OF MEASUREMENT…4033
FEATURE OF EACH DEVICE…4034
1. PAYLOAD METER Ⅱ…4034
2. PRESSURE SENSOR…4062
3. CLINOMETER…4063
4. LAMP DRIVE RELAY…4063
5. SELF-DIAGNOSTIC FUNCTION…4064
MACHINE MONITOR SYSTEM…4070
SYSTEM DRAWING…4070
MONITOR PANEL DIAGRAM…4072
MACHINE MONITOR NORMAL DISPLAY FUNCTONS…4073
SELF-DIAGNOSTIC FUNCTION WHEN STARTING SWITCH IS OPERATED…4080
TRAVEL SPEED COMPENSATION ROTARY SWITCH…4080
SENSORS, SWITCHES…4081
ENGINE SPEED SENSOR…4081
TRANSMISSION SPEED SENSOR…4081
ENGINE OIL PRESSURE…4082
ENGINE WATER TEMPERATURE SENSOR…4083
RETARDER OIL TEMPERATURE SENSOR…4083
TORQUE CONVERTER OIL TEMPERATURE SENSOR…4083
AIR PRESSURE SENSOR…4083
FUEL LEVEL SENSOR…4084
TRANSMISSION OIL FILTER SENSOR…4085
RADIATOR WATER LEVEL SENSOR…4085
STEERING OIL TEMPERATURE SENSOR…4086
BRAKE STROKE SENSOR…4086
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP)…4087
SYSTEM DIAGRAM…4087
ELECTRIC CIRCUIT DIAGRAM…4089
POWER TRAIN MANAGEMENT CONTROLLER (PMC)…4090
MESSAGE DISPLAY (MOM)…4092
SENSOR, SWITCHES…4094
ENGINE SPEED SENSOR…4094
TRANSMISSION SPEED SENSOR…4094
ACCELERATOR SENSOR…4095
SUSPENSION PRESSURE SENSOR…4096
SENSORS, SWITCHES…4097
ENGINE OIL LEVEL SENSOR…4097
BRAKE OIL LEVEL SENSOR…4097
HYDRAULIC OIL LEVEL SENSOR…4098
RETARDER OIL LEVEL SENSOR…4098
AIR CLEANER CLOGGING SENSOR…4098
RETARDER BRAKE WEAR SENSOR…4099
HYDRAULIC FILTER SENSOR…4099
RETARDER OIL FILTER SENSOR…4099
FULL-FLOW FILTER SENSOR…4100
BATTERY ELECTROLYTE LEVEL SENSOR…4100
MAINTENANCE MONITOR SYSTEM…4101
SYSTEM DIAGRAM…4101
MONITOR PANEL…4102
MONITOR DISPLAY, FUNCTIONS…4103
FUNCTIONS OF SWITCHES…4105
SENSORS, SWITCHES…4107
ENGINE OIL LEVEL SENSOR…4107
RADIATOR WATER LEVEL SENSOR…4107
TRANSMISSION OIL LEVEL SENSOR…4107
HYDRAULIC OIL LEVEL SENSOR…4108
RETARDER OIL LEVEL SENSOR…4108
AIR FILTER CLOGGING SENSOR…4108
RETARDER BRAKE WEAR SENSOR…4109
HYDRAULIC FILTER SENSOR…4109
RETARDER OIL FILTER SENSOR…4109
TRANSMISSION OIL FILTER SENSOR…4109
BATTERY ELECTROLYTE LEVEL SENSOR…4110
TORQUE CONVERTER OIL TEMPERATURE SWITCH…4110
RETARDER OIL TEMPERATURE SWITCH…4110
ABS/ASR SYSTEM…4111
SYSTEM CIRCUIT DIAGRAM…4111
PRINCIPLE OF OPERATION…4113
WHEN ABS IS ACTUATED…4114
WHEN ASR IS ACTUATED…4115
SYSTEM STRUCTURE DIAGRAM…4116
ABS/ASR ELECTRICAL CIRCUIT DIAGRAM…4118
ABS/ASR CONTROLLER (ECU)…4120
ABS PRESSURE CONTROL VALVE…4121
ASR CONTROL VALVE…4124
WHEEL SPEED SENSOR…4126
RELAY…4126
ASR-Ⅱ SYSTEM (IF EUQIPPED)…4127
SYSTEM DIAGRAM…4127
BASIC OPERATION…4128
SYSTEM CONFIGURATION…4128
CONTROLLER OF AUTOMATIC SPIN REGULATOR…4131
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)…4132
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM…4134
AUTO-GREASING SYSTEM…4135
ELECTRICAL CIRCUIT DIAGRAM OF AUTO-GREASING…4138
AIR AND GREASE CIRCUIT DIAGRAM OF AUTO-GREASING…4139
SOLENOID VALVE…4140
REGULATOR…4140
TIMER…4141
20 TESTING AND ADJUSTING…4142
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS…4143
STANDARD VALUE TABLE FOR CHASSIS…4144
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…4150
TESTING AND ADJUSTING…4164
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…4165
ADJUSTING VALVE CLEARANCE…4167
MEASURING COMPRESSION PRESSURE…4168
MEASURING BLOWBY PRESSURE…4169
MEASURING BOOST PRESSURE…4170
MEASURING EXHAUST TRMPERATURE…4171
TESTING AND ADJUSTING FUEL INJECTION TIMING…4172
ADJUSTING ALTERNATOR BELT TENSION…4175
ADJUSTING ENGINE SPEED SENSOR…4176
ADJSUTING TRANSMISSION SPEED SENSOR…4176
ADJUSTING ACCELERATOR PEDAL…4177
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE…4178
TESTING ECMV HYDRAULIC PRESSURE…4179
TESTING TRANSMISSION LUBRICATION PRESSURE…4182
TESTING TORQUE CONVERTER STALL SPEED…4183
TESTING BRAKE PRESSURE…4185
BLEEDING AIR FROM BRAKE CIRCUIT…4186
TESTING WEAR OF FRONT BRAKE PAD…4186
TESTING WEAR OF REAR BRAKE DISC…4187
ADJUSTING PARKING BRAKE…4189
TESTING BRAKE PERFORMANCE…4190
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE)…4191
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER…4195
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER…4199
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT…4200
INSPECTION OF AIR DRIER (DESICCANT TYPE)…4201
ADJUSTING HOIST LEVER LINKAGE…4203
ADJUSTING BODY POSITIONER…4204
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…4205
AIR BLEEDING FROM STEERING CYLINDER…4207
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE)…4208
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER…4209
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER…4210
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL)…4211
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…4214
PROCEDURE FOR OPERATING MODULATION CHECKER…4220
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION)…4225
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (=QUICK PM)…4226
PM-CLINIC SERVICE…4230
TROUBLESHOOTING…4232
POINTS TO REMEMBER WHEN TROUBLESHOOTING…4233
SEQUENCE OF EVENTS IN TROUBLESHOOTING…4234
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…4235
CHECKS BEFORE TROUBLESHOOTING…4243
TYPE OF CONNECTOR AND POSITION OF INSTALLATION…4245
CONNECTOR PIN ALLOCATION CHART…4251
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…4256
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM…4281
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION…4288
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS…4304
TABLE OF SERVICE CODES AND USER CODES…4311
METHOD OF USING JUDGEMENT TABLE…4321
METHOD OF USING TROUBLESHOOTING CHARTS…4322
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE)…4324
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE…4325
JUDGMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…4333
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM…4337
G-1 C010 [E.<–>1.0] ABNORMALITY IN POWER SOURCE…4338
G-2 C011 [E.<–>1.1] ABNORMALITY IN CONTROLLER…4338
G-3 C012 [E.<–>1.2] ABNORMALITY IN RACK SENSOR SYSTEM…4339
G-4 C013 [E.<–>1.3] ABNORMALITY IN RACK SENSOR SYSTEM LEFT BANK…4340
G-5 C014 [E.<–>1.4] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM RIGHT BANK…4341
G-6 C015 [E.<–>1.5] ABNORMALITY IN GOVERNOR SOLENOID SYSTEM LEFT BANK…4342
G-7 C016 [E.<–>1.6] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM RIGHT BANK…4343
G-8 C017 [E.<–>1.7] ABNORMALITY IN GOVERNOR CUT RELAY SYSTEM LEFT BANK…4344
G-9 C018 [E.<–>1.8] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM…4345
G-10 C019 [E.<–>1.9] ABNORMALITY IN GOVERNOR SERVO SYSTEM RIGHT BANK…4346
G-11 C01A [E.<–>1.A] ABNORMALITY IN GOVERNOR SERVO SYSTEM LEFT BANK…4346
G-12 C01b [E.<–>1.b] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM A…4347
G-13 C01C [E.<–>1.C] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM B…4348
G-14 C01d [E.<–>1.d] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM RIGHT BANK…4349
G-15 C01E [E.<–>1.E] ABNORMALITY IN PRE-STROKE SOLENOID SYSTEM LEFT BANK…4350
G-16 C021 [E.<–>2.1] MISTAKEN CONNECTION OF CONNECTOR…4351
G-17 C022 [E.<–>2.2] ENGINE OVERRUN…4352
G-18 C023 [E.<–>2.3] ENGINE OVERHEATING…4352
G-19 C024 [E.<–>2.4] DROP IN ENGING OIL PRESSURE…4352
G-20 C031 [E.<–>3.1] ABNORMALITY IN ACCELERATION SENSOR SYSTEM…4353
G-21 C034 [E.<–>3.4] ABNORMALITY IN ENGINE COOLANT TEMPERATURE SYSTEM…4356
G-22 C036 [E.<–>3.6] ABNORMALITY IN ENGINE OIL PRESSURE SENSOR…4357
G-23 C055 [E.<–>5.5] ABNORMALITY IN NETWORK…4358
G-24 C056 [E.<–>5.6] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM RIGHT…4359
G-25 C057 [E.<–>5.7] ABNORMALITY IN SOLENOID POWER SOURCE SYSTEM LEFT…4359
G-26 C058 [E.<–>5.8] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM…4359
G-27 C059 [E.<–>5.9] ABNORMALITY IN BACKUP POWER SOURCE SYSTEM…4361
G-28 C0C2 [E.<–>C.2] DEFECTIVE MODEL SELECTION DATA…4362
G-29 C0C4 [E.<–>C.4] ABNORMALITY IN ACCELERATION SENSOR SYSTEM…4363
G-30 C0C5 [E.<–>C.5] ABNORMALITY IN IDLE VALIDATION…4366
G-31 ENGINE DOES NOT START…4371
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…4374
METHOD OF USING TROUBLESHOOTING CHART…4375
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…4379
S-2 ENGINE DOES NOT START…4381
a) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…4381
b) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…4382
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…4383
S-4 ENGINE STOPS DURING OPERATIONS…4384
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…4386
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…4387
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…4388
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…4389
S-9 OIL BECOMES CONTAMINATED QUICKLY…4390
S-10 FUEL CONSUMPTION IS EXCESSIVE…4391
S-11 OIL IS IN COOLING, OR WATER SPURTS BACK, OR COOLANT LEVEL GOES DOWN…4392
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…4393
S-13 OIL LEVEL RISES…4394
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…4395
S-15 ABNORMAL NOISE IS MADE…4396
S-16 VIBRATION IS EXCESSIVE…4398
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)…4399
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…4403
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE…4405
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…4425
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM…4427
A-1 ABNORMALITY IN POWER SOURCE SYSTEM…4429
a) [u.u][OFF]CONTROLLER SELF-DIAGNOSTIC DISPLAY LED DOES NOT LIGHT UP…4429
b) bOO1 [E. <–>0.1, E.C<–>0.1] DROP IN VOLTAGE OF CONTROLLER POWER SOURCE IS DISPLAYED…4430
c) bOdA [E. <–>d.A, E.C<–>d.A] DROP IN VOLTAGE OF BATTERY DIRECT POWER SOURCE IS DISPLAYED…4431
d) bOdb [E. <–>d.b, E.C<–>d.b] DROP IN VOLTAGE OF MAIL POWER SOURCE IS DISPLAYED…4432
e) bOO2 [E. <–>0.2, E.C<–>0.2] ABNORMALITAY IN TRANSMISSION CUT RELAY POWER SOURCE IS DISPLAYED…4433
A-2 bOO3 [E. <–>0.3, E.C<–>0.3] ABNORMALITY IN NEUTRAL SAFETY SYSTEM IS DISPLAYED…4434
A-3 bOO5 [E. <–>0.5, E.C<–>0.5] DOUBLE ENGAGEMENT FOR CLUTCH IS DISPLAYED…4435
A-4 bOO6 [E. <–>0.6, E.C<–>0.6] ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED…4436
A-5 bOO8 [E. <–>0.8, E.C<–>0.8] ABNORMALITY IN REAR BRAKE SOLENOID SYSTEM IS DISPLAYED…4437
A-6 bOO9 [E. <–>0.9, E.C<–>0.9] ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM IS DISPLAYED…4438
A-7…4439
a) bOC4 [E. <–>C.4, E.C<–>C.4] SHORT CIRCUIT WITH GROUND IN BCV REAR SOLENOID IS DISPLAYED…4439
b) bOC6 [E. <–>C.6, E.C<–>C.6] SHORT CIRCUIT IN BCV REAR SOLENOID IS DISPLAYED…4440
c) bOC8 [E. <–>C.8, E.C<–>C.8] DISCONNECTION IN BCV REAR SOLENOID IS DISPLAYED…4441
A-8 ABNORMALITY IN SPEED SENSOR SYSTEM…4442
a) b010 [E. <–>1.0, E.C<–>1.0] OR b060 [E. <–>6.0, E.C<–>6.0] DISCONNECTION IN ENGINE SPEED SENSOR [B] SYSTEM IS DISPLAYED (ELECTRONIC GOVERNOR SPECIFICATION MACHINE) OR FAILURE OF ENGINE SPEED IS DISPLAYED (ELECTRONIC GOVERNOR SPECIFICATION MACHINE)…4442
b) b011 [E. <–>1.1, E.C<–>1.1] OR b061 [E. <–>6.1, E.C<–>6.1] DISCONNECTION IN INPUT SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INPUT SHAFT SPEED SENSOR IS DISPLAYED…4444
c) b012 [E. <–>1.2, E.C<–>1.2] OR b062 [E. <–>6.2, E.C<–>6.2] DISCONNECTION IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM IS DISPLAYED OR FAILURE OF INTERMEDIATE SHAFT SPEED SENSOR IS DISPLAYED…4445
d) b013 [E. <–>1.3, E.C<–>1.3] OR b063 [E. <–>6.3, E.C<–>6.3] DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)SYSTEM IS DISPLAYED OR FAILURE OF OUTPUT SHAFT SPEED SENSOR IS DISPLAYED…4446
A-9 SPEED SENSOR SYSTEM, CLUTCH SLIPPING…4447
a) b022 [E. <–>2.2, E.C<–>2.2] OR b023 [E. <–>2.3, E.C<–>2.3] INPUT SHAFT SPEED SENSOR OR H, L CLUTCH SYSTEM IS DISPLAYED…4447
b) b024 [E. <–>2.4, E.C<–>2.4] – b028 [E. <–>2.8, E.C<–>2.8] TRAVEL SPEED SENSOR SYSTEM OR SPEED CLUTCH(1, 2, 3, 4, R)SYSTEM IS DISPLAYED…4448
A-10 ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED…4449
a) b014 [E. <–>1.4, E.C<–>1.4] ABNORMALITY IN MODEL SELECTION (WIRING HARNESS) IS DISPLAYED…4449
b) b0A1 [E. <–>A.1, E.C<–>A.1] ABNORMALITY IN MODEL SELECTION (ROTARY SWITCH) IS DISPLAYED…4450
A-11 ABNORMALITY IN SHIFT LEVER SYSTEM…4451
a) b007 [E. <–>0.7, E.C<–>0.7] SHORT CIRCUIT IN SHIFT LEVER ASSEMBLY POWER SOURCE IS DISPLAYED…4451
b) b015 [E. <–>1.5, E.C<–>1.5] SHIFT LEVER POSITION SIGNAL INPUT FOR 2 OR MORE SYSTEM IS DISPLAYED…4452
c) b016 [E. <–>1.6, E.C<–>1.6] SHIFT LEVER POSITION SIGNAL IS NOT INPUT…4454
A-12 b017 [E. <–>1.7, E.C<–>1.7] ABNORMALITY IN ACCELERATOR SIGNAL IS DISPLAYED…4456
A-13 b019 [E. <–>1.9, E.C<–>1.9] ABNORMALITY IN TRANSMISSION OIL TRMPERATURE SENSOR IS DISPLAYED…4457
A-14 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM…4458
a) b032 [E. <–>3.2, E.C<–>3.2] – b038 [E. <–>3.8,E.C<–>3.8] FILL SIGNAL (CLUTCH ON) IS DISPLAYED REGARDLESS OF COMMAND…4458
b) b042 [E. <–>4.2, E.C<–>4.2] – b048 [E. <–>4.8,E.C<–>4.8] FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED…4460
b-1) INSPECTING FILL SIGNAL SYSTEM…4460
b-2) b042 [E. <–>4.2, E.C<–>4.2] ・ b043 [E. <–>4.3, E.C<–>4.3] INSPECTING TRANSMISSION INPUT SHAFT SPEED SIGNAL SYSTEM,H,L CLUTCH SYSTEM (CHECK CLUTCH SLIP)…4461
b-3) b044 [E. <–>4.4, E.C<–>4.4] ・ b048 [E. <–>4.8, E.C<–>4.8] INSPECTING TRANSMISSION OUTPUT SHAFT SPEED SIGNAL SYSTEM, 1-4, R CLUTCH SYSTEM (INSPECTING CLUTCH SLIP)…4461
A-15 b052 [E. <–>5.2, E.C<–>5.2] – b058 [E. <–>5.8, E.C<–>5.8] WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)…4462
A-16 b071 [E. <–>7.1, E.C<–>7.1] – b078 [E. <–>7.8, E.C<–>7.8] SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED…4463
A-17 ABNORMALITY IN SENSOR SYSTEM…4465
a) b0A2 [E. <–>A.2, E.C<–>A.2] ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM IS DISPLAYED…4465
b) b0A3 [E. <–>A.3, E.C<–>A.3] ABNORMALITY IN FUEL LEVEL SENSOR SYSTEM IS DISPLAYED…4466
c) b0b2 [E. <–>b.2, E.C<–>b.2] ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM IS DISPLAYED…4467
d) b0b3 [E. <–>b.3, E.C<–>b.3] ABNORMALITY IN AIR PRESSURE SENSOR SYSTEM IS DISPLAYED…4468
e) b0b4 [E. <–>b.4, E.C<–>b.4] ABNORMALITY IN RETARDER BRAKE OIL TEMPERATURE SENSOR IS DISPLAYED…4469
A-18 WARNING DISPLAY…4470
a) b0d1 [E. <–>d.1, E.C<–>d.1] TRANSMISSION FILTER CLOGGED WARNING IS DISPLAYED…4470
b) b0d5 [E. <–>d.5, E.C<–>d.5] TILT WARNING IS DISPLAYED…4471
c) b0d6 [E. <–>d.6, E.C<–>d.6] DROP IN RADIATOR WATER LEVEL WARNING IS DISPLAYED…4472
d) b0d7 [E. <–>d.7, E.C<–>d.7] BATTERY CHARGE LEVEL WARNING IS DISPLAYED…4473
e) b0E5 [E. <–>E.5, E.C<–>E.5] STEERING OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED…4474
f) b0F5 [E. <–>F.5, E.C<–>F.5] DROP IN ENGINE OIL PRESSURE WARNING IS DISPLAYED (MECHANICAL GOVERNOR SPECIFICATION MACHINE)…4475
g) b0F6 [E. <–>F.6, E.C<–>F.6] REAR BRAKE OIL PRESSURE WARNING IS DISPLAYED…4476
A-19 b0b7 [E. <–>b.7, E.C<–>b.7] ABNORMALITY IN ENGINE OIL PRESSURE SYSTEM SENSOR IS DISPLAYED (MECHANICAL GOVERNOR SPECIFITION MACHINE)…4477
A-20 b0C1 [E. <–>C.1, E.C<–>C.1] ABNORMALITY IN CONNECTOR CONNECTION IS DISPLAYED…4478
A-21 …4479
a) b0d2 [E. <–>d.2, E.C<–>d.2] TORQUE CONVERTER OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED…4479
b) b0d3 [E. <–>d.3, E.C<–>d.3] ENGINE COOLANT TEMPERATURE OVERHEAT WARNING IS DISPLAYED…4479
c) b0E9 [E. <–>E.9, E.C<–>E.9] AIR PRESSURE DROP WARNING IS DISPLAYED…4479
d) b0F3 [E. <–>F.3, E.C<–>F.3] RETARDER BRAKE OIL TEMPERATURE OVERHEAT WARNING IS DISPLAYED…4479
e) b0d8 [E. <–>d.8, E.C<–>d.8] ENGINE OVERRUN ACTUATED IS DISPLAYED…4480
f) b0d9 [E. <–>d.9, E.C<–>d.9] ENGINE OVERSHOOT ACTUATED IS DISPLAYED…4480
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)…4481
JUDGMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS…4482
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE…4484
ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION CONTROLLER SYSTEM…4488
SP-1 d001 [ALL OFF or E.<–>01] ABNORMALITY IN POWER SOURCE IS DISPLAYED…4490
SP-2 d011 [E.<–>11 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM IS DISPLAYED…4491
SP-3 d012 [E.<–>12 IS DISPLAYED] ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM IS DISPLAYED…4492
SP-4 d015 [E.<–>15 IS DISPLAYED] ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM IS DISPLAYED…4493
SP-5 d016 [E.<–>16 IS DISPLAYED] ABNORMALITY IN STEERING SENSOR SYSTEM IS DISPLAYED…4494
SP-6 d0C2 [E.<–>C2 IS DISPLAYED] DEFECTIVE MODEL SELECTION DATA IS DISPLAYED…4495
SP-7 d021 [E.<–>21 IS DISPLAYED] ABNORMALITY IN SOLENOID [1] SYSTEM IS DISPLAYED…4496
SP-8 d022 [E.<–>22 IS DISPLAYED] ABNORMALITY IN SOLENOID [2] SYSTEM IS DISPLAYED…4497
SP-9 d023 [E.<–>23 IS DISPLAYED] ABNORMALITY IN SOLENOID [3] SYSTEM IS DISPLAYED…4498
SP-10 d0C1 [E.<–>C1 IS DISPLAYED] DISCONNECTION IN NETWROK IS DISPLAYED…4499
SP-11 d0C3 [E.<–>C3 IS DISPLAYED] DEFECTIVE TRAVEL SPEED COMPENSATION DATA IS DISPLAYED…4500
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)…4501
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER (PRINTER TYPE)…4502
ELECTRIC CIRCUIT DIAGRAM FOR PAYLOAD METER (PRINTER TYPE) SYSTEM…4503
LP-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON…4505
LP-2 CALIBRATION DEMAND (CAL FLASHES) IS SHOWN CONTINUOUSLY AFTER STARTING SWITCH IS TURNED ON …4506
LP-3 CALIBRATION CANNOT BE CARRIED OUT …4508
LP-4 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP…4511
LP-5 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXERNAL DISPLAY LAMPS LIGHT UP…4513
LP-6 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT…4514
LP-7 ABNORMALITY IN DISPLAY LOGIC…4516
LP-8 E01-E04 IS DISPLAYED…4521
LP-9 E11-E14 IS DISPLAYED…4522
LP-10 E21-E28 IS DISPLAYED BY SENSOR CHECK…4523
LP-11 E31 IS DISPLAYED…4524
LP-12 E32 IS DISPLAYED…4526
LP-13 E41 IS DISPLAYED…4528
LP-14 E42 IS DISPLAYED…4529
LP-15 PRINTER DOES NOT PRINT ANYTHING (BLANK PAPER COMES OUT)…4530
LP-16 PRINTER PRINTS ONLY ‘NO DATA’…4530
LP-17 PRINTER DOES NOT PRINT OUT WHEN PRT SWITCH IS PRESSED…4530
LP-18 ‘PAPE’ FLASHES…4531
LP-19 TIME IS WRONG…4531
LP-20 E33 IS DISPLAYED…4531
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM (LC MODE)…4532
SERVICE CODES AND SELF-DIAGNOSIS OF PAYLOAD METER Ⅱ (CARD TYPE)…4533
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM…4536
LC-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON …4538
LC-2 AFTER STARTING SWITCH IS TURNED ON,ALL EXTERNAL DISPLAY LAMPS DO NOT LIGHT UP…4539
LC-3 CONDITION DOES NOT EXIST FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP…4540
LC-4 LEVEL OF LIGHTING UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT…4541
LC-5 CYCLE DATA IS NOT RECOREDE,ON/OFF DATA IS NOT RECORDED:BATTERY CHARGE SIGNAL SYSTEM:ENGINE IS NOT STARTED IS DETECTED…4543
LC-6 CALIBRATION CANNOT BE CARRIED OUT,TIME DISPLAY DOES NOT MATCH CONDITIONS:SHIFT LEVER N POSITION SIGNAL SYSTEM…4544
LC-7 ABNORMALITY IN DISPLAY LOGIC…4545
LC-8 B-FL REMAINS DISPLAYED AND DOES NOT CHANGE:BODY FLOAT RELAY SYSTEM:WHEN NOT DUMPING AND WHEN DUMP LEVER IS NOT AT FLOAT POSITION…4547
LC-9 F-09 IS DISPLAYED:DROP IN VOLTAGE OF BACK-UP BATTERY BUILT INTO PAYLOAD METER…4548
LC-10 FULL DISPLAY APPEARS…4548
LC-11 F-20 IS DISPLAYED:SENSOR POWER SOURCE VOLTAGE SYSTEM…4549
LC-12 F-21 – F-24 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND SUSPENSION PRESSURE SENSOR SYSTEM…4550
LC-13 F-25 – F-28 IS DISPLAYED:SHORT CIRCUIT IN SUSPENSION PRESSURE SENSOR SYSTEM POWER SOURCE…4552
LC-14 F.CAL IS DISPLAYED:CALIBRATION NOT CARRIED OUT,DAMAGED DATA INSIDE PAYLOAD METER…4553
LC-15 F-41 – F-45 IS DISPLAYED:SHORT CIRCUIT IN EXTERNAL DISPLAY LAMP SYSTEM POWER SOURCE…4554
LC-16 L-BAD IS DISPLAYED:CYCLE DATA SAVED WHEN MACHINE WAS SWAYING…4556
LC-17 MACHINE IS NOT LOADING BUT EXTERNAL DISPLAY LAMPS GIVE LOAD ESTIMATE DISPLAY. AFTER LOADING,DISPLAY SWITCHES TO TIME DISPLAY BEFORE TRAVELING 160m…4557
LC-18 F-31 IS DISPLAYED:DISCONNECTION,SHORT CIRCUIT WITH GROUND IN CLINOMETER SYSTEM…4558
LC-19 F-32 IS DISPLAYED:SHORT CIRCUIT WITH CLINOMETER SYSTEM POWER SOURCE…4559
LC-20 F-18 IS DISPLAYED:DISCONNECTION IN BATTERY CHARGE SIGNAL…4560
LC-21 F-93 – 99 ARE DISPLAYED:ABNORMALITY IN NETWORK (WHEN PMC IS INSTALLED)…4561
LC-22 F-71,73,80,91,92 ARE DISPLAYED:(WHEN PMC,TALKS ARE INSTALLED)…4562
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)…4563
OUTLINE…4564
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM…4568
R-1 0.1 (ABNORMALITY IN POWER SOURCE VOLTAGE) IS DISPLAYED…4570
R-2 1.0 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED…4571
R-3 1.3 (DISCONNECTION IN TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) IS DISPLAYED…4572
R-4 1.5 (FAILURE IN RETARDER OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED…4573
R-5 1.7 (FAILURE IN ACCELERATOR SIGNAL SYSTEM) IS DISPLAYED…4574
R-6 1.8 (FAILURE IN SUSPENSION PRESSURE SENSOR ‘LEFT’ SYSTEM) IS DISPLAYED…4575
R-7 1.9 (FAILURE IN SUSPENSION PRESSURE SENSOR ‘RIGHT’ SYSTEM) IS DISPLAYED…4576
R-8 4.2 (DISCONNECTION IN EXHAUST BRAKE SELECTOR SIGNAL SYSTEM) IS DISPLAYED…4577
R-9 4.3 (DISCONNECTION IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED…4578
R-10 4.4 (DISCONNECTION IN READY LAMP SYSTEM) IS DISPLAYED…4579
R-11 4.5 (DISCONNECTION IN PANEL CAUTION AND BUZZER SYSTEM) IS DISPLAYED…4580
R-12 5.2 (SHORT CIRCUIT WITH GROUND EXHAUST BRAKE SELECTOR SIGNAL OUTPUT SYSTEM) IS DISPLAYED…4581
R-13 5.3 (SHORT CIRCUIT WITH GROUND IN ARSC CAUTION LAMP SYSTEM) IS DISPLAYED…4582
R-14 5.4 (SHORT CIRCUIT WITH GROUND IN READY OUTPUT CIRCUIT SYSTEM) IS DISPLAYED…4583
R-15 5.5 (SHORT CIRCUIT WITH GROUND IN PANEL CAUTION LAMP AND BUZZER OUTPUT SYSTEM) IS DISPLAYED…4584
R-16 6.0 (FAILURE IN ENGINE SPEED SYSTEM) IS DISPLAYED…4585
R-17 7.0 (DISCONNECTION IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED…4586
R-18 7.1 (DISCONNECTION IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED…4587
R-19 7.2 (DISCONNECTION IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED…4588
R-20 7.3 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY UP OUTPUT SYSTEM) IS DISPLAYED…4589
R-21 7.4 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY DOWN OUTPUT SYSTEM) IS DISPLAYED…4590
R-22 7.5 (SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED DISPLAY CLEAR OUTPUT SYSTEM) IS DISPLAYED…4591
R-23 8.1 (SHORT CIRCUIT WITH GROUND IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED…4592
R-24 8.3 (DISCONNECTION IN PRESSURE CONTROL VALVE SYSTEM) IS DISPLAYED…4593
R-25 8.5 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE REMAINS OPEN)) IS DISPLAYED…4594
R-26 8.7 (FAILURE IN PRESSURE CONTROL VALVE (PRESSURE CONTROL VALVE DOES NOT OPEN)) IS DISPLAYED…4595
R-27 8.9 (SHORT CIRCUIT WITH GROUND IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED…4596
R-28 9.0 (DISCONNECTION IN PRESSURE SWITCH VALVE SYSTEM) IS DISPLAYED…4597
R-29 9.1 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (REMAINS OPEN)) IS DISPLAYED…4598
R-30 9.2 (FAILURE IN PRESSURE SWITCH VALVE SYSTEM (DOES NOT OPEN)) IS DISPLAYED…4599
R-31 9.3 (DISCONNECTION IN SYSTEM SWITCH SYSTEM) IS DISPLAYED…4600
R-32 9.4 (SHORT CIRCUIT WITH GROUND IN SYSTEM SWITCH SYSTEM) IS DISPLAYED…4601
R-33 9.5 (DISCONNECTION,SHORT CIRCUIT WITH GROUND IN TRAVEL SPEED SETTING SWITCH SYSTEM) IS DISPLAYED…4602
R-101 SET SPEED CANNOT BE SET…4603
R-102 FAILURE CODE IS ALWAYS CLEARED (CONTROLLER DISPLAY WINDOW ALWAYS SHOWS ‘–‘) OR FAILURE CODE CANNOT BE CLEARED…4606
R-103 EFFECT OF RETARDER IS TOO STRONG WHEN MACHINE IS EMPTY,OR TOO WEAK WHEN MACHINE IS LOADED (DOES NOT JUDGE LOADED/UNLOADED CONDITION PROPERLY)…4607
R-104 ABNORMALITY APPEARS IN OTHER CONTROLLER…4607
R-105 WHEN TRAVELING DOWNHILL,EVEN WHEN SET SPEED IS EXCEEDED,NO CONTROL IS CARRIED OUT…4608
R-106 MONITOR LAMP (BUZZER) STAYS ON (OR OFF)…4609
R-107 READY LAMP DOES NOT LIGHT UP (OR STAYS LIGHTED UP)…4610
R-108 EXHAUST BRAKE DOES NOT WORK PROPERLY…4612
R-109 THERE IS DIFFERENCE BETWEEN TRAVEL SPEED ROD VALUE AND ACTUAL MACHINE VALUE…4614
R-110 RETARDER LAMP DOES NOT LIGHT UP,OR STAYS LIGHTED UP…4617
R-111 TRAVEL SPEED DISPLAY ALWAYS GIVES DISPLAY (OR DOES NOT GIVE ANY DISPLAY)…4618
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…4619
H-1 MACHINE DOES NOT START…4620
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY …4622
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED…4622
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…4623
H-5 TRANSMISSION DOES NOT SHIFT UP…4623
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…4624
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…4628
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…4630
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…4631
H-10 FRONT BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE…4632
H-11 REAR BRAKE IS INEFFECTIVE,OR EFFECTIVE ONLY ON ONE SIDE…4633
H-12 STEERING WHEEL IS HEAVY…4634
H-13 STEERING WHEEL DOES NOT WORK…4635
H-14 STEERING WHEEL VIBRATES…4635
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)…4636
H-16 HOIST CYLINDER DOES NOT WORK…4637
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…4638
H-18 AIR PRESSURE DOES NOT RISE…4639
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)…4640
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND CONTROLLERS…4642
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE (MONITOR PANEL SYSTEM)…4643
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM…4647
P-1 CHECK PATTERN FOR WIRING HARNESSES BETWEEN MODULES…4649
P-2 NOTHING ON MONITOR PANEL WORKS…4653
P-3 LH,RH MODULE AND FUEL GAUGE DO NOT WORK…4654
P-4 LH,RH MODULE AND FUEL GAUGE DO NOT WORK…4655
P-5 RH MODULE DOES NOT WORK…4656
P-6 LH MODULE DOES NOT WORK…4657
P-7 TRAVEL CALCULATOR DOES NOT WORK…4658
P-8 SERVICE METER DISPLAY DOES NOT WORK CORRECTLY…4659
P-9 CENTRAL WARNING LAMP DOES NOT WORK, OR MONITOR PANEL DETECTS FAILURE CODE [A002]…4660
P-10 CENTRAL WARNING LAMP STAYS LIGHTED UP…4661
P-11 ALARM BUZZER DOES NOT WORK,OR MONITOR PANEL DETECTS FAILURE CODE [A003]…4662
P-12 ALARM BUZZER CONTINUES TO SOUND…4663
P-13 ALL DATA FROM SHIFT CONTROLLER (SPEEDOMETER,TACHOMETER,SHIFT INDICATOR,ETC.) ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE),OR MONITOR PANEL DETECTS SERVICE CODE [A013],OR MONITOR PANEL DETECTS SERVICE CODE [A018]…4664
P-14 SUSPENSION MODE,POWER/ECONOMY MODE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE),OR MONITOR PANEL DETECTS SEVICE CODE [A016]…4665
P-15 GAUGE DISPLAYS ARE ABNORMAL (NOTHING IS DISPLAYED,OR DISPLAY DOES NOT CHANGE)…4666
P-16 COOLANT LEVEL DROP CAUTION LAMPS DOES NOT WORK, OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4667
P-17 COOLANT LEVEL DROP CAUTION LAMP STAYS LIGHTED UP…4668
P-18 EMERGENCY STEERING PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SEVICE CODE [A001]…4669
P-19 EMERGENCY STEERING PILOT LAMP STAYS LIGHTED UP…4670
P-20 ENGINE OIL PRESSURE DROP CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4671
P-21 ENGINE OIL PRESSURE DROP CAUTION LAMP STAYS LIGHTED UP…4672
P-22 EXHAUST BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4673
P-23 EXHAUST BRAKE PILOT LAMP STAYS LIGHTED UP…4674
P-24 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4675
P-25 CHARGING CIRCUIT ABNORMALITY CAUTION LAMP STAYS LIGHTED UP…4676
P-26 TRANSMISSION FILTER CLOGGING CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4677
P-27 TRANSMISSION FILTER CLOGGING CAUTION LAMP STAYS LIGHTED UP…4678
P-28 BRAKE STROKE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4679
P-29 BRAKE STROKE CAUTION LAMP STAYS LIGHTED UP…4680
P-30 PREHEATING SWITCH PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4681
P-31 PREHEATING SWITCH PILOT LAMP STAYS LIGHTED UP…4682
P-32 TILT WARNING LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4683
P-33 TILT WARNING LAMP STAYS LIGHTED UP…4684
P-34 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4685
P-35 BODY FLOAT (EXCEPT FLOAT) PILOT LAMP STAYS LIGHTED UP…4686
P-36 REAR BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4687
P-37 REAR BRAKE PILOT LAMP STAYS LIGHTED UP…4688
P-38 PARKING BRAKE PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4689
P-39 PARKING BRAKE PILOT LAMP STAYS LIGHTED UP…4690
P-40 MAINTENANCE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4691
P-41 MAINTENANCE CAUTION LAMP STAYS LIGHTED UP…4692
P-42 STEERING OIL TEMPERATURE CAUTION LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4693
P-43 STEERING OIL TEMPERATURE CAUTION LAMP STAYS LIGHTED UP…4694
P-44 DIFFERENTIAL LOCK PILOT LAMP DOES NOT WORK,OR MONITOR PANEL DETECTS SERVICE CODE [A001]…4695
P-45 DIFFERENTIAL LOCK PILOT LAMP STAYS LIGHTED UP…4696
P-46 HIGH BEAM DISPLAY DOES NOT LIGHT UP…4697
P-47 TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP…4699
P-48 TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP…4700
P-49 LAMP CHECK SWITCH DOES NOT WORK…4701
P-50 AISS SWITCH DOES NOT WORK…4702
P-51 EXHAUST BRAKE SWITCH DOES NOT WORK…4703
P-52 MODE CHANGE SWITCH (1) DOES NOT WORK…4704
P-53 MODE CHANGE SWITCH (2) DOES NOT WORK…4705
P-54 KPH/MPH SPEEDOMETER UNIT SELECTOR DOES NOT WORK…4706
P-55 DEFECTIVE OPERATION OF ALL SWITCH INPUTS…4707
P-56 MONITOR PANEL DETECTS SERVICE CODES [A014] OR [A019]…4708
P-57 MONITOR PANEL DETECTS SERVICE CODE [A015]…4709
P-58 MONITOR PANEL DETECTS SERVICE CODE [A011]…4710
P-59 MONITOR PANEL DETECTS SERVICE CODE [A012]…4710
P-60 MONITOR PANEL DETECTS SERVICE CODE [A000]…4710
TROUBLESHOOTING OF PMC SYSTEM (M MODE)…4711
PMC RELATED ELECTRIC CIRCUIT DIAGRAM…4713
REMOVAL…4942
INSTALLATION…4944
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY…4945
TORQUE CONVERTER, CONTROL VALVE…4946
REMOVAL AND INSTALLATION…4946
DISASSEMBLY AND ASSEMBLY…4947
TORQUE CONVERTER AND TRANSMISSION…4948
DISCONNECTION…4948
CONNECTION…4949
TORQUE CONVERTER, PTO…4950
DISASSEMBLY…4950
ASSEMBLY…4956
TRANSMISSION…4962
DISASSEMBLY…4962
ASSEMBLY…4976
ECMV…4993
DISASSEMBLY AND ASSEMBLY…4993
DIFFERENTIAL (FOR STANFARD DIFFERENTIAL)…4995
REMOVAL…4995
INSTALLATION…4996
DISASSEMBLY…4997
ASSEMBLY…5001
DIFFERENTIAL (WITH DIFFERENTIAL LOCK)…5010
REMOVAL…5010
INSTALLATION…5011
DISASSEMBLY…5012
ASSEMBLY…5017
FRONT WHEEL…5027
REMOVAL AND INSTALLATION…5027
REAR WHEEL…5028
REMOVAL…5028
INSTALLATION…5029
FRONT BRAKE CALIPER …5030
REMOVAL AND INSTALLATION…5030
DISASSEMBLY…5031
ASSEMBLY…5032
FRONT BRAKE CALIPER PAD…5034
REMOVAL AND INSTALLATION…5034
FRONT WHEEL HUB…5035
DISASSEMBLY…5035
ASSEMBLY…5037
FINAL DRIVE CARRIER…5040
REMOVAL AND INSTALLATION…5040
DISASSEMBLY AND ASSEMBLY…5041
FINAL DRIVE…5042
DISASSEMBLY…5042
ASSEMBLY…5044
REAR BRAKE…5046
REMOVAL AND INSTALLATION…5046
REAR WHEEL BRAKE…5047
DISASSEMBLY…5047
ASSEMBLY…5048
PARKING BRAKE PAD…5050
REMOVAL…5050
INSTALLATION…5051
PARKING BRAKE CALIPER…5052
REMOVAL AND INSTALLATION…5052
DISASSEMBLY AND ASSEMBLY…5053
FRONT SUSPENDION CYLINDER…5054
REMOVAL AND ISNTALLATION…5054
DISASSEMBLY (STANDARD CYLINDER)…5055
ASSEMBLY (STANDARD CYLINDER)…5056
DISSASSEMBLY (CYLINDER WITH BUFFER RING)…5057
ASSEMBLY (CYLINDER WITH BUFFER RING)…5058
KING PIN…5060
REMOVAL AND INSTALLATION…5060
VARIBLE DAMPING SELECTIOR VALVE …5061
DISASSEMBLY…5061
ASSEMBLY…5062
REAR SUSPENSION CYLINDER…5063
REMOVAL AND INSTALLATION…5063
DISASSEMBLY (STANDARD CYLINDER)…5064
ASSEMBLY (STANDARD CYLINDER)…5065
DISASSEMBLY (CYLINDER WITH BUFFER RING)…5066
ASSEMBLY (CYLINDERWITH BUFFER RING)…5067
AIR GOVERNOR…5068
REMOVAL AND INATALLATION…5068
DISASSEMBLY AND ASSEMBLY…5069
BRAKE VALVE…5070
REMOVAL AND INSTALLATION…5070
DISASSEMBLY…5071
ASSEMBLY…5073
PARKING VRAKE CHAMBER…5075
REMOVAL AND INSTALLATION…5075
DISASSEMBLY…5076
ASSEMBLY…5077
REAR BRAKE VHAMBER…5079
REMOVAL AND INSTALLATION…5079
DISASSEMBLY…5080
ASSEMBLY…5084
FRONT BRAKE CHAMBER…5087
DISASSEMBLY…5087
ASSEMBLY…5089
SLACK ADJUSTER…5091
REMOVAL AND INSTALLATION…5091
DISASSEMBLY AND ASSEMBLY…5092
AIR DRIER (DESICCANT TYPE)…5093
REMOVAL AND INSTALLATION…5093
DISASSEMBLY AND ASSEMBLY…5094
BRAKE COLLING PUMP…5111
REMOVAL AND INSTALLATION…5111
STEERING, HOIST PUMP …5112
REMOVAL AND INSTALLATION…5112
TORQUE CONVERTER, TRANSMISSION PUMP…5113
REMOVAL AND INSTALLATION…5113
EMERGENCY STEERING MOTOR PUMP…5114
REMOVAL AND INSTALLATION…5114
STEERING VALVE…5115
REMOVAL AND INSTALLATION…5115
DISASSEMBLY…5116
ASSEMBLY…5120
BRAKE CONTROL VALVE (BCV)…5127
REMOVAL AND INSTALLATION…5127
DEMAND VALVE…5128
REMOVAL AND INSTALLATION…5128
DISASSEMBLY AND ASSEMBLY…5129
RELIEF VALVE…5130
DISASSEMBLY AND ASSEMBLY…5130
HOIST VALVE…5131
REMOVAL AND INSTALLATION…5131
DISASSEMBLY AND ASSEMBLY…5132
STEERING CYLINDER…5134
REMOVAL AND INSTALATION…5134
DISASSEMBLY…5135
ASSEMBLY…5137
HOIST CYLINDER…5140
REMOVAL AND INSTALLATION…5140
DISASSEMBLY…5141
ASSEMBLY…5142
BODY…5143
REMOVAL…5143
INSTALLATION…5144
CONTROLLER…5145
REMOVAL AND INSTALLATION…5145
AIR CONITIONER COMPRESSOR…5146
REMOVAL AND INSTALLATION…5146
RECEIVER TAKE…5147
REMOVAL AND INSTALLATION…5147
AIR CONDITIONER CONDENSER…5148
REMOVAL AND INSTALLATION…5148
40 MAINTENANCE STANDARD…5149
OUTPUT SHAFT…5150
TURQUE CONVERTER VALVE…5151
TORQUE CONVERTER…5152
TRANSMISSION…5154
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…5159
FRONT AXLE…5160
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED)…5162
REAR AXLE SUPPORT (HD785-5)…5163
REAR AXLE SUPPORT (HD985-5)…5164
DIFFERENTIAL…5165
FINAL DRIVE (HD785-5)…5167
FINAL DRIVE (HD985-5)…5170
FRONT BRAKE…5172
REAR BRAKE…5173
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED)…5175
PARKING BRAKE…5177
STEERING LINKAGE…5178
FRONT SUSPENSION CYLINDER…5180
REAR SUSPENSION CYLINDER…5181
PARKING BRAKE CHAMBER…5182
SLACK ADJUSTER…5183
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION)…5184
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING)…5185
DEMAND VALVE…5186
CROSS-OVER RELIEF VALVE…5186
HOIST VALVE…5187
STEERING CYLINDER…5188
HOIST CYLINDER…5189
90 OTHERS…5190
ELECTRICAL CIRCUIT DIAGRAM …5191
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3)…5191
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3)…5192
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3)…5193
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5)…5194
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (2/5)…5195
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (3/5)…5196
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (4/5)…5197
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (5/5)…5198
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)…5199
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)…5200
ELECTRICAL CONTROL SYSTEM…5201
ELECTRICAL CIRCUIT DIAGRAM…5201
AUTOMATIC SHIFT CONTROL SYSTEM…5202
ELECTRICAL CIRCUIT DIAGRAM (1/2)…5202
ELECTRICAL CIRCUIT DIAGRAM (2/2)…5203
AUTOMATIC SUSPENSION SYSTEM…5204
SYSTEM CIRCUIT DIAGRAM (1/2)…5204
SYSTEM CIRCUIT DIAGRAM (2/2)…5205
PAYLOAD METER (PRINTER TYPE) (OP)…5206
ELECTRICAL CIRCUIT DIAGRAM…5206
PAYLOAD METER Ⅱ(CARD TYPE) (OP)…5207
ELECTRICAL CIRCUIT DIAGRAM…5207
PMC SYSTEM (OP)…5208
ELECTRICAL CIRCUIT DIAGRAM (1/2)…5208
ELECTRICAL CIRCUIT DIAGRAM (2/2)…5210
ASR-Ⅱ SYSTEM (OP)…5210
ELECTRIAL CIRCUIT DIAGRAM…5210
AIR CIRCUIT DIAGRAM…5211
ELECTRICAL CIRCUIT DIAGRAM…5212
ENGINE CONTROL SYSTEM…5212
TRANSMISSION CONTROL SYSTEM…5213
1. ELECTRIC GOVENOR SPECIFICATION…5213
2. MECHANICAL GOVENOR SPECIFICATION…5214
4-4. ELECTRICAL CIRCUIT DIAGRAM…5215
SEBM05610311 – Dump Truck HD785-3, HD985-3 Shop Manual…5216
COVER PAGE…5216
CONTENTS…5217
10 STRUCTURE AND FUNCTION…5242
RADIATOR, TORQUE CONVERTER OIL COOLER…5244
BRAKE OIL COOLER…5245
POWER TRAIN SKELETON…5246
OUTPUT SHAFT…5247
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…5248
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM…5249
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS…5250
HYDRAULIC PUMP (SAR4-160)…5251
TORQUE CONVERTER (HD785-3)…5252
TORQUE CONVERTER (HD985-3)…6072
TORQUE CONVERTER VALVE…5254
LOCKUP SOLENOID VALVE…5259
TRANSMISSION (HD785-3)…5260
TRANSMISSION (HD985-3)…6074
TRANSMISSION VALVE…5262
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…5263
LUBRICATION RELIEF VALVE…5268
FRONT AXLE (HD785-3)…5269
FRONT AXLE (HD985-3)…6076
REAR AXLE (HD785-3)…5270
REAR AXLE (HD985-3)…6077
DIFFERENTIAL…5271
DIFFERENTIAL LOCK CONTROL…5272
STRUCTURE OF SYSTEM…5273
DIFFERENTIAL LOCK SYSTEM DIAGRAM…5274
SWITCH…5274
DIFFERENTIAL LOCK SOLENOID VALVE…5275
FINAL DRIVE (HD785-3)…5276
FINAL DRIVE (HD985-3)…6078
FRONT BRAKE…5277
REAR BRAKE…5278
PARKING BRAKE…5279
WHEELS (HD785-3)…5281
WHEELS (HD985-3)…6079
AXLE SUPPORT (HD785-3)…5282
AXLE SUPPORT (HD985-3)…6080
STEERING SYSTEM (HD785-3)…5283
STEERING SYSTEM (HD985-3)…6081
STEERING WHEEL…5284
STEERING LINKAGE…5285
SUSPENSION SYSTEM…5287
SUSPENSION CYLINDER…5289
FRONT SUSPENSION CYLINDER…5291
REAR SUSPENSION CYLINDER (HD785-3)…5294
REAR SUSPENSION CYLINDER (HD985-3)…6082
AIR CIRCUIT DIAGRAM…5295
AIR PIPING…5299
AIR GOVERNOR…5301
SAFETY VALVE…5303
CHECK VALVE…5303
DOUBLE-CHECK VALVE…5304
AUTO DRAIN VALVE…5305
HAND BRAKE VALVE (RETARDER CONTROL VALVE)…5306
BRAKE VALVE…5308
2-WAY CONTROL VALVE (PARKING BRAKE VALVE, EMERGENCY BRAKE VALVE)…5311
EMERGENCY BRAKE CONTROL VALVE (VARIABLE CONTROL TYPE)…5313
PARKING BRAKE PILOT VALVE…5316
RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)…5317
PARKING BRAKE RELAY VALVE…5320
QUICK-RELEASE VALVE…5322
BRAKE CHAMBER…5323
PARKING BRAKE CHAMBER…5325
SLACK ADJUSTER…5326
HYDRAULIC PIPING (STEERING AND HOIST, AND BRAKE COOLING)…5328
HYDRAULIC CIRCUIT DIAGRAM (STEERING AND HOIST, AND BRAKE COOLING)…5329
DUMP BODY CONTROL…5330
HYDRAULIC TANK AND BRAKE COOLING OIL TANK…5331
HYDRAULIC PUMP…5332
BRAKE COOLING OIL CONTROL VAVLE (BCV)…5333
STEERING VALVE…5334
CROSSOVER RELIEF VALVE…5338
DEMAND VALVE…5339
HOIST VALVE…5343
STEERING CYLINDER…5345
HOIST CYLINDER…5345
DUMP BODY (HD785-3)…5346
DUMP BODY (HD985-3)…6084
MAIN FRAME (HD785-3)…5346
MAIN FRAME (HD985-3)…6084
PRESSURE SWITCH…5347
STOP LAMP SWITCH…5347
HORN VALVE…5348
PARKING BRAKE SWITCH…5348
FRONT BRAKE CUT-OFF VALVE…5349
AUTOMATIC RETARDER VALVE…5350
EXHAUST BRAKE VALVE…5350
TILT SWITCH…5351
AIR CONDITIONER…5352
PIPING DIAGRAM…5352
ELECTRICAL CIRCUIT DIAGRAM…5353
REFRIGERANT CIRCUIT DIAGRAM…5353
CONDENSER…5354
COMPRESSOR…5354
ENGINE CONTROL SYSTEM (MECHANICAL GOVERNOR TYPE)…5355
ELECTRICAL CIRCUIT DIAGRAM…5356
HYDRAULIC CIRCUIT DIAGRAM…5356
SERVO CYLINDER…5357
AISS (AUTOMATIC IDLING SETTING SYSTEM)…5358
ENGINE CONTROL SYSTEM (ELECTRONIC GOVERNOR)…5359
SYSTEM DIAGRAM…5359
ELECTRIC CIRCUIT DIAGRAM…5360
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR…5361
HYDRAULIC CIRCUIT DIAGRAM…5362
AISS (AUTOMATIC IDLING SETTING SYSTEM)…5362
ENGINE CONTROLLER…5363
SENSORS, SWITCHES…5363
ACCELERATOR SENSOR…5363
ENGINE SPEED SENSOR…5363
EXHAUST BRAKE…5364
SYSTEM DIAGRAM…5364
AUTOMATIC SHIFT CONTROL SYSTEM…5367
TRANSMISSION CONTROLLER…5368
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES…5369
SHIFT LEVER SWITCH…5372
SENSORS, SWITCHES…5373
TRANSMISSION SPEED SENSOR…5373
TRANSMISSION OIL TEMPERATURE SENSOR…5373
FILL SWITCH…5374
ACCELERATOR SENSOR…5374
SHIFT LIMIT SWITCH…5375
MODE SELECTOR SWITCH…5375
SHIFT INDICATOR SYSTEM…5376
SHIFT INDICATOR…5377
AUTOMATIC EMERGENCY STEERING SYSTEM (HD785-3)…5380
AUTOMATIC EMERGENCY STEERING SYSTEM (HD985-3)…6085
ELECTRICAL CIRCUIT DIAGRAM…5381
FLOW SWITCH…5382
RELAY TIMER…5384
AUTOMATIC SUSPENSION SYSTEM…5385
AUTOMATIC SUSPENSION MODE SELECTION CONTROL…5387
SUSPENSION CONTROLLER…5388
SENSORS, SWITCHES…5389
STEERING ANGLE SENSOR…5389
PRESSURE SENSOR…5389
PAYLOAD METER…5390
STRUCTURE OF SYSTEM…5390
ELECTRICAL CIRCUIT DIAGRAM…5391
PRINCIPLE OF CALCULATION…5392
FEATURES OF EQUIPMENT…5394
ELECTRONIC MONITOR SYSTEM…5399
ELECTRONIC MONITOR PANEL…5400
ELECTRONIC MONITOR DISPLAYS, FUNCTIONS…5401
SENSORS, SWITCHES…5404
ENGINE SPEED SENSOR…5404
ENGINE OIL PRESSURE SENSOR…5404
ENGINE WATER TEMPERATURE SENSOR…5405
RETARDER OIL TEMPERATURE SENSOR…5405
TORQUE CONVERTER OIL TEMPERATURE SENSOR…5405
AIR PRESSURE SENSOR…5405
FUEL LEVEL SENSOR…5406
MAINTENANCE MONITOR SYSTEM…5407
SYSTEM DIAGRAM…5407
MONITOR PANEL…5408
MONITOR DISPLAY, FUNCTIONS…5409
FUNCTIONS OF SWITCHES…5411
SENSORS, SWITCHES…5413
ENGINE OIL LEVEL SENSOR…5413
RADIATOR WATER LEVEL SENSOR…5413
TRANSMISSION OIL LEVEL SENSOR…5413
HYDRAULIC OIL LEVEL SENSOR…5414
RETARDER OIL LEVEL SENSOR…5414
AIR FILTER CLOGGING SENSOR…5414
RETARDER BRAKE WEAR SENSOR…5415
HYDRAULIC FILTER SENSOR…5415
RETARDER OIL FILTER SENSOR…5415
TRANSMISSION OIL FILTER SENSOR…5415
BATTERY ELECTROLYTE LEVEL SENSOR…5416
ABS/ACR SYSTEM…5417
ABS/ASR CONTROLLER (ECU)…5424
ABS PRESSURE CONTROL VALVE…5425
ASR CONTROL VALVE…5428
WHEEL SPEED SENSOR…5430
20 TESTING AND ADJUSTING…5431
STANDARD VALUE TABEL FOR ENGINE RELATED PARTS (HD785-3)…5432
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS (HD985-3)…6088
STANDARD VALUE TABLE FOR CHASSIS (HD785-3)…5433
STANDARD VALUE TABLE FOR CHASSIS (HD985-3)…6089
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…5438
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…5445
ADJUSTING VALVE CLEARANCE…5447
MEASURING COMPRESSION PRESSURE…5448
MEASURING BLOWBY PRESSURE…5449
CHECKING AND ADJUSTING FUEL INJECTION TIMING…5450
ADJUSTING ACCELERATOR PEDAL…5455
ADJUSTING OF AISS LINKAGE…5456
ADJUSTING ENGINE STOP MOTOR CABLE…5456
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE…5457
TESTING ECMV HYDRAULIC PRESSURE …5458
TESTING TRANSMISSION LUBRICATION PRESSURE…5461
TESTING TORQUE CONVERTER STALL SPEED…5462
TESTING BRAKE PRESSURE…5464
BLEEDING AIR FROM BRAKE CIRCUIT…5465
TESTING WEAR OF FRONT BRAKE PAD…5466
TESTING WEAR OF REAR BRAKE DISC…5466
ADJUSTING PARKING BRAKE…5467
TESTING BRAKE PERFORMANCE…5468
TESTING AND ADJUSTING SUSPENSION CYLINDER…5469
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER…5478
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT…5479
ADJUSTING HOIST LEVER LINKAGE…5480
ADJUSTING BODY POSITIONER…5481
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…5482
AIR BLEEDING FROM STEERING CYLINDER…5484
ADJUSTING ENGINE SPEED SENSOR…5485
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER…5486
PROCEDURE FOR OPERATING SHIFT CHECKER AND MODULATION CHECKER…5488
METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMISSION CONTROL SYSTEM OR ENGINE C…5510
TROUBLESHOOTING…5513
POINTS TO REMEMBER WHEN TROUBLESHOOTING…5514
SEQUENCE OF EVENTS IN TROUBLESHOOTING…5515
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…5516
HANDLING CONNECTORS…5523
CHECKS BEFORE TROUBLESHOOTING…5524
METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES…5526
METHOD OF USING JUDGEMENT TABLE…5530
EXPLANATION OF FUNCTIONS OF ELECTRICAL SYSTEM (CONTROL MECHANISM)…5534
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND EACH CONTROLLER…5538
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (TRANSMISSION CONTROLLER SYSTEM)…5544
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (SUSPENSION CONTROLLER SYSTEM)…5550
ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (ENGINE CONTROLLER SYSTEM)…5551
TYPE AND LOCATION OF CONNECTOR, SENSOR (HD785-3)…5553
TYPE AND LOCATION OF CONNECTOR, SENSOR (HD985-3)…6094
CONNECTION TABLE FOR CONNECTOR…5570
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (FOR ENGINES WITH MECHANICAL GOVERNOR)…5581
G-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)…5582
G-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT FULL POSITION)…5583
G-3 DEFECTIVE OPERATION OF AISS…5584
A) STAYS AT LOW IDLING (HIGH SPEED) WHEN AISS SWITCH IS ON…5584
B) STAYS AT LOW IDLING (LOW SPEED) WHEN AISS SWITCH IS OFF…5584
C) STAYS AT LOW IDLING (HIGH SPEED) WHEN AISS SWITCH IS OFF…5585
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START AND STOP…5586
AISS ELECTRICAL CIRCUIT DIAGRAM…5586
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) (HD785-3)…5587
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) (HD985-3)…6103
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS…5589
G-1 ABNORMALITY IN POWER SOURCE SYSTEM…5590
G-2 ABNORMALITY IN CONTROLLER SYSTEM…5591
G-3(A) ABNORMALITY IN RIGHT BANK RACK SENSOR SYSTEM…5592
G-3(B) ABNORMALITY IN LEFT BANK RACK SENSOR SYSTEM…5593
G-4(A) ABNORMALITY IN RIGHT BANK GOVERNOR SOLENOID SYSTEM…5594
G-4(B) ABNORMALITY IN LEFT BANK GOVERNOR SOLENOID SYSTEM…5595
G-5(A) ABNORMALITY IN RIGHT BANK GOVERNOR RELAY SYSTEM…5596
G-5(B) ABNORMALITY IN LEFT BANK GOVERNOR CUT RELAY SYSTEM…5597
G-6(A) ABNORMALITY IN RIGHT BANK PRE-STROKE SOLENOID SYSTEM…5598
G-6(B) ABNORMALITY IN LEFT BANK PRE-STROKE SOLENOID SYSTEM…5599
G-7 ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM…5600
G-8(A) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM…5601
G-8(B) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM…5602
G-9 ABNORMALITY IN ACCELERATOR SENSOR…5603
G-10 ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM…5605
G-11(A) ABNORMALITY IN RIGHT BANK GOVERNOR SERVO SYSTEM…5606
G-11(B) ABNORMALITY IN LEFT BANK GOVERNOR SERVO SYSTEM…5606
G-12 ENGINE DOES NOT START…5607
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM…5610
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (HD785-3)…5611
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (HD985-3)…6127
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…5613
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…5614
A-1 ABNORMALITY IN POWER SOURCE…5615
A) (OFF) SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP…5615
B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED…5617
C) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED…5618
A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED…5619
A-3 ABNORMALITY IN CONTROLLER SYSTEM…5620
A) ONLY DOT LIGHTS UP OR ABNORMALITY IN CONTROLLER DISPLAYED…5620
B) DOUBLE SYSTEM FOR CLUTCH IS DISPLAYED…5621
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED…5622
A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM IS DISPLAYED…5623
A-6 ABNORMALITY IN SPEED SENSOR SYSTEM…5625
A) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED…5625
B) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED…5627
C) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) DISPLAYED…5628
A-7 SPEED SENSOR SYSTEM, CLUTCH SLIPPING…5629
A) INPUT SHAFT SENSOR OR H.L. CLUTCH SYSTEM DISPLAYED…5629
B) TRAVEL SPEED SENSOR OR SPEED CLUTCH (1,2,3,4,R) SYSTEM DISPLAYED…5630
A-8 ABNORMALITY IN MODEL SELECTION DISPLAYED…5631
A-9 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM…5632
A) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED…5632
B) TRANSMISSION SHIFT LEVER POSITION SIGNAL DISPLAYS 2-SYSTEM ABNORMAL INPUT…5633
C) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT…5638
A-10 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED…5639
A-11 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED…5642
A-12 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM…5643
A) FILL SIGNAL DISPLAYS ON REGARDLESS OF COMMAND…5643
B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED…5644
1) WHEN 42.43 IS DISPLAYED…5646
2) WHEN 44-48 IS DISPLAYED…5646
A-13 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)…5647
A-14 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED…5648
OR A-14 DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED…5648
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM…5650
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM…5652
JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS…5653
S-1 ABNORMALITY IN POWER SOURCE SYSTEM…5654
S-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM…5655
S-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM…5657
S-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM…5659
S-5 ABNORMALITY IN STEERING SENSOR SYSTEM…5660
S-6 ABNORMALITY IN MODEL SELECTION SYSTEM…5661
S-7 ABNORMALITY IN SOLENOID [1] SYSTEM…5662
S-8 ABNORMALITY IN SOLENOID [11] SYSTEM…5663
S-9 ABNORMALITY IN SOLENOID [111] SYSTEM…5664
S-10 ABNORMALITY IN CONTROLLER…5665
ELECTRICAL CIRCUIT DIAGRAM FOR SUSPENSION CONTROL SYSTEM…5666
TROUBLESHOOTING OF PAYLOAD METER SYSTEM…5667
L-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY APPEARS…5668
L-2 AFTER THE STARTING SWITCH IS TURNED ON, THE DEMAND FOR CALIBRATION (CAL FLASHES) CONTINUES TO BE GIVEN…5668
L-3 CALIBRATION CANNOT BE CARRIED OUT…5669
L-4 AFTER THE STARTING SWITCH IS TURNED ON, THE EXTERNAL DISPLAY LAMPS DO NOT ALL LIGHT UP…5671
L-5 EXTERNAL DISPLAY LAMPS LIGHT UP EVEN WHEN IT IS NOT THE CONDITION FOR LIGHTING UP…5671
L-6 THE LEVEL OF LIGHTING UP OF THE EXTERNAL DISPLAY LAMPS IS NOT CORRECT…5672
L-7 THERE IS ABNORMALITY IN THE DISPLAY LOGIC…5673
A) EVEN WHEN THE DUMP BODY IS OPERATED, THE DISPLAY DOES NOT BECOME 0 TONS…5673
B) THE DISPLAY STAYS AT 0 TONS AND DOES NOT CHANGE…5673
C) WHEN THE TRANSMISSION LEVER IS AT NEUTRAL, THE WEIGHT DISPLAY IS NOT GIVEN (TIME DISPLAY IS GIVEN)…5674
D) WHEN THE TRANSMISSION LEVER IS AT A POSITION OTHER THAN NEUTRAL, THE TIME DISPLAY IS NOT GIVEN…5676
L-8 E01-E04 IS DISPLAYED…5677
L-9 E11-E14 IS DISPLAYED…5678
L-10 E21-E28 IS DISPLAYED BY SENSOR CHECK…5678
L-11 E31 IS DISPLAYED…5679
L-12 E32 IS DISPLAYED…5681
L-13 E41 IS DISPLAYED…5681
L-14 E42 IS DISPLAYED…5682
L-15 THE PRINTER DOES NOT PRINT ANYTHING (ONLY BLANK PAPER COMES OUT)…5682
L-16 THE PRINTER ONLY PRINTS NO DATA…5683
L-17 EVEN WHEN THE [PRT] SWITCH IS PRESSED NOTHING IS PRINTED OUT…5683
L-18 PAPE FLASHES…5684
L-19 THE TIME IS WRONG…5684
L-20 E33 IS DISPLAYED…5684
RELATED ELECTRICAL CIRCUIT DIAGRAMS…5685
ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM…5688
TROUBLESHOOTING OF PILOT LAMP SYSTEM…5689
F-1 ABNORMALITY IN LIGHTING UP OF REAR BRAKE LAMP…5690
A) BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHTS UP…5690
B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN BRAKE IS APPLIED…5691
F-2 ABNORMALITY IN LIGHTING UP OF BODY FLOAT PILOT LAMP…5693
A) HOIST LEVER IS AT FLOAT POSITION, BUT PILOT LAMP LIGHTS UP…5693
B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN HOIST LEVER IS OPERATED…5694
F-3 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP…5695
A) PARKING BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHTS UP…5695
B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE IS APPLIED…5696
F-4 ABNORMAL LIGHTING UP OF EXHAUST BRAKE PILOT LAMP…5697
A) PILOT LAMP LIGHTS UP EVEN WHEN EXHAUST BRAKE IS NOT BEING OPERATED…5697
B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN EXHAUST BRAKE IS BEING OPERATED…5698
F-5 ABNORMAL ACTUATION OF AISS…5699
A) WHEN AISS SWITCH IS ON, IT DOES NOT BECOME LOW IDLING (LOW SPEED)…5699
B) WHEN AISS SWITCH IS ON, IT DOES NOT BECOME LOW IDLING (HIGH SPEED)…5699
ELECTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP CIRCUIT…5701
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (HD785-3)…5702
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (HD985-3)…6166
P-1 MONITOR PANEL DOES NOT WORK AT ALL…5704
P-2 PART OF MONITOR PANEL DOES NOT WORK…5705
A) SPEEDOMETER DISPLAY DOES NOT WORK…5705
B) SPEEDOMETER DISPLAY WORKS, BUT OTHER PARTS DO NOT WORK…5705
C) SUSPENSION DISPLAY DOES NOT WORK…5705
D) (MECHATRONICS) CAUTION, FUEL GAUGE DISPLAYS DO NOT WORK…5706
P-3 AUTOMATIC SHIFT DISPLAY (MECHATRONICS) FLASHES…5707
P-4 SUSPENSION (MECHATRONICS) DISPLAY FLASHES…5707
P-5 ABNORMALITY IN SUSPENSION DISPLAY…5708
A) HARD DISPLAY DOES NOT LIGHT UP…5708
B) MEDIUM DISPLAY DOES NOT LIGHT UP…5708
C) SOFT DISPLAY DOES NOT LIGHT UP…5709
D) SUSPENSION MODE DISPLAYS ALL LIGHT UP…5709
P-6 ABNORMALITY IN SHIFT POSITION DISPLAY…5710
A) R DISPLAY DOES NOT LIGHT UP…5710
B) N DISPLAY DOES NOT LIGHT UP…5710
C) D DISPLAY DOES NOT LIGHT UP…5711
D) 5 DISPLAY DOES NOT LIGHT UP…5711
E) 4 DISPLAY DOES NOT LIGHT UP…5712
F) 3 DISPLAY DOES NOT LIGHT UP…5712
G) L DISPLAY DOES NOT LIGHT UP…5713
P-7 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP…5714
P-8 LOCK-UP DISPLAY DOES NOT LIGHT UP…5714
P-9 HI BEAM DISPLAY DOES NOT LIGHT UP…5715
P-10 ABNORMALITY IN TURN SIGNAL…5716
A) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP…5716
B) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP…5716
P-11 ABNORMALITY IN SHIFT INDICATOR DISPLAY…5717
A) WHEN 1,2,4,5,R IS DISPLAYED, DISPLAY CHANGES TO E…5717
B) WHEN 3,5,7 IS DISPLAYED, DISPLAY CHANGES TO E…5717
C) WHEN 1 IS DISPLAYED, DISPLAY CHANGES TO E…5718
D) WHEN 2, 3 IS DISPLAYED, DISPLAY CHANGES TO E…5718
E) WHEN 4, 5 IS DISPLAYED, DISPLAY CHANGES TO E…5719
F) WHEN 6, 7 IS DISPLAYED, DISPLAY CHANGES TO E…5719
G) WHEN R IS DISPLAYED, DISPLAY CHANGES TO E…5720
P-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY…5721
P-13 TACHOMETER DISPLAY DOES NOT WORK NORMALLY…5721
P-14 SERVICE METER DOES NOT WORK…5722
P-15 ODOMETER DOES NOT WORK…5722
P-16 ABNORMALITY IN ALARM BUZZER…5723
A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT SOUND…5723
B) ALARM BUZZER CONTINUES TO SOUND…5723
P-17 ABNORMALITY IN WARNING LAMP…5724
A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT WARNING LAMP DOES NOT FLASH…5724
B) WARNING LAMP STAYS ON…5724
P-18 CAUTION DISPLAY DOES NOT FLASH (DOES NOT LIGHT UP), BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS…5725
A) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS…5725
B) WARNING LAMP FLASHES WHEN ENGINE STOPS…5725
C) WARNING LAMP FLASHES WHEN ENGINE IS RUNNING…5725
P-19 ABNORMALITY IN AIR PRESSURE GAUGE…5726
A) NO DISPLAY GIVEN IN DISPLAY AREA…5726
B) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE…5726
P-20 ABNORMALITY IN COOLANT TEMPERATURE GAUGE…5727
A) NO DISPLAY GIVEN IN DISPLAY AREA…5727
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…5727
P-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE…5728
A) NO DISPLAY GIVEN IN DISPLAY AREA…5728
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…5728
P-22 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE…5729
A) NO DISPLAY GIVEN IN DISPLAY AREA…5729
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…5729
P-23 ABNORMALITY IN FUEL GAUGE…5730
A) NO DISPLAY GIVEN IN DISPLAY AREA…5730
B) DISPLAY SHOWS FULL AND DOES NOT MOVE…5730
P-24 ABNORMALITY IN NIGHT LIGHTING (ABNORMALITY ONLY IN NIGHT LIGHTING OF MONITOR PANEL)…5731
A) NONE OF PANEL LAMPS LIGHT UP…5731
B) SERVICE METER AND ODOMETER LIGHT UP, BUT OTHER PARTS DO NOT LIGHT UP…5732
C) SERVICE METER AND ODOMETER DO NOT LIGHT UP…5732
P-25 ENGINE (MECHATRONICS) DISPLAY FLASHES…5733
P-26 ABNORMALITY IN POWER MODE DISPLAY…5734
A) HIGH POWER DISPLAY DOES NOT LIGHT UP…5734
B) ECONOMY DISPLAY DOES NOT LIGHT UP…5734
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM…5735
RELATED ELECTRICAL CIRCUIT DIAGRAMS…5737
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (HD785-3)…5746
TROUBLESHOOTING MAINTENANCE MONITOR SYSTEM (HD985-3)…6208
M-1 MAINTENANCE MONITOR DOES NOT WORK…5747
A) WHEN NOTHING WORKS…5747
B) WHEN CHECK DISPLAY DOES NOT WORK…5747
M-2 WHEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES…5748
M-3 WHEN ENGINE IS STOPPED, TRANSMISSION OIL LEVEL DISPLAY FLASHES…5749
M-4 WHEN ENGINE IS STOPPED HYDRAULIC OIL LEVEL DISPLAY FLASHES…5750
M-5 WHEN ENGINE IS STOPPED RETARDER OIL LEVEL DISPLAY FLASHES…5751
M-6 WHEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES…5752
M-7 WHEN ENGINE IS STOPPED, BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES…5753
M-8 AT NEUTRAL, RETARDER WEAR DISPLAY FLASHES…5754
M-9 WHEN ENGINE IS RUNNING, AIR CLEANER CLOGGING DISPLAY FLASHES…5755
M-10 WHEN ENGINE IS RUNNING, FULL-FLOW FILTER CLOGGING DISPLAY FLASHES…5756
M-11 WHEN ENGINE IS RUNNING, TRANSMISSION FILTER CLOGGING DISPLAY FLASHES…5757
M-12 WHEN ENGINE IS RUNNING, HYDRAULIC FILTER CLOGGING DISPLAY FLASHES…5758
M-13 WHEN ENGINE IS RUNNING, RETARDER FILTER CLOGGING DISPLAY FLASHES…5759
M-14 MAINTENANCE TIMER DOES NOT WORK (TIME DOES NOT ADVANCE)…5760
M-15 MAINTENANCE TIMER IS NOT OH OR BELOW, BUT MAINTENANCE ITEM LIGHTS UP…5760
M-16 ABNORMALITY IN SWITCH…5761
A) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK…5761
B) REPLACEMENT SWITCH, MISOPERATION CANCEL SWITCH DO NOT WORK…5761
M-17 NIGHT LIGHTING DOES NOT LIGHT UP (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)…5762
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM…5763
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM…5764
H-1 MACHINE DOES NOT MOVE…5765
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY…5767
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED…5767
H-4 LARGE SHOCK WHEN STARTING OF SHIFTING…5768
H-5 TRANSMISSION DOES NOT SHIFT UP…5768
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELLING…5769
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…5775
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…5777
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…5778
H-10 FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE…5779
H-11 REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE…5780
H-12 STEERING WHEEL IS HEAVY…5781
H-13 STEERING WHEEL DOES NOT FUNCTION…5782
H-14 STEERING WHEEL VIBRATES…5782
H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)…5783
H-16 HOIST CYLINDER DOES NOT WORK…5784
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…5785
H-18 AIR PRESSURE DOES NOT RISE…5786
30 DISASSEMBLY AND ASSEMBLY…5787
METHOD OF USING MANUAL…5789
PRECAUTIONS WHEN CARRYING OUT OPERATION…5790
SPECIAL TOOL LIST…5792
TIGHTENING TORQUES AND STANDARD VALUES TABLE…5794
WEIGHT TABLE…5798
LUBRICANT AND COOLANT TABLE…5799
STARTING MOTOR…5800
REMOVAL…5800
INSTALLATION…5800
ALTERNATOR…5800
REMOVAL…5800
INSTALLATION…5800
ENGINE OIL COOLER…5800
REMOVAL…5800
INSTALLATION…5800
FUEL INJECTION PUMP (LEFT AND RIGHT)…5802
REMOVAL…5802
INSTALLATION…5802
AIR COMPRESSOR…5802
REMOVAL…5802
INSTALLATION…5802
WATER PUMP …5804
REMOVAL…5804
INSTALLATION…5804
AFTER-COOLER…5804
REMOVAL…5804
INSTALLATION…5804
TURBOCHARGER…5806
REMOVAL…5806
INSTALLATION…5806
NOZZLE HOLDER ASSEMBLY…5806
REMOVAL…5806
INSTALLATION…5806
CYLINDER HEAD…5808
REMOVAL…5808
INSTALLATION…5810
ENGINE…5811
REMOVAL…5811
INSTALLATION…5815
RADIATOR, TORQUE CONVERTER OIL COOLER…5816
REMOVAL…5816
INSTALLATION…5816
OUTPUT SHAFT…5818
REMOVAL…5818
INSTALLATION…5818
DISASSEMBLY…5820
ASSEMBLY…5820
TORQUE CONVERTER, TRANSMISSION…5824
REMOVAL…5824
INSTALLATION…5826
TORQUE CONVERTER CONTROL VALVE…5828
REMOVAL…5828
INSTALLATION…5828
DISASSEMBLY…5830
ASSEMBLY…5830
TORQUE CONVERTER AND TRANSMISSION…5832
DISCONNECTION…5832
CONNECTION…5832
TORQUE CONVERTER, PTO…5834
DISASSEMBLY…5834
ASSEMBLY…5840
PTO…5846
DISASSEMBLY…5846
ASSEMBLY…5846
TRANSMISSION…5848
DISASSEMBLY…5848
ASSEMBLY…5862
TRANSMISSION CONTROL VALVE (ECMV)…5880
REMOVAL…5880
INSTALLATION…5880
TRANSMISSION PUMP…5880
REMOVAL…5880
INSTALLATION…5880
ECMV…5882
DISASSEMBLY…5882
ASSEMBLY…5882
DIFFERENTIAL (FOR STANDARD)…5886
REMOVAL…5886
INSTALLATION…5886
DISASSEMBLY…5888
ASSEMBLY…5892
DIFFERENTIAL (FOR WITH DIFFERENTIAL LOCK)…5901
REMOVAL…5901
INSTALLATION…5901
DISASSEMBLY…5903
ASSEMBLY…5907
CARRIER…5918
REMOVAL…5918
INSTALLATION…5918
DISASSEMBLY…5918
ASSEMBLY…5918
FINAL DRIVE…5920
DISASSEMBLY…5920
ASSEMBLY…5922
REAR WHEEL BRAKE…5924
REMOVAL…5924
INSTALLATION…5924
DISASSEMBLY…5924
ASSEMBLY…5926
PARKING BRAKE CALIPER…5928
REMOVAL…5928
INSTALLATION…5928
DISASSEMBLY…5928
ASSEMBLY…5928
PARKING BRAKE PAD…5930
REMOVAL…5930
INSTALLATION…5930
FRONT BRAKE CALIPER…5930
REMOVAL…5930
INSTALLATION…5930
DISASSEMBLY…5932
ASSEMBLY…5932
FRONT BRAKE CALIPER PAD…5932
REMOVAL…5932
INSTALLATION…5932
STEERING VALVE…5934
REMOVAL (A HD785-3)…5934
REMOVAL (BH985-3)…6227
INSTALLATION (A HD785-3)…5934
INSTALLATION (B HD985-3)…6227
DISASSEMBLY…5936
ASSEMBLY…5942
FRONT WHEEL …5952
REMOVAL…5952
INSTALLATION…5952
REAR WHEEL …5954
REMOVAL…5954
INSTALLATION…5954
FRONT WHEEL HUB…5956
DISASSEMBLY…5956
ASSEMBLY…5958
FRONT SUSPENSION…5962
REMOVAL…5962
INSTALLATION…5962
VARIABLE DAMPER VALVE …5964
REMOVAL…5964
INSTALLATION…5964
VARIABLE DAMPER SELECTOR VALVE…5966
DISASSEMBLY…5966
ASSEMBLY…5966
FIXED ATTENUATION VALVE…5968
DISASSEMBLY…5968
ASSEMBLY…5968
FRONT SUSPENSION CYLINDER…5970
DISASSEMBLY…5970
ASSEMBLY…5970
REAR SUSPENSION CYLINDER…5972
REMOVAL…5972
INSTALLATION…5972
DISASSEMBLY…5974
ASSEMBLY…5974
PARKING BRAKE SPRING CYLINDER…5978
REMOVAL…5978
INSTALLATION…5978
DISASSEMBLY…5980
ASSEMBLY…5980
BRAKE VALVE…5982
REMOVAL…5982
INSTALLATION…5982
DISASSEMBLY…5984
ASSEMBLY…5986
FRONT BRAKE CHAMBER…5988
REMOVAL…5988
INSTALLATION…5988
DISASSEMBLY…5990
ASSEMBLY…5994
REAR BRAKE CHAMBER…5988
REMOVAL…5988
INSTALLATION…5988
DISASSEMBLY…5998
ASSEMBLY…6002
AIR GOVERNOR…6006
REMOVAL…6006
INSTALLATION…6006
DISASSEMBLY…6006
ASSEMBLY…6006
SLACK ADJUSTER…6008
REMOVAL…6008
INSTALLATION…6008
DISASSEMBLY…6008
ASSEMBLY…6008
BRAKE COOLING PUMP…6010
REMOVAL…6010
INSTALLATION…6010
STEERING, HOIST PUMP…6010
REMOVAL…6010
INSTALLATION…6010
BRAKE COOLER…6010
REMOVAL…6010
INSTALLATION…6010
DEMAND VALVE…6012
REMOVAL…6012
INSTALLATION…6012
DISASSEMBLY…6014
ASSEMBLY…6014
RELIEF VALVE…6014
DISASSEMBLY…6014
ASSEMBLY…6014
EMERGENCY STEERING MOTOR PUMP…6016
REMOVAL…6016
INSTALLATION…6016
STEERING CYLINDER…6016
REMOVAL…6016
INSTALLATION…6016
DISASSEMBLY…6018
ASSEMBLY…6020
HOIST VALVE…6024
REMOVAL…6024
INSTALLATION…6024
DISASSEMBLY…6026
ASSEMBLY…6026
HOIST CYLINDER…6028
REMOVAL…6028
INSTALLATION…6028
DISASSEMBLY…6030
ASSEMBLY…6032
BODY…6034
REMOVAL…6034
INSTALLATION…6034
TRANSMISSION CONTROLLER…6036
REMOVAL…6036
INSTALLATION…6036
40 MAINTENANCE STANDARD…6038
OUTPUT SHAFT…6039
TORQUE CONVERTER VALVE…6040
TORQUE CONVERTER…6041
TRANSMISSION (HD785-3) (HD785-3)…6043
TRANSMISSION (HD985-3)…6230
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…6048
FRONT AXLE…6049
REAR AXLE SUPPORT (HD785-3)…6050
REAR AXLE SUPPORT (HD985-3)…6235
DIFFERENTIAL…6051
FINAL DRIVE (HD785-3)…6053
FINAL DRIVE (HD985-3)…6236
FRONT BRAKE…6054
REAR BRAKE…6055
PARKING BRAKE…6056
STEERING LINKAGE…6057
FRONT SUSPENSION CYLINDER…6059
REAR SUSPENSION CYLINDER (HD785-3)…6060
REAR SUSPENSION CYLINDER (HD 985-3)…6237
PARKING BRAKE CHAMBER…6061
SLACK ADJUSTER…6062
HYDRAULIC PUMP (SAR4-160)…6063
DEMAND VALVE…6065
CROSS-OVER RELIEF VALVE…6065
HOIST VALVE…6066
STEERING CYLINDER…6067
HOIST CYLINDER…6068
90 OTHERS: CONTENTS (FOR HD985-3)…6069
10 STRUCTURE AND FUNCTION…6070
TORQUE CONVERTER…6072
TRANSMISSION…6074
FRONT AXLE…6076
REAR AXLE…6077
FINAL DRIVE…6078
WHEELS…6079
AXLE SUPPORT…6080
STEERING WHEEL…6081
REAR SUSPENSION CYLINDER…6082
DUMP BODY…6084
MAIN FRAME…6084
AUTOMATIC EMERGENCY STEERING SYSTEM…6085
ELECTRICAL CIRCUIT DIAGRAM…6086
20 TESTING AND ADJUSTING…6087
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…6088
STANDARD VALUE TABLE FOR CHASSIS…6089
TYPE AND LOCATION OF CONNECTOR, SENSOR…6094
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR)…6103
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS…6105
G-1 ABNORMALITY IN POWER SOURCE SYSTEM…6106
G-2 ABNORMALITY IN CONTROLLER SYSTEM…6107
G-3(A) ABNORMALITY IN RIGHT BANK RACK SENSOR SYSTEM…6108
G-3(B) ABNORMALITY IN LEFT BANK RACK SESNOR SYSTEM…6109
G-4(A) ABNORMALITY IN RIGHT BANK GOVERNOR SOLENOID SYSTEM…6110
G-4(B) ABNORMALITY IN LEFT BANK GOVERNOR SOLENOID SYSTEM…6111
G-5(A) ABNORMALITY IN RIGHT BANK GOVERNOR RELAY SYSTEM…6112
G-5(B) ABNORMALITY IN LEFT BANK GOVERNOR CUT RELAY SYSTEM…6113
G-6(A) ABNORMALITY IN RIGHT BANK PRE-STROKE SOLENOID SYSTEM…6114
G-6(B) ABNORMALITY IN LEFT BANK PRE-STROKE SOLENOID SYSTEM…6115
G-7 ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM…6116
G-8(A) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM…6117
G-8(B) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM…6118
G-9 ABNORMALITY IN ACCELERATOR SENSOR…6119
G-10 ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM…6121
G-11(A) ABNORMALITY IN RIGHT BANK GOVERNOR SERVO SYSTEM…6122
G-11(B) ABNORMALITY IN LEFT BANK GOVERNOR SERVO SYSTEM…6122
G-12 ENGINE DOES NOT START…6123
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM…6126
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…6127
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM…6129
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…6130
A-1 ABNORMALITY INPOWER SOURCE…6131
A) (OFF) SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP…6131
B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED…6133
C) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED…6134
A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED…6135
A-3 ABNORMALITY IN CONTROLLER SYSTEM…6136
A) ONLY DOT LIGHTS UP OR ABNORMALITY IN CONTROLLER DISPLAYED…6136
B) DOUBLE SYSTEM FOR CLUTCH IS DISPLAYED…6137
A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED…6138
A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM DISPLAYED…6139
A-6 ABNORMALITY IN SPEED SENSOR SYSTEM…6141
A) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED…6141
B) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED…6143
C) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) DISPLAYED…6144
A-7 SPEED SENSOR SYSTEM, CLUTCH SLIPPING…6145
A) INPUT SHAFT SENSOR OR H.L. CLUTCH SYSTEM DISPLAYED…6145
B) TRAVEL SPEED SENSOR OR SPEED CLUTCH (1,2,3,4,R) SYSTEM DISPLAYED…6146
A-8 ABNORMALITY IN MODEL SELECTION DISPLAYED…6147
A-9 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM…6148
A) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED…6148
B) TRANSMISSION SHIFT LEVER POSITION SIGNAL DISPLAYS 2-SYSTEM ABNORMAL INPUT…6149
C) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT…6154
A-10 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED…6155
A-11 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED…6158
A-12 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM…6159
A) ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM…6159
B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED…6160
1) WHEN 42.43 IS DISPLAYED…6162
2) WHEN 44-48 IS DISPLAYED…6162
A-13 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)…6163
A-14 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED…6164
OR A-14 DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED…6164
TROUBLESHOOTING OF MONITOR PANEL SYSTEM…6166
P-1 MONITOR PANEL DOES NOT WORK AT ALL…6168
P-2 PART OF MONITOR PANEL DOES NOT WORK…6169
A) SPEEDOMETER DISPLAY DOES NOT WORK…6169
B) SPEEDOMETER DISPLAY WORKS, BUT OTHER PARTS DO NOT WORK…6169
C) SUSPENSION DISPLAY DOES NOT WORK…6169
D) (MECHATRONICS) CAUTION FUEL GAUGE DISPLAYS DO NOT WORK…6170
P-3 AUTOMATIC SHIFT DISPLAY (MECHATRONICS) FLASHES…6171
P-4 SUSPENSION (MECHATRONICS) DISPLAY FLASHES…6171
P-5 ABNORMALITY IN SUSPENSION DISPLAY…6172
A) HARD DISPLAY DOES NOT LIGHT UP…6172
B) MEDIUM DISPLAY DOES NOT LIGHT UP…6172
C) SOFT DISPLAY DOES NOT LIGHT UP…6173
D) SUSPENSION MODE DISPLAYS ALL LIGHT UP…6173
P-6 ABNORMALITY IN SHIFT POSITION DISPLAY…6174
A) R DISPLAY DOES NOT LIGHT UP…6174
B) N DISPLAY DOES NOT LIGHT UP…6174
C) D DISPLAY DOES NOT LIGHT UP…6175
D) 5 DISPLAY DOES NOT LIGHT UP…6175
E) 4 DISPLAY DOES NOT LIGHT UP…6176
F) 3 DISPLAY DOES NOT LIGHT UP…6176
G) L DISPLAY DOES NOT LIGHT UP…6177
P-7 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP…6178
P-8 LOCK-UP DISPLAY DOES NOT LIGHT UP…6178
P-9 HI BEAM DISPLAY DOES NOT LIGHT UP…6179
P-10 ABNORMALITY IN TURN SIGNAL…6180
A) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP…6180
B) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP…6180
P-11 ABNORMALITY IN SHIFT INDICATOR DISPLAY…6181
A) WHEN 1,2,4,6,R IS DISPLAYED, DISPLAY CHANGES TO E…6181
B) WHEN 3,5,7 IS DISPLAYED, DISPLAY CHANGES TO E…6181
C) WHEN 1 IS DISPLAYED, DISPLAY CHANGES TO E…6182
D) WHEN 2,3 IS DISPLAYED, DISPLAY CHANGES TO E…6182
E) WHEN 4,5 IS DISPLAYED, DISPLAY CHANGES TO E…6183
F) WHEN 6,7 IS DISPLAYED, DISPLAY CHANGES TO E…6183
G) WHEN R IS DISPLAYED, DISPLAY CHANGES TO E…6184
P-12 SPEEDOMETER DISPLY DOES NOT WORK NORMALLY…6185
P-13 TACHOMETER DISPLAY DOES NOT WORK NORMALLY…6185
P-14 SERVICE METER DOES NOT WORK…6186
P-15 ODOMETER DOES NOT WORK…6186
P-16 ABNORMALITY IN ALARM BUZZER…6187
A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT SOUND…6187
B) ALARM BUZZER CONTINUES TO SOUND…6187
P-17 ABNORMALITY IN WARNING LAMP…6188
A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT WARNING LAMP DOES NOT FLASH…6188
B) WARNING LAMP STAYS ON…6188
P-18 CAUTION DISPLAY DOES NOT FLASH (DOES NOT LIGHT UP), BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS…6189
A) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS…6189
B) WARNING LAMP FLASHES WHEN ENGINE STOPS…6189
C) WARNING LAMP FLASHES WHEN ENGINE IS RUNNING…6189
P-19 ABNORMALITY IN AIR PRESSURE GAUGE…6190
A) NO DISPLAY GIVEN IN DISPLAY AREA…6190
B) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE…6190
P-20 ABNORMALITY IN COOLANT TEMPERATURE GAUGE…6191
A) NO DISPLAY GIVEN IN DISPLAY AREA…6191
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…6191
P-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE…6192
A) NO DISPLAY GIVEN IN DISPLAY AREA…6192
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…6192
P-22 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE…6193
A) NO DISPLAY GIVEN IN DISPLAY AREA…6193
B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE…6193
P-23 ABNORMALITY IN FUEL GAUGE…6194
A) NO DISPLAY GIVEN IN DISPLAY AREA…6194
B) DISPLAY SHOWS FULL AND DOES NOT MOVE…6194
P-24 ABNORMALITY IN NIGHT LIGHTING (ABNORMALITY ONLY IN NIGHT LIGHTING OF MONITOR PANEL)…6195
A) NONE OF PANEL LAMPS LIGHT UP…6195
B) SERVICE METER AND ODOMETER LIGHT UP, BUT OTHER PARTS DO NOT LIGHT UP…6196
C) SERVICE METER AND ODOMETER DO NOT LIGHT UP…6196
P-25 ENGINE (MECHATRONICS) DISPLAY FLASHES…6197
P-26 ABNORMALITY IN POWER MODE DISPLAY…6198
A) HIGH POWER DISPLAY DOES NOT LIGHT UP…6198
B) ECONOMY DISPLAY DOES NOT LIGHT UP…6198
RELATED ELECTRICAL CIRCUIT DIAGRAMS…6199
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM…6208
M-1 MAINTENANCE MONITOR DOES NOT WORK…6209
A) WHEN NOTHING WORKS…6209
B) WHEN CHECK DISPLAY DOES NOT WORK…6209
M-2 WHEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES…6210
M-3 WHEN ENGINE IS STOPPED, TRANSMISSION OIL LEVEL DISPLAY FLASHES…6211
M-4 WHEN ENGINE IS STOPPED, HYDRAULIC OIL LEVEL DISPLAY FLASHES…6212
M-5 WHEN ENGINE IS STOPPED, RETARDER OIL LEVEL DISPLAY FLASHES…6213
M-6 WHEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES…6214
M-7 WHEN ENGINE IS STOPPED, BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES…6215
M-8 AT NEUTRAL, RETARDER WEAR DISPLAY FLASHES…6216
M-9 WHEN ENGINE IS RUNNING, AIR CLEANER CLOGGING DISPLAY FLASHES…6217
M-10 WHEN ENGINE IS RUNNING, FULL-FLOW FILTER CLOGGING DISPLAY FLASHES…6218
M-11 WHEN ENGINE IS RUNNING, TRANSMISSION FILTER CLOGGING DISPLAY FLASHES…6219
M-12 WHEN ENGINE IS RUNNING, HYDRAULIC FILTER CLOGGING DISPLAY FLASHES…6220
M-13 WHEN ENGINE IS RUNNING, RETARDER FILTER CLOGGING DISPLAY FLASHES…6221
M-14 MAINTENANCE TIMER DOES NOT WORK (TIME DOES NOT ADVANCE)…6222
M-15 MAINTENANCE TIMER IS NOT OH OR BELOW, BUT MAINTENANCE ITEM LIGHTS UP…6222
M-16 ABNORMALITY IN SWITCH…6223
A) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK…6223
B) REPLACEMENT SWITCH, MISOPERATION CANCEL SWITCH DO NOT WORK…6223
M-17 NIGHT LIGHTING DOES NOT LIGHT UP (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)…6224
30 DISASSEMBLY AND ASSEMBLY…6225
STEERING VALVE (B)…6227
REMOVAL (B)…6227
INSTALLATION (B)…6227
40 MAINTENANCE STANDARD…6229
TRANSMISSION…6230
REAR AXLE SUPPORT…6235
FINAL DRIVE…6236
REAR SUSPENSION CYLINDER…6237
SEN01274-23 – Dump Truck HD785-7 Shop Manual…6239
COVER…6239
00 Index and foreword…0
Index…6241
Composition of shop manual…6242
Table of contents…6244
Foreword and general information…6261
Safety notice…6262
How to read the shop manual…6267
Explanation of terms for maintenance standard…6269
Handling of electric equipment and hydraulic component…6271
Handling of connectors newly used for engines…6280
How to read electric wire code…6283
Precautions when carrying out operation…6286
Method of disassembling and connecting push-pull type coupler…6289
Standard tightening torque table…6292
Conversion table…6296
01 Specification…0
Specification and technical data…6303
Specification drawing…6304
Specifications…6306
Weight table…6309
Fuel, coolant and lubricants…6310
10 Structure, function and maintenance standard…0
Engine and cooling system…6315
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler…6316
Fuel system…6318
Power train, Part 1…6321
Power train skeleton…6322
Output shaft…6324
Drive shaft…6326
Torque converter and transmission hydraulic piping…6328
Brake cooling oil control valve (BCV)…6330
Torque converter…6331
Torque converter valve…6339
Transmission…6342
Transmission control valve…6370
ECMV…6372
Lubricating oil amount selector valve…6379
Power train, Part 2…6383
Axle…6384
Differential…6386
Final drive…6387
Wheels…6388
Steering system…6391
Steering column…6392
Steering linkage…6393
Brake system…6397
Brake piping…6398
Brake valve…6400
Secondary brake valve…6403
Accumulator charge valve…6404
Accumulator…6408
Slack adjuster…6410
Brake, parking brake…6414
Parking brake solenoid…6420
Retarder control valve…6421
Exhaust brake…6422
Undercarriage and frame…6425
Suspension…6426
Suspension cylinder…6428
Rear axle support…6436
Hydraulic system…6439
Steering and hoist hydraulic piping…6440
Steering, hoist filter (high pressure circuit)…6442
Dump body control…6444
Power ladder system…6446
Hydraulic tank…6453
Steering valve…6454
Crossover relief valve…6458
Steering cylinder…6459
Steering control valve…6460
Hoist valve…6469
Dump control valve (EPC valve)…6475
Hydraulic pump…6478
Work equipment (Body)…6483
Auto greasing system…6484
Hoist cylinder…6495
Cab and its attachments…6497
ROPS cab…6498
Air conditioner…6499
Rear view monitor…6508
Controller related…6511
Electrical system, Part 1…6513
Machine monitor system…6514
Electrical system, Part 2…6539
Automatic shift control system…6540
External power supply heater…6560
Automatic emergency steering system…6562
Automatic suspension system…6566
Retarder control system…6569
Battery disconnector switch…6582
Emergency engine stop switch…6586
Dump control lever…6588
Ladder control functio…6592
Electrical system, Part 3…6595
VHMS controller related…6596
ABS/ASR system…6622
Altitude setting function…6640
Speed limit function…6643
Electrical system, Part 4…6649
Sensors, switches…6650
20 Standard value table…0
Standard service value table…6667
Standard value table for engine…6668
Standard value table for machine…6670
30 Testing and adjusting…0
Testing and adjusting, Part 1…6683
Testing and adjusting tools list…6685
Sketch of special tool…6690
Testing engine speed…6691
Testing air supply pressure (boost pressure)…6692
Testing exhaust temperature…6694
Testing exhaust gas color…6696
Adjustment of valve clearance…6698
Testing compression pressure…6700
Troubleshooting of engine (S-mode)…7827
Method of using troubleshooting charts…7829
S-1 Starting performance is poor…7832
S-2 Engine does not start…7833
S-3 Engine does not pick up smoothly…7836
S-4 Engine stops during operations…7837
S-5 Engine does not rotate smoothly…7838
S-6 Engine lacks output (or lacks power)…7839
S-7 Exhaust smoke is black (incomplete combustion)…7841
S-8 Oil consumption is excessive (or exhaust smoke is blue)…7842
S-9 Oil becomes contaminated quickly…7843
S-10 Fuel consumption is excessive…7844
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…7845
S-12 Oil pressure drops…7846
S-13 Oil level rises (Entry of coolant or fuel)…7847
S-14 Coolant temperature becomes too high (overheating)…7848
S-15 Abnormal noise is made…7849
S-16 Vibration is excessive…7850
50 Disassembly and assembly…0
General information on disassembly and assembly…7853
How to read this manual…7854
Coating materials list…7856
Special tool list…7859
Sketches of special tools…7862
Engine and cooling system…7869
Removal and installation of fuel supply pump assembly…7870
Removal and installation of fuel injector assembly…7872
Removal and installation of cylinder head assembly…7873
Removal and installation of engine hood assembly…7886
Removal and installation of radiator assembly…7887
Removal and installation of engine assembly…7896
Removal and installation of engine front oil seal…7901
Removal and installation of engine rear oil seal…7904
Power train, Part 1…7909
Removal and installation of front drive shaft…7910
Removal and installation of rear drive shaft…7912
Removal and installation of output shaft assembly…7913
Disassembly and assembly of damper assembly…7918
Removal and installation of torque converter and transmission assembly…7920
Disconnection and connection of torque converter assembly and transmission assembly…7923
Disassembly and assembly of torque converter PTO assembly…7930
Disassembly and assembly of transmission assembly…7943
Power train, Part 2…7977
Removal and installation of final drive carrier assembly…7978
Disassembly and assembly of final drive carrier assembly…7980
Removal and installation of differential assembly…7982
Disassembly and assembly of differential assembly…7985
Steering system…7999
Removal and installation of steering cylinder assembly…8000
Disassembly and assembly of steering cylinder assembly…8001
Removal and installation of steering valve assembly…8005
Disassembly and assembly of steering valve assembly…8006
Brake system…8019
Removal and installation of front wheel hub and brake assembly…8020
Disassembly and assembly of front wheel hub and brake assembly…8024
Removal and installation of final drive and rear brake assembly…8032
Disassembly and assembly of final drive and rear brake assembly…8034
Undercarriage and frame…8049
Removal and installation of front wheel assembly…8050
Removal and installation of rear wheel assembly…8052
Removal and installation of front suspension cylinder assembly…8054
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)…8056
Removal and installation of king pin…8059
Removal and installation of rear suspension cylinder assembly…8061
Disassembly and assembly of rear suspension cylinder assembly…8062
Hydraulic system…8067
Removal and installation of hoist valve assembly…8068
Disassembly and assembly of hoist valve assembly…8069
Disassembly and assembly of hoist cylinder assembly…8071
Body…8075
Removal and installation of body assembly…8076
Cab and its attachments…8081
Disassembly and assembly of operator’s seat assembly…8082
Removal and installation of air conditioner unit assembly…8092
Electrical system…8095
Removal and installation of engine controller assembly…8096
Removal and installation of transmission controller assembly…8096
Removal and installation of retarder controller assembly…8097
Removal and installation of ABS controller assembly…8097
Removal and installation of VHMS controller assembly…8098
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…8101
Power train hydraulic circuit diagram…8103
Steering and hoist hydraulic circuit diagram…8104
Brake hydraulic circuit diagram…8105
Brake hydraulic circuit diagram (ASR specification)…8106
Brake hydraulic circuit diagram (ABS specification)…8107
Brake hydraulic circuit diagram (ASR and ABS specification)…8108
Hydraulic circuit diagram for power ladder…8109
Electrical diagrams and drawings…8111
Electrical circuit diagram for outside cab (1/3)…8113
Electrical circuit diagram for outside cab (2/3)…8114
Electrical circuit diagram for outside cab (3/3)…8115
Electrical circuit diagram for inside cab (1/3)…8116
Electrical circuit diagram for inside cab (2/3)…8117
Electrical circuit diagram for inside cab (3/3)…8118
Electrical circuit diagram for VHMS (If equipped)…8119
Electrical circuit diagram for ABS (Outside cab) (If equipped)…8120
Electrical circuit diagram for ABS (Inside cab) (If equipped)…8121
Electrical circuit diagram for ASR (If equipped)…8122
Air conditioner electrical circuit diagram (If equipped)…8123
Electrical circuit diagram for auto greasing (If equipped)…8124
Electrical circuit diagram of external power supply heater…8125
Connectors table and arrangement drawing…8126
Electrical circuit diagram of external power supply heater…8127
Connectors table and arrangement drawing…8128
SEN01274-28 – Dump Truck HD785-7 Shop Manual…8131
Cover…8131
00 Index and foreword…0
Index…8133
Composition of shop manual…8134
Table of contents…8136
Foreword and general information…8155
Safety notice…8156
How to read the shop manual…8161
Explanation of terms for maintenance standard…8163
Handling of electric equipment and hydraulic component…8165
Handling of connectors newly used for engines…8174
How to read electric wire code…8177
Precautions when carrying out operation…8180
Method of disassembling and connecting push-pull type coupler…8183
Standard tightening torque table…8186
Conversion table…8190
01 Specification…0
Specification and technical data…8197
Specification drawing…8198
Specifications…8200
Weight table…8203
Fuel, coolant and lubricants…8204
10 Structure, function and maintenance standard…0
Engine and cooling system…8209
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler…8210
Fuel system…8212
Power train, Part 1…8215
Power train skeleton…8216
Output shaft…8218
Drive shaft…8220
Torque converter and transmission hydraulic piping…8222
Brake cooling oil control valve (BCV)…8224
Torque converter…8225
Torque converter valve…8233
Transmission…8236
Transmission control valve…8264
ECMV…8266
Lubricating oil amount selector valve…8273
Power train, Part 2…8277
Axle…8278
Differential…8280
Final drive…8281
Wheels…8282
Steering system…8285
Steering column…8286
Steering linkage…8287
Brake system…8291
Brake piping…8292
Brake valve…8294
Secondary brake valve…8297
Accumulator charge valve…8298
Accumulator…8302
Slack adjuster…8304
Brake, parking brake…8308
Parking brake solenoid…8314
Retarder control valve…8315
Exhaust brake…8316
Undercarriage and frame…8319
Suspension…8320
Suspension cylinder…8322
Rear axle support…8330
Hydraulic system…8333
Steering and hoist hydraulic piping…8334
Steering, hoist filter (high pressure circuit)…8336
Dump body control…8338
Power ladder system…8340
Hydraulic tank…8347
Steering valve…8348
Crossover relief valve…8352
Steering cylinder…8353
Steering control valve…8354
Hoist valve…8363
Dump control valve (EPC valve)…8369
Hydraulic pump…8372
Work equipment (Body)…8377
Auto greasing system…8378
Hoist cylinder…8389
Cab and its attachments…8391
ROPS cab…8392
Air conditioner…8393
Rear view monitor…8402
Controller related…8405
Electrical system, Part 1…8407
Machine monitor system…8408
Electrical system, Part 2…8433
Automatic shift control system…8434
External power supply heater…8454
Automatic emergency steering system…8456
Automatic suspension system…8460
Retarder control system…8463
Battery disconnector switch…8476
Emergency engine stop switch…8480
Dump control lever…8482
Ladder control function…8486
Electrical system, Part 3…8489
VHMS controller related…8490
ABS/ASR system…8516
Komatsu traction control system (KTCS)…8534
Altitude setting function…8536
Speed limit function…8539
Electrical system, Part 4…8545
Sensors, switches…8546
20 Standard value table…0
Standard service value table…8563
Standard value table for engine…8564
Standard value table for machine…8566
30 Testing and adjusting…0
Testing and adjusting, Part 1…8579
Testing and adjusting tools list…8581
Sketch of special tool…8586
Testing engine speed…8587
Testing air supply pressure (boost pressure)…8588
Testing exhaust temperature…8590
Testing exhaust gas color…8592
Adjustment of valve clearance…8594
Testing compression pressure…8596
Testing blow-by pressure…8598
Testing engine oil pressure…8599
Handling of fuel system devices…8600
Releasing residual pressure from fuel system…8600
Testing fuel pressure…8601
Reduced cylinder mode operation…8602
No-injection cranking…8602
Testing leakage-from pressure limiter and return rate from injector…8603
Bleeding air from fuel circuit (Standard spec.)…8606
Bleeding air from fuel circuit (Extra low-grade fuel spec.)…8608
Testing the fuel circuit for leakage…8610
Replacement and adjustment of fan belt…8611
Testing and adjusting alternator belt tension…8612
Testing and adjusting air conditioner compressor belt…8613
Testing and adjusting, Part 2…8615
Testing torque converter stall speed…8617
Testing and adjusting brake oil pressure…8628
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…8631
Testing brake performance…8636
Releasing remaining pressure in brake circuit…8638
Bleeding air from brake circuit…8639
Bleeding air from ASR circuit (if equipped)…8641
Testing wear of front brake disc…8642
Testing wear of rear brake disc…8643
Method of releasing parking brake in an emergency…8644
Testing and adjusting front suspension cylinder…8645
Testing and adjusting rear suspension cylinder…8649
Testing and adjusting front suspension cylinder (Automatic suspension specification)…8653
Testing and adjusting hydraulic pressure in steering, hoist circuit…8654
Testing and adjusting oil pressure in dump EPC circuit…8657
Air bleeding from steering cylinder…8658
Procedure for raising dump body in emergency…8659
Adjusting body positioner sensor…8660
Resetting method for dump body seating control…8662
Handling of high voltage circuit of engine controller…8663
Adjusting transmission controller…8663
Method for emergency escape at electrical system failure…8664
Testing and adjusting ladder potentiometer…8668
Calibration method of ladder position…8669
Testing and adjusting, Part 3…8673
Setting and adjusting of devices…8674
Testing and adjusting, Part 4…8689
Special functions of machine monitor (EMMS)…8690
Testing and adjusting, Part 5…8761
Opening ORBCOMM terminal…8762
VHMS controller initial setting procedure…8764
Precautions for replacing VHMS controller…8789
Pm Clinic check sheet…8795
Initial setting of payload meter…8799
Setting of payload meter built in VHMS…8800
40 Troubleshooting…0
Failure code table and fuse locations…8809
Failure codes table…8810
Fuse locations…8827
General information on troubleshooting…8835
Points to remember when troubleshooting…8836
S-15 Abnormal noise is made…9769
S-16 Vibration is excessive…9770
50 Disassembly and assembly…0
General information on disassembly and assembly…9773
How to read this manual…9774
Coating materials list…9776
Special tool list…9779
Sketches of special tools…9782
Engine and cooling system…9791
Removal and installation of fuel supply pump assembly…9792
Removal and installation of fuel injector assembly…9794
Removal and installation of cylinder head assembly…9795
Removal and installation of engine hood assembly…9808
Removal and installation of radiator assembly…9809
Removal and installation of engine assembly…9818
Removal and installation of engine front oil seal…9823
Removal and installation of engine rear oil seal…9826
Power train, Part 1…9831
Removal and installation of front drive shaft…9832
Removal and installation of rear drive shaft…9834
Removal and installation of output shaft assembly…9835
Disassembly and assembly of damper assembly…9841
Removal and installation of torque converter and transmission assembly…9843
Disconnection and connection of torque converter assembly and transmission assembly…9846
Disassembly and assembly of torque converter PTO assembly…9857
Disassembly and assembly of transmission assembly…9874
Power train, Part 2…9915
Removal and installation of final drive carrier assembly…9916
Disassembly and assembly of final drive carrier assembly…9918
Removal and installation of differential assembly…9920
Disassembly and assembly of differential assembly…9923
Steering system…9937
Removal and installation of steering cylinder assembly…9938
Disassembly and assembly of steering cylinder assembly…9939
Removal and installation of steering valve assembly…9943
Disassembly and assembly of steering valve assembly…9944
Brake system…9957
Removal and installation of front wheel hub and brake assembly…9958
Disassembly and assembly of front wheel hub and brake assembly…9962
Removal and installation of final drive and rear brake assembly…9970
Disassembly and assembly of final drive and rear brake assembly…9972
Undercarriage and frame…9987
Removal and installation of front wheel assembly…9988
Removal and installation of rear wheel assembly…9990
Removal and installation of front suspension cylinder assembly…9992
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)…9994
Removal and installation of king pin…9997
Removal and installation of rear suspension cylinder assembly…9999
Disassembly and assembly of rear suspension cylinder assembly…10000
Hydraulic system…10005
Removal and installation of hoist valve assembly…10006
Disassembly and assembly of hoist valve assembly…10007
Disassembly and assembly of hoist cylinder assembly…10009
Body…10013
Removal and installation of body assembly…10014
Cab and its attachments…10019
Disassembly and assembly of operator’s seat assembly…10020
Removal and installation of air conditioner unit assembly…10030
Electrical system…10033
Removal and installation of engine controller assembly…10034
Removal and installation of transmission controller assembly…10034
Removal and installation of retarder controller assembly…10035
Removal and installation of ABS controller assembly…10035
Removal and installation of VHMS controller assembly…10036
80 Appendix…0
Air conditioner…10039
Precautions for refrigerant…10041
Configuration and function of refrigeration cycle…10042
Outline of refrigeration cycle…10043
Air conditioner unit…10046
Air conditioner control panel…10052
Troubleshooting procedure…10054
Circuit diagram and arrangement of connector pins…10056
System diagram…10058
Details of air conditioner unit…10059
Inspection by self-diagnosis function…10060
Testing temperature control system…10061
Testing vent (mode) changeover…10062
Testing FRESH/RECIRC air changeover…10064
Check evaporator temperature sensor…10066
Testing relays…10067
Troubleshooting chart 1…10068
Troubleshooting chart 2…10069
Information in troubleshooting table…10071
Troubleshooting for power supply system (Air conditioner does not operate)…10072
Troubleshooting for compressor and refrigerant system (Air is not cooled)…10075
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)…10079
Troubleshooting for temperature control…10082
Troubleshooting for vent (mode) changeover…10084
Troubleshooting for FRESH/RECIRC air changeover…10086
Troubleshooting with gauge pressure…10089
Connection of service tool…10091
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit…10092
Handling of compressor oil…10094
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…10097
Power train hydraulic circuit diagram…10099
Steering and hoist hydraulic circuit diagram…10100
Brake hydraulic circuit diagram…10101
Brake hydraulic circuit diagram (ASR specification)…10102
Brake hydraulic circuit diagram (ABS specification)…10103
Brake hydraulic circuit diagram (ASR and ABS specification)…10104
Hydraulic circuit diagram for power ladder…10105
Electrical diagrams and drawings…10107
Electrical circuit diagram for outside cab…10109
Electrical circuit diagram for inside cab…10113
Electrical circuit diagram for VHMS…10119
Electrical circuit diagram for ABS(Outside cab)…10120
Electrical circuit diagram for ABS(Inside cab)…10121
Electrical circuit diagram for ASR…10122
Air conditioner electrical circuit diagram…10123
Electrical circuit diagram for power ladder…10124
Electrical circuit diagram for auto greasing…10125
Electrical circuit diagram of external power supply heater…10126
Connectors table and arrangement drawing…10127
SEN05900-01 – Dump Truck HD785-7 Shop Manual…10130
Cover…10130
00 Index and foreword…0
Index…10132
Composition of shop manual…10133
Table of contents…10135
Foreword and general information…10152
Foreword and general informationSafety notice…10153
How to read the shop manual…10158
Explanation of terms for maintenance standard…10160
Handling of hydraulic components…10162
Method of disconnecting and connecting push-pull type coupler…10164
Handling of electric equipment…10167
How to read electric wire code…10177
Precautions when performing work…10180
Standard tightening torque table…10183
List of Abbreviation…10187
Conversion table…10191
01 Specification…0
Specification and technical data…10198
Specification drawing…10199
Specifications…10201
Weight table…10204
Fuel, coolant and lubricants…10205
10 Structure, function andmaintenance standard…0
Engine and cooling system…10210
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist …10211
Fuel system…10213
Power train, Part 1…10216
Power train skeleton…10217
Output shaft…10219
Drive shaft…10221
Torque converter and transmission hydraulic piping…10223
Brake cooling oil control valve (BCV)…10225
Torque converter…10227
Torque converter valve…10234
Transmission…10237
Transmission control valve…10265
ECMV…10267
Power train, Part 2…10278
Axle…10279
Differential…10281
Final drive…10282
Wheels…10283
Steering system…10286
Steering column…10287
Steering linkage…10288
Brake system…10292
Brake piping…10293
Brake valve…10295
Secondary brake valve…10298
Accumulator charge valve…10299
Accumulator…10304
Slack adjuster…10306
Brake, parking brake…10310
Parking brake solenoid…10316
Retarder control valve…10317
Exhaust brake…10318
Undercarriage and frame…10322
Suspension…10323
Suspension cylinder…10325
Rear axle support…10333
Hydraulic system…10336
Steering and hoist hydraulic piping…10337
Steering, hoist filter (high pressure circuit)…10339
Dump body control…10341
Power ladder system (If equipped)…10343
Hydraulic tank…10349
Steering valve…10350
Crossover relief valve…10354
Steering cylinder…10355
Steering control valve…10356
Hoist valve…10365
Dump control valve (EPC valve)…10371
Hydraulic pump…10373
Work equipment (Body)…10378
Auto greasing system (If equipped)…10379
Hoist cylinder…10390
Cab and its attachments…10392
ROPS cab…10393
Air conditioner…10394
Rear view monitor system…10403
Controller related…10408
Electrical system, Part 1…10410
Machine monitor system…10411
Electrical system, Part 2…10436
Automatic shift control system…10437
External power supply heater…10457
Automatic emergency steering system…10459
Automatic suspension system…10463
Retarder control system…10466
Dump control lever…10479
Ladder control function (If equipped)…10483
Electrical system, Part 3…10486
VHMS controller related…10487
ABS/ASR system…10513
Altitude setting function…10531
Speed limit function…10534
Electrical system, Part 4…10540
Sensors, switches…10541
20 Standard value table…0
Standard service value table…10560
Standard value table for engine…10561
Standard value table for machine…10563
30 Testing and adjusting…0
Testing and adjusting, Part 1…10576
Testing and adjusting tools list…10578
Sketch of special tool…10583
Testing engine speed…10584
Testing air supply pressure (boost pressure)…10585
Testing exhaust temperature…10587
Testing exhaust gas color…10589
Adjustment of valve clearance…10591
Testing compression pressure…10593
Testing blow-by pressure…10595
Testing engine oil pressure…10596
Handling of fuel system devices…10597
Releasing residual pressure from fuel system…10597
Testing fuel pressure…10598
Reduced cylinder mode operation1…10599
No-injection cranking…10599
Testing leakage-from pressure limiter and return rate from injector…10600
Bleeding air from fuel circuit (Standard spec.)…10603
Bleeding air from fuel circuit (Extra low-grade fuel spec.)…10607
Testing the fuel circuit for leakage1…10609
Replacement and adjustment of fan belt…10610
Testing and adjusting alternator belt tension…10611
Testing and adjusting air conditioner compressor belt…10612
Testing and adjusting, Part 2…10614
Testing torque converter stall speed…10616
Testing power train oil pressure…10618
Adjusting transmission speed sensor…10626
Testing and adjusting brake oil pressure…10627
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…10630
Testing brake performance…10635
Bleeding air from brake circuit…10637
Bleeding air from ASR circuit (if equipped)…10639
Testing wear of front brake disc…10640
Testing wear of rear brake disc…10641
Method of releasing parking brake in an emergency…10642
Testing and adjusting front suspension cylinder…10643
Testing and adjusting rear suspension cylinder…10647
Testing and adjusting front suspension cylinder (Automatic suspension specification)…10651
Testing and adjusting hydraulic pressure in steering, hoist circuit…10652
Testing and adjusting oil pressure in dump EPC circuit…10655
Air bleeding from steering cylinder…10656
Procedure for raising dump body in emergency…10657
Adjusting body positioner sensor…10658
Handling of high voltage circuit of engine controller…10660
Adjusting transmission controller…10660
Method for emergency escape at electrical system failure…10661
Testing and adjusting ladder potentiometer…10665
Calibration method of ladder position…10666
Testing and adjusting, Part 3…10670
Setting and adjusting of devices…10671
Testing and adjusting, Part 4…10686
Special functions of machine monitor (EMMS)…10687
Testing and adjusting, Part 5…10758
Opening ORBCOMM terminal…10759
VHMS controller initial setting procedure…10761
Precautions for replacing VHMS controller…10786
Pm Clinic check sheet…10792
Initial setting of payload meter…10796
Setting of payload meter built in VHMS…10797
40 Troubleshooting…0
Failure code table and fuse locations…10806
Failure codes table…10807
Fuse locations…10823
General information on troubleshooting…10830
Points to remember when troubleshooting…10831
Sequence of events in troubleshooting…10832
Check before troubleshooting…10833
Classification and procedures for troubleshooting…10834
Contents of troubleshooting table…10835
H-11 Rear brake is ineffective…11734
H-12 Steering wheel is heavy…11735
H-13 Steering wheel does not work…11736
H-14 Steering wheel vibrates…11737
H-15 Dump body lifting speed is slow…11738
H-16 Dump body does not work…11739
H-17 Excessive hydraulic drift of dump body…11740
H-18 Power ladder does not move or its speed is low…11741
Troubleshooting of engine (S-mode)…11744
Method of using troubleshooting charts…11746
S-1 Starting performance is poor1…11749
S-2 Engine does not start…11750
S-3 Engine does not pick up smoothly…11753
S-4 Engine stops during operations…11754
S-5 Engine does not rotate smoothly…11755
S-6 Engine lacks output (or lacks power)…11756
S-7 Exhaust smoke is black (incomplete combustion)…11758
S-8 Oil consumption is excessive (or exhaust smoke is blue)…11759
S-9 Oil becomes contaminated quickly…11760
S-10 Fuel consumption is excessive…11761
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1…11762
S-12 Oil pressure drops…11763
S-13 Oil level rises (Entry of coolant or fuel)…11764
S-14 Coolant temperature becomes too high (overheating)…11765
S-15 Abnormal noise is made…11766
S-16 Vibration is excessive…11767
50 Disassembly and assembly…0
General information on disassembly and assembly…11770
How to read this manual…11771
Coating materials list…11773
Special tool list…11776
Sketches of special tools…11779
Engine and cooling system…11786
Removal and installation of fuel supply pump assembly…11787
Removal and installation of fuel injector assembly…11789
Removal and installation of cylinder head assembly…11790
Removal and installation of engine hood assembly…11803
Removal and installation of radiator assembly…11804
Removal and installation of engine assembly…11813
Removal and installation of engine front oil seal…11818
Removal and installation of engine rear oil seal…11821
Power train, Part 1…11826
Removal and installation of front drive shaft…11827
Removal and installation of rear drive shaft…11829
Removal and installation of output shaft assembly…11830
Disassembly and assembly of damper assembly…11835
Removal and installation of torque converter and transmission assembly…11837
Disconnection and connection of torque converter assembly and transmission assembly…11840
Disassembly and assembly of torque converter PTO assembly…11847
Disassembly and assembly of transmission assembly…11860
Power train, Part 2…11894
Removal and installation of final drive carrier assembly…11895
Disassembly and assembly of final drive carrier assembly…11897
Removal and installation of differential assembly…11899
Disassembly and assembly of differential assembly…11902
Steering system…11916
Removal and installation of steering cylinder assembly…11917
Disassembly and assembly of steering cylinder assembly…11918
Removal and installation of steering valve assembly…11922
Disassembly and assembly of steering valve assembly…11923
Brake system…11936
Removal and installation of front wheel hub and brake assembly…11937
Disassembly and assembly of front wheel hub and brake assembly…11941
Removal and installation of final drive and rear brake assembly…11949
Disassembly and assembly of final drive and rear brake assembly…11951
Undercarriage and frame…11966
Removal and installation of front wheel assembly…11967
Removal and installation of rear wheel assembly…11969
Removal and installation of front suspension cylinder assembly…11971
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring)…11973
Removal and installation of king pin…11976
Removal and installation of rear suspension cylinder assembly…11978
Disassembly and assembly of rear suspension cylinder assembly…11979
Hydraulic system…11984
Removal and installation of hoist valve assembly…11985
Disassembly and assembly of hoist valve assembly…11986
Disassembly and assembly of hoist cylinder assembly…11988
Body…11996
Removal and installation of body assembly…11997
Cab and its attachments…12002
Disassembly and assembly of operator's seat assembly…12003
Removal and installation of air conditioner unit assembly…12013
Electrical system…12016
Removal and installation of engine controller assembly…12017
Removal and installation of transmission controller assembly…12017
Removal and installation of retarder controller assembly…12018
Removal and installation of ABS controller assembly…12018
Removal and installation of VHMS controller assembly…12019
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…12022
Power train hydraulic circuit diagram…12024
Steering and hoist hydraulic circuit diagram…12025
Brake hydraulic circuit diagram…12026
Brake hydraulic circuit diagram (ASR specification)…12027
Brake hydraulic circuit diagram (ABS specification)…12028
Brake hydraulic circuit diagram (ASR and ABS specification)…12029
Hydraulic circuit diagram for power ladder…12030
Electrical diagrams and drawings…12032
Electrical circuit diagram for outside cab…12034
Electrical circuit diagram for inside cab…12038
Electrical circuit diagram for ABS (Outside cab) (If equipped)…12046
Electrical circuit diagram for ABS (Inside cab) (If equipped)…12047
Electrical circuit diagram for ASR (If equipped)…12048
Electrical circuit diagram for power ladder…12049
Air conditioner electrical circuit diagram…12050
Electrical circuit diagram for auto greasing (If equipped)…12051
Electrical circuit diagram of external power supply heater…12052
TEN00042-05 – Dump Truck HD785-5 Operation & Maintenance Manual…12055
COVER…12055
FOREWORD…12056
FOREWORD…12057
SAFETY INFORMATION…12060
INTENDED USE…12062
DIRECTIONS OF MACHINE…12062
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12063
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…12063
ENGINE SERIAL NO. PLATE POSITION…12063
SERVICE METER POSITION…12063
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12064
CONTENTS…12065
SAFETY…12070
SAFETY…12071
SAFETY LABELS…12073
POSITION FOR ATTACHING SAFETY LABELS…12074
SAFETY LABELS…12075
GENERAL PRECAUTIONS…12080
PRECAUTIONS DURING OPERATION…12088
BEFORE STARTING ENGINE…12088
AFTER STARTING ENGINE…12090
BATTERY…12093
TOWING…12095
PRECAUTIONS FOR MAINTENANCE…12096
PRECAUTIONS WITH TIRES…12102
OPERATION…12104
GENERAL VIEW…12105
GENERAL VIEW OF MACHINE…12105
GENERAL VIEW OF CONTROLS AND GAUGES…12106
EXPLANATION OF COMPONENTS…12108
MACHINE MONITOR…12108
SWITCHES…12125
CONTROL LEVERS AND PEDALS…12133
MECHATRONICS EQUIPMENT CONTROLLER…12137
BODY PIVOT PIN…12138
DUST INDICATOR…12138
FUSES…12139
CAR STEREO…12141
AIR CONDITIONER…12150
CAR HEATER…12155
LOCATION OF FIRE EXTINGUISHER…12156
LOCATION OF FIRST AID KIT…12156
OPERATION…12157
CHECK BEFORE STARTING ENGINE…12157
STARTING ENGINE…12173
OPERATIONS, CHECKS AFTER STARTING ENGINE…12176
STOPPING ENGINE…12177
CHECKS AFTER STOPPING ENGINE…12177
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…12178
SHIFTING GEAR…12183
TRAVELING DOWNHILL…12184
STEERING THE MACHINE…12190
LOADING OPERATIONS…12190
DUMP OPERATIONS…12191
PRECAUTIONS FOR OPERATION…12192
PARKING MACHINE…12193
CHECKS AFTER COMPLETION OF WORK…12194
DRAIN WATER FROM AIR TANK…12194
LOCKING…12195
HANDLING TIRES…12196
DETERMINING AND MAINTAINING TRAVEL ROAD…12198
DETERMINING TRAVEL ROAD…12198
MAINTAINING TRAVEL ROAD…12198
TRANSPORTATION…12199
PRECAUTIONS WHEN TRANSPORTING…12199
STEPS FOR TRANSPORTATION…12199
METHOD OF SECURING MACHINE…12200
METHOD OF LIFTING MACHINE…12201
COLD WEATHER OPERATION…12203
PRECAUTIONS FOR LOW TEMPERATURE…12203
PRECAUTIONS AFTER COMPLETION OF WORK…12204
AFTER COLD WEATHER…12205
LONG-TERM STORAGE…12206
BEFORE STORAGE…12206
DURING STORAGE…12206
AFTER STORAGE…12206
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…12206
TROUBLESHOOTING…12207
AFTER RUNNING OUT OF FUEL…12207
METHOD OF TOWING MACHINE…12207
IF BATTERY IS DISCHARGED…12212
OTHER TROUBLE…12216
MAINTENANCE…12224
GUIDES TO MAINTENANCE…12225
OUTLINE OF SERVICE…12227
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…12227
OUTLINE OF ELECTRIC SYSTEM…12230
WEAR PARTS…12231
WEAR PARTS LIST…12231
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…12232
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…12233
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…12234
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…12235
TORQUE LIST…12235
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…12236
SAFETY CRITICAL PARTS…12237
MAINTENANCE SCHEDULE CHART…12238
MAINTENANCE SCHEDULE CHART…12238
SERVICE PROCEDURE…12241
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…12241
WHEN REQUIRED…12242
CHECK BEFORE STARTING…12259
EVERY 100 HOURS SERVICE…12260
EVERY 250 HOURS SERVICE…12261
EVERY 500 HOURS SERVICE…12276
EVERY 1000 HOURS SERVICE…12281
EVERY 2000 HOURS SERVICE…12288
EVERY 4000 HOURS SERVICE…12294
EVERY 15000 HOURS SERVICE…12296
SPECIFICATIONS…12298
SPECIFICATIONS…12299
ATTACHMENTS, OPTIONS…12302
HANDLING PAYLOAD METER…12303
NAME OF PARTS…12303
EXTERNAL DISPLAY LAMPS…12304
OPERATING PAYLOAD METER…12306
TACHOGRAPH (TCO 15-6)…12314
EXPLANATION OF COMPONENTS…12314
METHOD OF USING KEY…12316
METHOD OF USE…12316
REVO TACHOGRAPH (TCO 15-7)…12318
EXPLANATION OF COMPONENTS…12318
METHOD OF USE…12320
USING DIFFERENTIAL LOCK…12322
DIFFERENTIAL LOCK PEDAL…12322
PRECAUTIONS AND METHOD OF USE…12323
OPERATION OF ABS AND ABS/ASR…12324
EXPLANATION OF COMPONENTS…12324
OPERATION METHOD…12326
PRECAUTIONS FOR USE…12327
TROUBLESHOOTING…12327
ARSC (AUTOMATIC RETARDER SPEED CONTROL)…12328
EXPLANATION OF COMPONENTS…12329
METHOD OF OPERATION…12331
TROUBLESHOOTING…12333
PMC (POWERTRAIN MANAGEMENT CONTROLLER) AND MOM (MESSAGE FOR OPERATION AND MAINTENANCE)…12336
ABNORMALITY DISPLAYED DURING OPERATION…12336
HOW TO DOWNLOAD THE STORED DATA IN PMC AND OTHER CONTROLLERS…12336
MESSAGE FOR OPERATION AND MAINTENANCE (MOM)…12337
ASR-II (AUTOMATIC SPIN REGULATOR II)…12342
EXPLANATION OF COMPONENTS…12342
ACTUATION OF ASR-II SYSTEM…12343
PRECAUTIONS WHEN USING…12343
TROUBLESHOOTING…12344
HANDLING AUTO-GREASING SYSTEM…12346
OUTLINE OF AUTO-GREASING SYSTEM…12346
SETTING GREASE CAN…12347
INITIAL SETTING OF AUTO-GREASING SYSTEM…12348
METHOD OF OPERATING AUTO-GREASING SYSTEM…12348
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM…12349
POSITION OF EACH INJECTOR…12353
GREASING POINTS FOR EACH INJECTOR…12357
HIGH ATITUDE SPECIFICATIONS…12362
EXPLANATION OF COMPONENTS…12363
SERVICE PROCEDURE…12364
CHECK BEFORE STARTING…12364
EVERY 2000 HOURS SERVICE…12365
INDEX…12368
TEN00164-08 – Dump Truck HD785-7 Operation & Maintenance Manual…12372
COVER…12372
FOREWORD…12373
BEFORE READING THIS MANUAL…12374
SAFETY INFORMATION…12375
INTENDED USE…12376
USE OF MACHINE…12376
DIRECTIONS OF MACHINE…12376
VISIBILITY FROM OPERATOR'S SEAT…12377
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12378
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…12378
EPA REGULATIONS, ENGINE NUMBER PLATE…12378
SERVICE METER POSITION…12379
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12379
CONTENTS…12380
SAFETY…12385
SAFETY…12386
SAFETY LABELS…12389
POSITION FOR ATTACHING SAFETY LABELS…12390
SAFETY LABELS…12391
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…12395
PRECAUTIONS BEFORE STARTING OPERATION…12395
PREPARATIONS FOR SAFE OPERATION…12395
FIRE PREVENTION…12397
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…12398
DO NOT GET CAUGHT IN DUMP BODY…12400
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…12400
UNAUTHORIZED MODIFICATION…12400
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…12401
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…12401
PRECAUTIONS FOR OPERATION…12402
PRECAUTIONS FOR JOBSITE…12402
STARTING ENGINE…12404
OPERATION…12406
TRANSPORTATION…12410
TOWING…12411
PRECAUTIONS FOR MAINTENANCE…12412
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…12412
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…12416
TIRES…12421
OPERATION…12423
GENERAL VIEW…12424
GENERAL VIEW OF MACHINE…12424
GENERAL VIEW OF CONTROLS AND GAUGES…12425
EXPLANATION OF COMPONENTS…12427
MACHINE MONITOR…12427
OTHER FUNCTIONS OF MACHINE MONITOR…12449
SWITCHES…12454
CONTROL LEVERS AND PEDALS…12463
BODY PIVOT PIN…12468
LOCATION OF FIRE EXTINGUISHER…12468
DUST INDICATOR…12469
FUSES…12470
CAR RADIO…12473
CAR STEREO…12479
AIR CONDITIONER…12488
HANDLING MACHINES EQUIPPED WITH VHMS…12493
OPERATION…12495
CHECK BEFORE STARTING ENGINE…12495
STARTING ENGINE…12517
BREAKING-IN THE MACHINE…12519
OPERATIONS, CHECKS AFTER STARTING ENGINE…12519
STOPPING ENGINE…12520
CHECKS AFTER STOPPING ENGINE…12520
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…12521
SHIFTING GEAR…12526
TRAVELING DOWNHILL…12528
STEERING THE MACHINE…12542
LOADING OPERATIONS…12542
DUMP OPERATIONS…12543
PRECAUTIONS FOR OPERATION…12545
PARKING MACHINE…12546
CHECKS AFTER COMPLETION OF WORK…12547
LOCKING…12547
HANDLING TIRES…12548
DETERMINING AND MAINTAINING TRAVEL ROAD…12551
DETERMINING TRAVEL ROAD…12551
MAINTAINING TRAVEL ROAD…12551
TRANSPORTATION…12552
PRECAUTIONS WHEN TRANSPORTING…12552
STEPS FOR TRANSPORTATION…12552
METHOD OF SECURING MACHINE…12552
METHOD OF LIFTING MACHINE…12553
COLD WEATHER OPERATION…12556
PRECAUTIONS FOR LOW TEMPERATURE…12556
PRECAUTIONS AFTER COMPLETION OF WORK…12557
AFTER COLD WEATHER…12558
LONG-TERM STORAGE…12559
BEFORE STORAGE…12559
DURING STORAGE…12559
AFTER STORAGE…12559
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…12559
TROUBLESHOOTING…12560
AFTER RUNNING OUT OF FUEL…12560
IF TRANSMISSION HAS TROUBLE…12561
METHOD OF LOWERING DUMP BODY IN EMERGENCY…12561
METHOD OF TOWING MACHINE…12562
IF BATTERY IS DISCHARGED…12566
OTHER TROUBLE…12570
MAINTENANCE…12577
GUIDES TO MAINTENANCE…12578
OUTLINE OF SERVICE…12582
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…12582
OUTLINE OF ELECTRIC SYSTEM…12586
WEAR PARTS…12587
WEAR PARTS LIST…12587
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…12588
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…12589
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…12590
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…12591
TORQUE LIST…12591
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…12592
SAFETY CRITICAL PARTS…12593
MAINTENANCE SCHEDULE CHART…12600
MAINTENANCE SCHEDULE CHART…12600
SERVICE PROCEDURE…12602
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…12602
WHEN REQUIRED…12603
CHECK BEFORE STARTING…12630
EVERY 250 HOURS SERVICE…12631
EVERY 500 HOURS SERVICE…12645
EVERY 1000 HOURS SERVICE…12649
EVERY 2000 HOURS SERVICE…12663
EVERY 4000 HOURS SERVICE…12666
EVERY 8000 HOURS SERVICE…12670
EVERY 15000 HOURS SERVICE…12671
SPECIFICATIONS…12673
SPECIFICATIONS…12674
ATTACHMENTS, OPTIONS…12675
SELECTING DUMP BODY…12676
HANDLING AIR SUSPENSION SEAT…12677
SEAT ADJUSTMENT…12677
REMOVAL AND INSTALLATION OF HEADREST…12679
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…12680
EXPLANATION OF COMPONENTS…12680
ACTUATION OF ASR SYSTEM…12681
PRECAUTIONS WHEN USING…12681
TROUBLESHOOTING…12682
BLEEDING AIR FROM ASR CIRCUIT…12683
HANDLING ABS…12684
EXPLANATION OF COMPONENTS…12684
ABS SYSTEM CHECK AFTER STARTING ENGINE…12686
OPERATION OF ABS…12686
PRECAUTIONS WHEN USING…12687
TROUBLESHOOTING…12688
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…12690
OUTLINE OF SYSTEM…12690
NORMAL OPERATION DISPLAY…12692
EXTERNAL DISPLAY LAMPS…12693
PERFORMING CALIBRATION…12694
DATA STORED IN PAYLOAD METER…12696
PROCEDURE WHEN DOWNLOADING…12696
METHOD OF SETTING MACHINE ID, OPEN ID…12700
PAYLOAD (CYCLE DATA ITEM)…12702
SERVICE FUNCTIONS…12702
OTHERS…12702
HANDLING AUTO-GREASING SYSTEM…12703
METHOD OF OPERATING AUTO-GREASING SYSTEM…12703
METHOD OF SETTING TIMER…12704
BLEEDING AIR FROM GREASE CIRCUIT…12705
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR…12705
CHECKING OPERATION OF INJECTOR…12706
METHOD OF CHARGING WITH GREASE…12707
USE OF REAR VIEW MONITOR…12708
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…12708
SETTING OF REAR VIEW MONITOR…12711
CAUTIONS WHEN USING REAR VIEW MONITOR…12711
HANDLING DUMPING COUNTER…12712
HANDLING BATTERY ISOLATOR…12713
HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE)…12715
PRECAUTIONS WHEN USING…12715
INDEX…12717
TEN00371-03 – Dump Truck HD785-7 Operation & Maintenance Manual…12721
COVER…12721
FOREWORD…12722
BEFORE READING THIS MANUAL…12723
SAFETY INFORMATION…12724
INTENDED USE…12725
USE OF MACHINE…12725
DIRECTIONS OF MACHINE…12725
VISIBILITY FROM OPERATOR'S SEAT…12726
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12727
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…12727
EPA REGULATIONS, ENGINE NUMBER PLATE…12727
SERVICE METER POSITION…12728
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…12728
CONTENTS…12729
SAFETY…12734
SAFETY…12735
SAFETY LABELS…12738
POSITION FOR ATTACHING SAFETY LABELS…12739
SAFETY LABELS…12740
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…12745
PRECAUTIONS BEFORE STARTING OPERATION…12745
PREPARATIONS FOR SAFE OPERATION…12745
FIRE PREVENTION…12747
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…12748
DO NOT GET CAUGHT IN DUMP BODY…12750
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…12750
UNAUTHORIZED MODIFICATION…12750
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…12751
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…12751
PRECAUTIONS FOR OPERATION…12752
PRECAUTIONS FOR JOBSITE…12752
STARTING ENGINE…12754
OPERATION…12756
TRANSPORTATION…12760
TOWING…12761
PRECAUTIONS FOR MAINTENANCE…12762
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…12762
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…12766
TIRES…12771
OPERATION…12774
GENERAL VIEW…12775
GENERAL VIEW OF MACHINE…12775
GENERAL VIEW OF CONTROLS AND GAUGES…12776
EXPLANATION OF COMPONENTS…12778
MACHINE MONITOR…12778
OTHER FUNCTIONS OF MACHINE MONITOR…12800
SWITCHES…12805
CONTROL LEVERS AND PEDALS…12815
BODY PIVOT PIN…12820
LOCATION OF FIRE EXTINGUISHER…12820
DUST INDICATOR…12821
FUSES…12822
CAR RADIO…12826
CAR STEREO…12832
AIR CONDITIONER…12841
HANDLING MACHINES EQUIPPED WITH VHMS…12846
OPERATION…12848
CHECK BEFORE STARTING ENGINE…12848
STARTING ENGINE…12871
BREAKING-IN THE MACHINE…12873
OPERATIONS, CHECKS AFTER STARTING ENGINE…12873
STOPPING ENGINE…12874
CHECKS AFTER STOPPING ENGINE…12874
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…12875
SHIFTING GEAR…12880
TRAVELING DOWNHILL…12882
STEERING THE MACHINE…12896
LOADING OPERATIONS…12896
DUMP OPERATIONS…12897
PRECAUTIONS FOR OPERATION…12899
PARKING MACHINE…12900
CHECKS AFTER COMPLETION OF WORK…12901
LOCKING…12901
HANDLING TIRES…12902
DETERMINING AND MAINTAINING TRAVEL ROAD…12905
DETERMINING TRAVEL ROAD…12905
MAINTAINING TRAVEL ROAD…12905
TRANSPORTATION…12906
PRECAUTIONS WHEN TRANSPORTING…12906
STEPS FOR TRANSPORTATION…12906
METHOD OF SECURING MACHINE…12906
METHOD OF LIFTING MACHINE…12908
COLD WEATHER OPERATION…12911
PRECAUTIONS FOR LOW TEMPERATURE…12911
PRECAUTIONS AFTER COMPLETION OF WORK…12912
AFTER COLD WEATHER…12913
LONG-TERM STORAGE…12914
BEFORE STORAGE…12914
DURING STORAGE…12914
AFTER STORAGE…12914
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…12914
TROUBLESHOOTING…12915
AFTER RUNNING OUT OF FUEL…12915
IF TRANSMISSION HAS TROUBLE…12916
METHOD OF LOWERING DUMP BODY IN EMERGENCY…12916
METHOD OF TOWING MACHINE…12917
IF BATTERY IS DISCHARGED…12921
OTHER TROUBLE…12925
MAINTENANCE…12932
GUIDES TO MAINTENANCE…12933
OUTLINE OF SERVICE…12937
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…12938
OUTLINE OF ELECTRIC SYSTEM…12941
WEAR PARTS…12942
WEAR PARTS LIST…12942
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…12943
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…12944
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…12948
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…12949
TORQUE LIST…12949
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…12950
SAFETY CRITICAL PARTS…12951
MAINTENANCE SCHEDULE CHART…12958
MAINTENANCE SCHEDULE CHART…12958
SERVICE PROCEDURE…12960
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…12960
WHEN REQUIRED…12961
CHECK BEFORE STARTING…12988
EVERY 250 HOURS SERVICE…12989
EVERY 500 HOURS SERVICE…13003
EVERY 1000 HOURS SERVICE…13007
EVERY 2000 HOURS SERVICE…13021
EVERY 4000 HOURS SERVICE…13024
EVERY 8000 HOURS SERVICE…13028
EVERY 15000 HOURS SERVICE…13029
SPECIFICATIONS…13030
SPECIFICATIONS…13031
ATTACHMENTS, OPTIONS…13032
SELECTING DUMP BODY…13033
HANDLING AIR SUSPENSION SEAT…13034
SEAT ADJUSTMENT…13034
REMOVAL AND INSTALLATION OF HEADREST…13036
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…13037
EXPLANATION OF COMPONENTS…13037
ACTUATION OF ASR SYSTEM…13038
PRECAUTIONS WHEN USING…13038
TROUBLESHOOTING…13039
BLEEDING AIR FROM ASR CIRCUIT…13040
HANDLING ABS…13041
EXPLANATION OF COMPONENTS…13041
ABS SYSTEM CHECK AFTER STARTING ENGINE…13043
OPERATION OF ABS…13043
PRECAUTIONS WHEN USING…13044
TROUBLESHOOTING…13045
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…13047
OUTLINE OF SYSTEM…13047
NORMAL OPERATION DISPLAY…13049
EXTERNAL DISPLAY LAMPS…13050
PERFORMING CALIBRATION…13051
DATA STORED IN PAYLOAD METER…13053
PROCEDURE WHEN DOWNLOADING…13053
METHOD OF SETTING MACHINE ID, OPEN ID…13057
PAYLOAD (CYCLE DATA ITEM)…13059
SERVICE FUNCTIONS…13059
OTHERS…13059
HANDLING AUTO-GREASING SYSTEM…13060
METHOD OF OPERATING AUTO-GREASING SYSTEM…13060
METHOD OF SETTING TIMER…13061
BLEEDING AIR FROM GREASE CIRCUIT…13062
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR…13062
CHECKING OPERATION OF INJECTOR…13063
METHOD OF CHARGING WITH GREASE…13064
USE OF REAR VIEW MONITOR…13065
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…13065
SETTING OF REAR VIEW MONITOR…13068
CAUTIONS WHEN USING REAR VIEW MONITOR…13068
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…13069
SOCKET FOR ENGINE HEATER…13069
SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUB-TANK HEATER…13069
CONNECTING EXTERNAL POWER SOURCE…13070
RESTARTING ENGINE…13071
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…13073
HANDLING PRELUBE SYSTEM…13080
EXPLANATION OF COMPONENTS…13080
OPERATION…13082
TROUBLESHOOTING…13085
HANDLING DUMPING COUNTER…13087
HANDLING BATTERY ISOLATOR…13088
HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE)…13090
PRECAUTIONS WHEN USING…13090
INDEX…13092
TEN00440-08 – Dump Truck HD785-7 Operation & Maintenance Manual…13096
TEN00598-02 – Dump Truck HD785-7 Operation & Maintenance Manual…13507
COVER…13507
FOREWORD…13508
BEFORE READING THIS MANUAL…13509
SAFETY INFORMATION…13510
INTENDED USE…13511
USE OF MACHINE…13511
DIRECTIONS OF MACHINE…13511
VISIBILITY FROM OPERATOR'S SEAT…13512
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…13513
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…13513
EPA REGULATIONS, ENGINE NUMBER PLATE…13513
SERVICE METER POSITION…13514
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…13514
CONTENTS…13515
SAFETY…13520
SAFETY…13521
SAFETY LABELS…13524
POSITION FOR ATTACHING SAFETY LABELS…13525
SAFETY LABELS…13526
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…13531
PRECAUTIONS BEFORE STARTING OPERATION…13531
PREPARATIONS FOR SAFE OPERATION…13531
FIRE PREVENTION…13533
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…13534
DO NOT GET CAUGHT IN DUMP BODY…13536
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…13536
UNAUTHORIZED MODIFICATION…13536
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…13537
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…13537
PRECAUTIONS FOR OPERATION…13538
PRECAUTIONS FOR JOBSITE…13538
STARTING ENGINE…13540
OPERATION…13542
TRANSPORTATION…13546
TOWING…13547
PRECAUTIONS FOR MAINTENANCE…13548
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…13548
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…13552
TIRES…13557
OPERATION…13560
GENERAL VIEW…13561
GENERAL VIEW OF MACHINE…13561
GENERAL VIEW OF CONTROLS AND GAUGES…13562
EXPLANATION OF COMPONENTS…13564
MACHINE MONITOR…13564
OTHER FUNCTIONS OF MACHINE MONITOR…13586
SWITCHES…13591
CONTROL LEVERS AND PEDALS…13601
BODY PIVOT PIN…13607
LOCATION OF FIRE EXTINGUISHER…13607
DUST INDICATOR…13608
FUSES…13609
CAR RADIO…13613
AIR CONDITIONER…13617
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…13622
OPERATION…13625
CHECK BEFORE STARTING ENGINE…13625
STARTING ENGINE…13650
BREAKING-IN THE MACHINE…13652
OPERATIONS, CHECKS AFTER STARTING ENGINE…13652
STOPPING ENGINE…13653
CHECKS AFTER STOPPING ENGINE…13653
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…13654
SHIFTING GEAR…13659
TRAVELING DOWNHILL…13661
STEERING THE MACHINE…13675
LOADING OPERATIONS…13675
DUMP OPERATIONS…13676
PRECAUTIONS FOR OPERATION…13678
PARKING MACHINE…13679
CHECKS AFTER COMPLETION OF WORK…13680
LOCKING…13680
HANDLING TIRES…13681
DETERMINING AND MAINTAINING TRAVEL ROAD…13684
DETERMINING TRAVEL ROAD…13684
MAINTAINING TRAVEL ROAD…13684
TRANSPORTATION…13685
PRECAUTIONS WHEN TRANSPORTING…13685
STEPS FOR TRANSPORTATION…13685
METHOD OF SECURING MACHINE…13685
METHOD OF LIFTING MACHINE…13687
COLD WEATHER OPERATION…13690
PRECAUTIONS FOR LOW TEMPERATURE…13690
INSTALLATION OF RADIATOR CURTAIN…13691
PRECAUTIONS AFTER COMPLETION OF WORK…13691
AFTER COLD WEATHER…13692
LONG-TERM STORAGE…13693
BEFORE STORAGE…13693
DURING STORAGE…13693
AFTER STORAGE…13693
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…13693
TROUBLESHOOTING…13694
AFTER RUNNING OUT OF FUEL…13694
IF TRANSMISSION HAS TROUBLE…13695
METHOD OF LOWERING DUMP BODY IN EMERGENCY…13695
METHOD OF TOWING MACHINE…13696
IF BATTERY IS DISCHARGED…13700
OTHER TROUBLE…13704
MAINTENANCE…13710
GUIDES TO MAINTENANCE…13711
OUTLINE OF SERVICE…13715
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…13716
OUTLINE OF ELECTRIC SYSTEM…13719
WEAR PARTS…13720
WEAR PARTS LIST…13720
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…13721
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…13722
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…13726
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…13727
TORQUE LIST…13727
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…13728
SAFETY CRITICAL PARTS…13729
MAINTENANCE SCHEDULE CHART…13736
MAINTENANCE SCHEDULE CHART…13736
SERVICE PROCEDURE…13738
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…13738
WHEN REQUIRED…13739
CHECK BEFORE STARTING…13766
EVERY 250 HOURS SERVICE…13767
EVERY 500 HOURS SERVICE…13781
EVERY 1000 HOURS SERVICE…13785
EVERY 2000 HOURS SERVICE…13799
EVERY 4000 HOURS SERVICE…13803
EVERY 8000 HOURS SERVICE…13807
EVERY 15000 HOURS SERVICE…13808
SPECIFICATIONS…13810
SPECIFICATIONS…13811
ATTACHMENTS, OPTIONS…13814
SELECTING DUMP BODY…13815
AUXILIARY ELECTRIC POWER…13816
HANDLING AIR SUSPENSION SEAT…13817
SEAT ADJUSTMENT…13817
REMOVAL AND INSTALLATION OF HEADREST…13819
HANDLING KOMATSU TRACTION CONTROL SYSTEM (KTCS)…13820
EXPLANATION OF COMPONENTS…13820
ACTUATION OF KTCS SYSTEM…13821
PRECAUTIONS WHEN USING…13821
TROUBLESHOOTING…13822
BLEEDING AIR FROM KTCS CIRCUIT…13824
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…13825
EXPLANATION OF COMPONENTS…13825
ACTUATION OF ASR SYSTEM…13826
PRECAUTIONS WHEN USING…13826
TROUBLESHOOTING…13827
BLEEDING AIR FROM ASR CIRCUIT…13828
HANDLING ABS…13829
EXPLANATION OF COMPONENTS…13829
ABS SYSTEM CHECK AFTER STARTING ENGINE…13831
OPERATION OF ABS…13831
PRECAUTIONS WHEN USING…13832
TROUBLESHOOTING…13833
HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE)…13835
OUTLINE OF SYSTEM…13835
NORMAL OPERATION DISPLAY…13837
EXTERNAL DISPLAY LAMPS…13838
PERFORMING CALIBRATION…13839
DATA STORED IN PAYLOAD METER…13841
PROCEDURE WHEN DOWNLOADING…13841
METHOD OF SETTING MACHINE ID, OPEN ID…13845
PAYLOAD (CYCLE DATA ITEM)…13847
SERVICE FUNCTIONS…13847
OTHERS…13847
HANDLING AUTO-GREASING SYSTEM…13848
METHOD OF OPERATING AUTO-GREASING SYSTEM…13848
METHOD OF SETTING TIMER…13849
BLEEDING AIR FROM GREASE CIRCUIT…13850
METHOD OF ADJUSTING DISCHARGE FROM INJECTOR…13850
CHECKING OPERATION OF INJECTOR…13851
METHOD OF CHARGING WITH GREASE…13852
HANDLING REAR VIEW MONITOR…13853
EXPLANATION OF COMPONENTS…13853
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…13854
SOCKET FOR ENGINE HEATER…13854
SOCKET FOR ENGINE, TRANSMISSION, HYDRAULIC TANK AND BRAKE SUB-TANK HEATER…13854
CONNECTING EXTERNAL POWER SOURCE…13855
RESTARTING ENGINE…13856
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…13858
HANDLING PRELUBE SYSTEM…13865
EXPLANATION OF COMPONENTS…13865
OPERATION…13867
TROUBLESHOOTING…13870
HANDLING DUMPING COUNTER…13872
HANDLING HIGH-ALTITUDE SETTING SELECTOR FUNCTION (FOR PLACES AT HIGH ALTITUDE)…13873
PRECAUTIONS WHEN USING…13873
EMERGENCY ENGINE STOP SWITCH…13874
HANDLING BATTERY DISCONNECTOR SWITCH…13876
EXPLANATION OF COMPONENTS…13876
PRECAUTIONS WHEN OPERATING…13877
HANDLING VEHICLE SPEED LIMIT…13878
EXPLANATION OF COMPONENTS…13878
OPERATION OF VEHICLE SPEED LIMIT…13879
TROUBLESHOOTING…13880
HANDLING OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE…13881
EXPLANATION OF COMPONENTS…13881
OPERATION OF SPEED LIMIT CONTROL FUNCTION IN OVERLOAD STATE…13882
TROUBLESHOOTING…13883
AUTO-GREASING REFILLING SYSTEM…13884
SYSTEM EXPLANATION…13884
OPERATING PROCEDURE OF THE REFILLING SYSTEM…13885
HANDLING POWER LADDER…13886
EXPLANATION OF COMPONENTS…13887
OPERATION OF POWER LADDER…13889
OPERATING THE LADDER WHEN THE STARTING SWITCH IS TURNED OFF…13891
POWER LADDER RELATED FUNCTIONS…13891
MAINTENANCE OF POWER LADDER…13892
SAFETY CRITICAL PARTS FOR PERIODIC REPLACEMENT…13896
PROCEDURES WHEN MACHINE BECOMES IMMOVABLE BECAUSE PARKING BRAKE CANNOT BE RELEASED…13897
PROCEDURES WHEN THE LADDER BECOMES IMMOVABLE…13898
TROUBLESHOOTING…13900
Komatsu Dump Trucks HD785, HD985 Repair Service Manuals
