Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD785-5LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Dump Truck HD785-5LC 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.
CEBM006103 – Dump Truck HD785-5LC Shop Manual.pdf
CEBM013801 – Dump Truck HD785-5LC Shop Manual.pdf
CEAM006003 – Dump Truck HD785-5LC Operation & Maintenance Manual.pdf
CEAM014100 – Dump Truck HD785-5LC Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,663 pages
File Format: PDF
Language: English
MAIN SECTIONS
CEAM006003 – Dump Truck HD785-5LC Operation & Maintenance Manual…2
OM6005.pdf…0
PAYLOAD METER II™…133
PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)…136
GENERAL INFORMATION…136
Haul Cycles…136
LIGHTS, SWITCHES, and COMPONENTS…137
TIPS FOR OPERATION…138
EXTERNAL DISPLAY LIGHTS…138
THEORY OF OPERATION…139
Basic Description…139
Inclinometer…139
Linkage Factor…139
Gain Factor…140
Brake Lock…140
Sources of Error…140
Typical Data From Service Check Mode…140
Example Calculation of Payload…141
Viewing Payload Calculation Inputs…141
Checking the Gain…142
Adjusting the Gain…142
TYPES OF DATA STORED…143
Cycle Data…143
Engine ON/OFF Data…144
Fault Codes and Warning Data…144
Engine Operation…145
Total Payload and Total Number of Cycles…145
Other Data…145
OPERATOR FUNCTIONS…146
Using the Operator Load Counter…146
Viewing the Operator Load Counter…146
Clearing the Operator Load Counter…146
Dimming the Lights on the Display…146
INITIAL SETUP OF PAYLOAD METER…147
Switch Settings…147
Checking the Operator Check Mode…148
Checking the Service Check Mode…148
Checking the Gt setting:…149
Checking the Inclinometer Settings…149
Calibrating a Truck…149
DISPLAYS AT START-UP…150
NORMAL OPERATION…150
SETUP AND MAINTENANCE…151
Setting The Speed Limit…151
Setting the Option Code…151
Setting The Machine I.D. Code…152
Setting The Operator I.D. Code…152
Setting The Time and Date…152
DOWNLOAD OF INFORMATION…153
DISPLAY OF FAULT CODES…153
Monitoring Input Signals…157
Service Check Mode…157
UP Factor – Payload Calculation Gain…158
PL Mode – Load Calculation Timing…158
FINAL GEAR RATIO SELECTION…159
BATTERY REPLACEMENT PROCEDURE…160
Replacing the Battery…160
After Replacing the Battery…161
SUSPENSION PRESSURE SENSOR…161
Removal…161
Installation…162
INCLINOMETER…162
Removal…162
Installation…162
Adjustment…162
PAYLOAD METER BACK PANEL…163
CONNECTIONS…164
PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE…165
PAYLOAD CIRCUIT NUMBERS…166
CEAM014100 – Dump Truck HD785-5LC Operation & Maintenance Manual…169
COVER…169
INTRODUCTION…175
FOREWORD…175
ALERTS PAGE…176
TABLE OF CONTENTS…177
TRUCK MODEL ILLUSTRATION…185
ABOUT THIS MANUAL…186
STANDARD CHARTS AND TABLES…187
INDEX OF TABLES…187
GENERAL SAFETY…193
Safety Rules…193
Safety Features…193
Clothing And Personal Protective Items…193
Unauthorized Modification…193
Leaving The Operator's Seat…194
Mounting And Dismounting…194
Fire Prevention For Fuel And Oil…194
Precautions When Handling At High Temperatures…195
Asbestos Dust Hazard Prevention…195
Prevention Of Injury By Work Equipment…195
Fire Extinguisher And First Aid Kit…195
Precautions When Using ROPS…196
Precautions For Attachments…196
PRECAUTIONS DURING OPERATION…197
BEFORE STARTING ENGINE…197
Safety At Worksite…197
Fire Prevention…197
In Operator's Cab…197
Ventilation For Enclosed Areas…197
In Operator's Cab – Before Starting Engine…198
Keep Mirrors, Windows, And Lights Clean…198
OPERATING THE MACHINE…198
When Starting Engine…198
Truck Operation – General…198
Check When Traveling In Reverse…199
Traveling…199
Traveling On Slopes…200
Ensure Good Visibility…200
Operate Carefully On Snow…200
Avoid Damage To Dump Body…200
Do Not Go Close To High-voltage Cables…200
When Dumping…201
Working On Loose Ground…201
When Loading…201
Parking The Machine…201
TOWING…201
When Towing, Attach Cable To Hook…201
BATTERY…202
Battery Hazard Prevention…202
Starting With Booster Cables…202
PRECAUTIONS FOR MAINTENANCE…203
BEFORE CARRYING OUT MAINTENANCE…203
Warning Tag…203
Proper Tools…203
Periodic Replacement Of Critical Parts…203
Stopping The Engine Before Service…203
Securing The Dump Body…204
DURING MAINTENANCE…204
Personnel…204
Attachments…204
Work Under The Machine…204
Keep The Machine Clean…204
Rules To Follow When Adding Fuel Or Oil…205
Radiator Water Level…205
Use Of Lighting…205
Precautions With Battery…205
Handling High-Pressure Hoses…205
Precautions With High Pressure Oil…206
Precautions When Carrying Out Maintenance At High Temperature Or High Pressure…206
Rotating Fan And Belt…206
Waste Materials…206
TIRES…207
Handling Tires…207
Storing Tires After Removal…207
WARNINGS AND CAUTIONS…209
OPERATION…219
OPERATING INSTRUCTIONS…219
PREPARING FOR OPERATION…219
SAFETY IS THINKING AHEAD…219
At The Truck – Ground Level Walk Around Inspection…219
ENGINE START-UP SAFETY PRACTICES…223
Before Starting The Engine…223
Starting The Engine…224
Starting The Engine In Cold Weather…224
AFTER ENGINE HAS STARTED…225
MACHINE OPERATION SAFETY PRECAUTIONS…226
LOADING…226
HAULING…227
RETARDER OPERATION…227
Engine Overspeed…228
PASSING…229
DUMPING…229
To Raise dump body:…229
To Lower Body:…230
SAFE PARKING PROCEDURES…230
SHUTDOWN PROCEDURE…230
TOWING…231
BRAKE RELEASE…232
Release Of Parking Brake…232
Release Of Emergency Brake…232
OPERATOR CAB AND CONTROLS…233
(1) STEERING WHEEL AND CONTROLS…233
(2) Tilt Lever…233
(3) Turn Signal Lever Switch…233
(4) Horn…233
(5) Windshield Wiper / Washer Switch…233
(6) Headlights and Dimmer Switch…234
(7) Retard Control Lever…234
(8) BRAKE PEDAL…234
(9) THROTTLE PEDAL…234
(10) CENTER CONSOLE AND CONTROLS…234
Transmission Range Selector (1, Figure 32-2)…234
Shift Limiter Switch (2, Figure 32-2)…236
Economy / Power Mode Switch (3, Figure 32-2)…236
Emergency Steering Switch (4, Figure 32-2)…236
Emergency Brake Lever (5, Figure 32-2)…237
Parking Brake Valve Lever (6, Figure 32-2)…237
ENGINE ELECTRONIC CONTROL SYSTEM…238
Engine Shutdown Light (Stop Engine)…238
Engine Maintenance Light (Check Engine)…238
Engine Maintenance Light…238
Fault Check Switch (11, Figure 32-2)…239
Fault Scroll Switch (12, Figure 32-2)…239
Determining Fault Codes…239
EXITING THE DIAGNOSTICS MODE…239
(11) HOIST CONTROL…240
SAFETY LOCK…240
ASR (AUTOMATIC SPIN REGULATOR) / ARSC (Automatic Retard Speed Control) (Optional)…241
ASR SYSTEM CONTROLS…241
System Switch (1, Figure 32-3)…242
ASR/ARSC Caution Lamp (6, Figure 32-3)…242
ASR Operation Lamp (8, Figure 32-3)…242
Central Warning Lamp (12, Figure 32-3)…242
Retarder Control Lever (10, Figure 32-3)…242
Accelerator Pedal (5, Figure 32-3)…242
Brake Pedal (4, Figure 32-3)…242
PRECAUTIONS WHEN USING THE ASR SYSTEM…242
ARSC SYSTEM CONTROLS…243
System Switch (2, Figure 32-3)…243
ARSC Set Lever (3, Figure 32-3)…243
Brake Pedal (4, Figure 32-3)…243
Accelerator Pedal (5, Figure 32-3)…243
ASR/ARSC Caution Lamp (6, Figure 32-3)…243
ARSC Standby Lamp (7, Figure 32-3)…243
Set Speed Display (9, Figure 32-3)…243
Retarder Control Lever (10, Figure 32-3)…243
Central Warning Lamp (12, Figure 32-3)…243
ARSC SYSTEM ACTUATION…244
Traveling Again At Set Speed…244
Relationship With Exhaust Brake…245
Recommended Set Speed…245
TROUBLESHOOTING THE ASR/ARSC SYSTEM…246
When a problem occurs in the system…246
Model Selection, Tire Selection, And Failure Code Display…246
Failure Codes…246
Clearing The Failure Code…248
OPERATOR SEAT…249
INSTRUMENT PANEL AND INDICATORS…250
WARNING & CAUTION LAMPS…251
GAUGE AND MONITOR PANEL…252
1. Air Pressure Monitor…252
2. Air Pressure Gauge…252
3. Coolant Temperature Monitor…252
4. Engine Cooling Water Temperature Gauge…252
5. Torque Converter Oil Temperature Monitor…253
6. Torque Converter Oil Temperature Gauge…253
7. Retarder Oil Temperature Monitor…253
8. Retarder Oil Temperature Gauge…253
9. High Beam Pilot Lamp…253
10. Left Turn Signal Pilot Lamp…253
11. Right Turn Signal Pilot Lamp…253
12. Speedometer…253
13. Tachometer…253
14. Shift Limiter Pilot Lamp…253
15. Lock-up Pilot Lamp…254
16. Transmission Shift Position Pilot Lamp…254
17. Shift Indicator…254
18. Engine Controller Monitor…254
19. Automatic Transmission Mechatronics Monitor…254
20. Other Mechatronics Monitor (OPTIONAL)…254
21. Fuel Level Monitor…254
22. Fuel Gauge…254
26. Service Meter…255
27. Service Meter Indicator…255
28. Odometer…255
29. Power Mode Indicator…255
INDICATORS AND CONTROLS PANEL…255
Optional Equipment…255
30. Coolant Level Monitor…256
31. Engine Oil Pressure Monitor…256
32. Charge Monitor…256
33. Transmission Oil Filter Monitor…256
34. Hazard Warning Lights…256
35. Front Brake On/Off Switch…256
36. Panel Dimmer Switch…256
37. AISS/Auto Switch…257
38. Manual Starting Aid Switch…257
39. Starting Switch…257
40. Pilot Lamp Bulb Check Switch…257
41. Rear Brake Pilot Lamp…257
42. Body Float Caution Monitor…257
43. Parking Brake Monitor…258
44. Emergency Steering Monitor…258
45. Exhaust Brake (Optional)…258
46. Cold Start…258
48. Steering Oil Temperature…258
50. Side Slope Warning (Optional)…258
51. Rear Brake Caution Lamp…258
52. Exhaust Brake Switch (Optional)…259
53. Fog Light Switch (Optional)…259
54. Central Warning Lamp (Red Convex Lens)…259
HEATER/AIR CONDITIONER CONTROLS…260
55. Temperature Adjustment Lever…260
56. Blower Switch…260
57. Air Selector Lever…260
58. Vent Selector Lever…260
59. Air Vent…261
60. Glove Box Storage Compartment…261
61. Air Conditioner Switch…261
62. Correction Code Display…261
MAINTENANCE…263
LUBRICATION AND SERVICE…263
10 HOUR (DAILY) INSPECTION…265
FLUID LEVELS & OTHER CHECKS…265
ENGINE…267
WHEELS AND TIRES…267
Tires…267
WHEELS…268
OPERATIONAL CHECKS…269
250 HOURS SERVICE…271
INITIAL 250 HOURS SERVICE ONLY…271
EVERY 250 HOURS SERVICE…271
500 HOUR SERVICE…273
1000 HOUR SERVICE…274
EVERY 2000 HOUR SERVICE…275
EVERY 5000 HOUR SERVICE…276
HYDRAULIC TANK SERVICE…277
Filling Instructions (Hoist Oil Supply)…277
Filling Instructions (Rear Brake Cooling Oil Supply)…277
HYDRAULIC FILTERS…278
Filter Replacement…278
HYDRAULIC TANK BREATHER…278
Cleaning…278
HIGH PRESSURE HYDRAULIC FILTERS…279
Filter Assembly Removal…279
Filter Assembly Installation…279
Filter Element Replacement…280
TRANSMISSION FILTER…281
Service…281
PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES…282
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…283
CHECKING FRONT BRAKE PAD WEAR…283
TESTING BRAKE PRESSURE…283
CHECKING REAR BRAKE DISC WEAR…284
BRAKE BLEEDING…285
Rear brakes…285
Front brakes…285
PARKING BRAKE…286
PARKING BRAKE PAD…286
Inspection…286
PARKING BRAKE ADJUSTMENT…286
Testing…286
Adjusting…286
AUTOMATIC LUBRICATION SYSTEM…289
OPERATION…289
COMPONENTS…289
COMPONENT LOCATION…290
GENERAL INFORMATION…292
Lubricant Required for System…292
Air Pressure Regulator…292
Initial Reservoir Fill…292
System Priming…292
SYSTEM CHECKOUT…293
24 VDC Solid State Timer Check…293
Timer Adjustment…293
Injectors (SL-1 Series H)…294
Injector Specifications…294
Injector Adjustment…294
INJECTOR OPERATION…295
STAGE 3…295
STAGE 4…295
TROUBLESHOOTING CHART…296
MAJOR COMPONENTS AND SPECIFICATIONS…299
OPTIONAL EQUIPMENT…303
PAYLOAD METER II™…303
PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)…306
GENERAL INFORMATION…306
Haul Cycles…306
LIGHTS, SWITCHES, and COMPONENTS…307
TIPS FOR OPERATION…308
EXTERNAL DISPLAY LIGHTS…308
THEORY OF OPERATION…309
Basic Description…309
Inclinometer…309
Linkage Factor…309
Gain Factor…310
Brake Lock…310
Sources of Error…310
Typical Data From Service Check Mode…310
Example Calculation of Payload…311
Viewing Payload Calculation Inputs…311
Checking the Gain…312
Adjusting the Gain…312
TYPES OF DATA STORED…313
Cycle Data…313
Engine ON/OFF Data…314
Fault Codes and Warning Data…314
Engine Operation…315
Total Payload and Total Number of Cycles…315
Other Data…315
OPERATOR FUNCTIONS…316
Using the Operator Load Counter…316
Viewing the Operator Load Counter…316
Clearing the Operator Load Counter…316
Dimming the Lights on the Display…316
INITIAL SETUP OF PAYLOAD METER…317
Switch Settings…317
Checking the Operator Check Mode…318
Checking the Service Check Mode…318
Checking the Gt setting:…319
Checking the Inclinometer Settings…319
Calibrating a Truck…319
DISPLAYS AT START-UP…320
NORMAL OPERATION…320
SETUP AND MAINTENANCE…321
Setting The Speed Limit…321
Setting the Option Code…321
Setting The Machine I.D. Code…322
Setting The Operator I.D. Code…322
Setting The Time and Date…322
DOWNLOAD OF INFORMATION…323
DISPLAY OF FAULT CODES…323
Monitoring Input Signals…327
Service Check Mode…327
UP Factor – Payload Calculation Gain…328
PL Mode – Load Calculation Timing…328
FINAL GEAR RATIO SELECTION…329
BATTERY REPLACEMENT PROCEDURE…330
Replacing the Battery…330
After Replacing the Battery…331
SUSPENSION PRESSURE SENSOR…331
Removal…331
Installation…332
INCLINOMETER…332
Removal…332
Installation…332
Adjustment…332
PAYLOAD METER BACK PANEL…333
CONNECTIONS…334
PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE…335
PAYLOAD CIRCUIT NUMBERS…336
RADIO, AM/FM STEREO CASSETTE…337
RECEIVER CONTROLS…337
BASIC OPERATION…338
Power ON/OFF and Selecting a Source…338
To Listen To The Radio…338
Storing and Recalling Broadcast Frequencies…338
Tuning Strong Signals…338
Storing the Strongest Broadcast Frequencies…338
Playing a Cassette Tape…339
Radio Intercept…339
AUDIO ADJUSTMENTS…339
Accessing Audio Controls…339
Audio Controls Description and Adjustment…339
BTB (bass treble booster) Adjustment…339
Loudness Adjustment…340
Source Level Adjustment…340
SETTING THE CLOCK…340
Turning Clock Display on or off…340
XM SATELLITE RECEIVER OPERATION…340
Switching the XM Channel Select Setting…340
LIGHTER & ASH TRAY…341
Lighter…341
Ash Tray…341
CEBM006103 – Dump Truck HD785-5LC Shop Manual…345
CEBM013801 – Dump Truck HD785-5LC Shop Manual…1517
COVER…1517
FOREWORD…1521
TABLE OF CONTENTS…1523
SECTION A GENERAL INFORMATION…1525
MAJOR COMPONENTS AND SPECIFICATIONS…1527
SPECIFICATIONS…1529
GENERAL SAFETY AND OPERATING INSTRUCTIONS…1531
GENERAL SAFETY…1533
Safety Rules…1533
Safety Features…1533
Clothing And Personal Protective Items…1533
Unauthorized Modification…1533
Leaving The Operator's Seat…1534
Mounting And Dismounting…1534
Fire Prevention For Fuel And Oil…1534
Precautions When Handling At High Temperatures…1535
Asbestos Dust Hazard Prevention…1535
Prevention Of Injury By Work Equipment…1535
Fire Extinguisher And First Aid Kit…1535
Precautions When Using ROPS…1536
Precautions For Attachments…1536
PRECAUTIONS DURING OPERATION…1537
BEFORE STARTING ENGINE…1537
Safety At Worksite…1537
Fire Prevention…1537
In Operator's Cab…1537
Ventilation For Enclosed Areas…1537
In Operator's Cab – Before Starting Engine…1538
OPERATING THE MACHINE…1538
When Starting Engine…1538
Truck Operation – General…1538
Check When Traveling In Reverse…1539
Traveling…1539
Traveling On Slopes…1540
Ensure Good Visibility…1540
Operate Carefully On Snow…1540
Avoid Damage To Dump Body…1540
Do Not Go Close To High-voltage Cables…1540
When Dumping…1541
Working On Loose Ground…1541
When Loading…1541
Parking The Machine…1541
TOWING…1541
WORKING NEAR BATTERIES…1542
Battery Hazard Prevention…1542
Starting With Booster Cables…1542
PRECAUTIONS FOR MAINTENANCE…1543
BEFORE PERFORMING MAINTENANCE…1543
Warning Tag…1543
Proper Tools…1543
Stopping The Engine Before Service…1543
Securing The Dump Body…1544
DURING MAINTENANCE…1544
Personnel…1544
Attachments…1544
Work Under The Machine…1544
Keep The Machine Clean…1544
Rules To Follow When Adding Fuel Or Oil…1544
Radiator Water Level…1545
Use Of Lighting…1545
Precautions With The Battery…1545
Handling High-Pressure Hoses…1545
Precautions With High-Pressure Oil…1545
Precautions When Carrying Out Maintenance At High Temperature Or High Pressure…1546
Rotating Fan And Belt…1546
Waste Materials…1546
TIRES…1547
Handling Tires…1547
Storing Tires After Removal…1547
ADDITIONAL JOB SITE RULES…1548
OPERATING INSTRUCTIONS…1549
PREPARING FOR OPERATION…1549
At The Truck – Ground Level Walk Around Inspection…1549
ENGINE START-UP SAFETY PRACTICES…1553
Before Starting The Engine…1553
Starting The Engine…1554
Starting The Engine In Cold Weather…1554
AFTER ENGINE HAS STARTED…1555
MACHINE OPERATION SAFETY PRECAUTIONS…1556
LOADING…1556
HAULING…1557
RETARDER OPERATION…1557
Engine Overspeed…1558
PASSING…1559
DUMPING…1559
To Raise dump body:…1559
To Lower Body:…1560
SAFE PARKING PROCEDURES…1560
SHUTDOWN PROCEDURE…1560
TOWING…1561
BRAKE RELEASE…1562
Release Of Parking Brake…1562
Release Of Emergency Brake…1562
WARNINGS AND CAUTIONS…1563
STANDARD CHARTS AND TABLES…1573
INDEX OF TABLES…1573
Sealants and Adhesives…1577
STANDARD VALUE TABLES…1579
SECTION B STRUCTURES…1591
STRUCTURAL COMPONENTS…1593
STRUCTURAL COMPONENTS…1595
GRILLE AND HOOD…1595
Removal…1595
Installation…1595
DECKS…1595
LEFT DECK AND CAB…1596
Removal…1596
Installation…1596
RIGHT DECK…1597
Removal…1597
Installation…1597
CENTER DECK…1598
Removal…1598
Installation…1598
DUMP BODY…1599
DUMP BODY…1601
Removal…1601
Installation…1602
BODY PAD…1603
Removal…1603
Installation…1603
BODY PAD ADJUSTMENT (SIDE)…1603
(With pads in place)…1603
(With pads removed)…1603
BODY PAD ADJUSTMENT (FRONT)…1604
BODY GUIDE…1604
BODY PIN…1604
ROCK EJECTORS…1605
Inspection…1605
FUEL TANK…1607
FUEL TANK…1609
Removal…1609
Installation…1610
Cleaning…1610
VENT…1610
QUICK FUEL INSTALLATION (OPTION)…1610
SECTION C ENGINE…1611
COOLING SYSTEM…1613
COOLING SYSTEM…1615
COOLING SYSTEM COMPONENTS…1615
RADIATOR…1615
Removal…1615
Service…1617
Installation…1617
BRAKE OIL COOLER…1618
Removal…1618
Installation…1618
FAN…1618
Removal…1618
Installation…1618
FAN BELT…1619
Fan Belt Replacement…1619
Fan Belt Adjustment…1619
ENGINE…1621
ENGINE…1623
GENERAL INSTRUCTIONS…1623
PREPARATION FOR ENGINE REMOVAL…1623
Removal…1623
Installation…1626
DRIVE LINE ADAPTER…1628
Drive Line Adapter Removal…1628
Drive Line Adapter Installation…1629
Drive Line Adapter Damper Disassembly…1630
Drive Line Adapter Damper Assembly…1631
RECOMMENDED LUBRICANTS…1631
AIR FILTRATION SYSTEM…1633
AIR FILTRATION SYSTEM…1635
AIR CLEANER…1635
Service Checks…1635
Filter Element Replacement…1635
Main Filter Element Cleaning…1637
Air Intake Troubleshooting…1638
SECTION D ELECTRICAL SYSTEM…1639
24V ELECTRIC SUPPLY SYSTEM…1641
24VDC ELECTRIC SUPPLY SYSTEM…1643
ELECTRICAL SYSTEM DESCRIPTION…1643
BATTERY…1643
Service…1643
Storage…1643
Maintenance and Troubleshooting…1644
Spillage…1645
BATTERY DISCONNECT SWITCH (Optional)…1645
BATTERY CHARGING CIRCUIT COMPONENTS…1646
Battery Charging Alternator…1646
Operation…1647
Magnetizing The Rotor…1647
ENGINE PRELUB SYSTEM…1648
OPERATION…1648
Pressure Switch…1648
Check Valve…1648
Timer Solenoid…1648
MAINTENANCE…1650
Prelub™ System Operation…1650
Starter/Prelub Pump…1650
Check Valve…1650
Timer Solenoid…1650
Troubleshooting Prelub Starter Circuit…1651
24VDC ELECTRICAL SYSTEM COMPONENTS…1653
24VDC ELECTRICAL SYSTEM COMPONENTS…1655
VEHICLE MONITOR SYSTEM…1655
General Description…1655
Normal Mode…1655
Service Mode…1655
NETWORK SIGNALS…1655
VEHICLE MONITOR PANEL…1658
SENSORS, SWITCHES…1658
Engine Water Temperature Sensor…1658
Retarder Oil Temperature Sensor…1658
Torque Converter Oil Temperature Sensor…1658
Air Pressure Sensor…1658
Fuel Level Sensor…1659
Engine Speed Sensor…1659
MONITOR PANEL DISPLAYS…1660
INSTRUMENT PANEL INDICATORS, TEST SWITCH…1664
ELECTRONIC ACCELERATOR PEDAL…1666
Operation…1666
AISS (Automatic Idling Setting System)…1667
TRANSMISSION CONTROLLER…1668
Outline…1668
OPERATION:…1669
INTRODUCTION TO ELECTRICAL TROUBLESHOOTING…1671
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1673
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE…1674
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT…1674
Handling Controller Boxes…1679
POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT…1680
CHECKS BEFORE TROUBLESHOOTING…1682
CONNECTOR TYPE AND LOCATION…1683
CONNECTOR LOCATION (Chassis)…1690
CONNECTOR LOCATION (Instrument Panel, Console)…1692
CONNECTOR LOCATION (Transmission, Rear Cab Area)…1693
CONNECTOR LOCATION (General Cab Area)…1694
CONNECTOR TYPE IDENTIFICATION CHARTS…1695
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM…1705
SYSTEM FUNCTION…1705
SELF-DIAGNOSTIC DISPLAY FUNCTIONS…1705
CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)…1707
LOCK-UP FUNCTION CHECK…1708
OPTIONAL CONTROLLERS…1708
MONITOR PANEL ACTION CODES AND SERVICE MODE…1709
OUTLINE…1709
ACTION CODE DISPLAY…1709
Service Mode…1710
SERVICE MODE OPERATION…1714
Brake Air Pressure Sensor…1722
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS…1723
MONITOR PANEL…1723
TRANSMISSION CONTROLLER…1723
TABLE OF SERVICE CODES AND ACTION CODES…1728
1. Table of service codes and action codes related to Monitor Panel…1728
2. Table of service codes and action codes related to Transmission Controller…1729
METHOD OF USING TABLE…1732
METHOD OF USING TROUBLESHOOTING CHARTS…1733
ADJUSTING ELECTRONIC MONITOR…1735
Adjustment procedure…1735
SETTING ROTARY SWITCH…1736
METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY…1737
TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING…1741
POINTS TO REMEMBER WHEN TROUBLESHOOTING TRANSMISSION CONTROLLER…1744
TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK…1746
TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK…1747
TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…1766
A-1 FAULTS IN POWER SOURCE SYSTEM…1768
a) (OFF) Controller self-diagnostic display LED does not light up…1768
b) Drop in voltage of controller power source is displayed…1769
c) Drop in voltage of battery direct power source is displayed…1770
d) Drop in voltage of main power source is displayed…1771
e) Faults in transmission cut relay power source is displayed…1772
A-2 FAULT IN NEUTRAL SAFETY SYSTEM DISPLAYED…1773
A-3 DOUBLE ENGAGEMENT FOR CLUTCH DISPLAYED…1774
A-4 FAULTS IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED…1775
A-5 FAULTS IN REAR BRAKE SOLENOID CIRCUIT DISPLAYED…1776
A-6 FAULTS IN EXHAUST BRAKE SOLENOID CIRCUIT IS DISPLAYED…1777
A-7 FAULTS IN BCV VALVE SYSTEM…1778
a) Short circuit with ground in BCV rear solenoid is displayed…1778
b) Short circuit in BCV rear solenoid is displayed…1779
c) Disconnection in BCV rear solenoid is displayed…1780
A-8 FAULT IN SPEED SENSOR…1781
a) Disconnection in engine speed sensor [B] is displayed on truck or Failure of engine speed sensor is displayed on truck…1781
b) Disconnection in input shaft speed sensor is displayed or Failure of input shaft speed sensor is displayed…1782
c) Disconnection in intermediate shaft speed sensor is displayed or Failure of intermediate shaft speed sensor is displayed…1783
d) Disconnection in speed sensor (transmission output shaft speed sensor) is displayed or Failure of output shaft speed sensor is displayed…1784
A-9 SPEED SENSOR, CLUTCH SLIPPING…1785
a) Input shaft speed sensor or H,L clutch is displayed…1785
b) Output shaft speed sensor or speed clutch (1,2,3,4,R) system is displayed…1786
A-10 FAULT IN MODEL SELECTION (WIRING HARNESS) DISPLAYED…1787
a) Fault in model selection (wiring harness) is displayed…1787
b) Fault in model selection (rotary switch) is displayed…1788
A-11 FAULT IN SHIFT LEVER CIRCUIT…1789
a) Short circuit in shift lever assembly power source is displayed…1789
b) Shift lever position signal input for 2 or more circuits is displayed…1790
c) Shift lever position signal is not inputted…1792
A-12 FAULT IN ACCELERATOR SIGNAL IS DISPLAYED…1794
A-13 FAULT IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED…1795
A-14 FAULT IN PRESSURE CONTROL VALVE…1796
a) Fill switch (clutch ON) is displayed regardless of command…1796
b) Fill switch signal is not input and clutch slipping is displayed…1798
A-15 NO FILL SWITCH SIGNAL INPUT (FLOW DETECTOR VALVE)…1800
A-16 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED or DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED…1801
A-17 FAULT IN SENSOR CIRCUITS…1803
a) Fault in torque converter oil temperature sensor is displayed…1803
b) Fault in fuel level sensor is displayed…1804
c) Fault in cooling water temperature sensor is displayed…1805
d) Fault in air pressure sensor is displayed…1806
e) Fault in retarder brake oil temperature sensor is displayed…1807
A-18 WARNING DISPLAY…1808
a) Transmission filter restricted warning displayed…1808
b) Tilt warning is displayed…1809
c) Drop in radiator water level warning is displayed…1810
d) Battery charge warning is displayed…1811
e) Steering oil temperature overheat warning is displayed…1812
f) Drop in engine oil pressure warning is displayed…1813
g) Rear brake oil pressure warning is displayed…1814
A-19 FAULT IN ENGINE OIL PRESSURE SENSOR DISPLAYED…1815
A-20 FAULT IN CONNECTOR CONNECTION DISPLAYED…1816
A-21…1817
a) Torque converter oil temperature overheat warning displayed…1817
b) Engine water temperature overheat warning displayed…1817
c) Air pressure drop warning displayed…1817
d) Retarder brake oil temperature overheat warning displayed…1817
e) Engine overrun actuated displayed…1818
f) Engine overshoot actuated displayed…1818
MONITOR PANEL TROUBLESHOOTING…1819
MONITOR PANEL AND CONTROLLER SELF-DIAGNOSTIC DISPLAY…1821
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON TRUCK…1822
TROUBLESHOOTING…1826
P-1 Check pattern for wiring harnesses between modules…1826
P-2 Nothing on Monitor Panel Operates…1829
P-3 LH, RH Module and fuel gauge do not operate…1830
P-4 LH, RH Module and fuel gauge do not operate…1831
P-5 RH Module does not operate…1832
P-6 LH module does not operate…1833
P-7 Odometer does not operate…1834
P-8 Service meter does not operate correctly…1835
P-9 Central Warning Lamp does not operate, or monitor panel detects fault code (monitor panel display) [A002]…1836
P-10 Central warning lamp stays ON…1837
P-11 Alarm buzzer does not operate. or Monitor Panel detects fault code A003:…1838
P-12 Alarm buzzer continues to sound…1839
P-13 All data from Shift Controller (speedometer, tachometer, shift indicator, etc.) is faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A013, or service code A0018:…1840
P-14 Suspension mode, power/economy mode displays are faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A016:…1841
P-15 Gauge displays are faulty (nothing is displayed or display does not change)…1842
P-16 Cooling water level drop caution lamp does not operate, or Monitor Panel detects service code A001:…1843
P-17 Cooling water level drop caution lamp stays ON…1844
P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code A001:…1845
P-19 Emergency steering pilot lamp stays ON…1846
P-20 Engine oil pressure drop caution lamp does not operate, or monitor panel detects service code A001:…1847
P-21 Engine oil pressure drop caution lamp stays ON…1848
P-22 Exhaust brake (Optional) pilot lamp does not operate, or monitor panel detects service code A001:…1849
P-23 Exhaust brake pilot lamp stays ON (Optional)…1850
P-24 Charging circuit fault caution lamp does not operate. or monitor panel detects service code A001:…1851
P-25 Charging circuit fault caution lamp stays ON…1852
P-26 Transmission filter clogging caution lamp does not operate, or monitor panel detects service code A001:…1853
P-27 Transmission filter clogging caution lamp stays ON…1854
P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code A001:…1855
P-29 Brake stroke caution lamp stays ON…1856
P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code A001:…1857
P-31 Preheating switch pilot lamp stays ON…1858
P-32 Tilt warning lamp does not operate, or monitor panel detects service code A001:…1859
P-33 Tilt warning lamp stays ON…1860
P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or monitor panel detects service code A001:…1861
P-35 Body FLOAT (except FLOAT) pilot lamp stays ON…1862
P-36 Rear brake pilot lamp does not work, or monitor panel detects service code A001:…1863
P-37 Rear brake pilot lamp stays ON…1864
P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code A001:…1865
P-39 Parking brake pilot lamp stays ON…1866
P-40 Maintenance caution lamp does not operate, or monitor panel detects service code A001:…1867
P-41 Maintenance caution lamp stays ON…1868
P-42 Steering oil temperature caution lamp does not operate, or monitor panel detects service code A001:…1869
P-43 Steering oil temperature caution lamp stays ON…1870
P-46 High beam display does not light up…1871
P-47 Turn signal lamp (right) does not light up…1873
P-48 Turn signal lamp (left) does not light up…1874
P-49 Lamp check switch does not operate…1875
P-50 AISS switch does not operate…1876
P-51 Exhaust brake switch does not operate (Optional)…1877
P-52 Mode change switch (1) does not operate…1878
P-53 Mode change switch (2) does not operate…1879
P-54 KPH/MPH speedometer unit selector does not operate…1880
P-55 Improper operation of all switch inputs…1881
P-56 Monitor panel detects service codes A014 or A019:…1882
P-58 Monitor panel detects service code A011:…1883
P-59 Monitor panel detects service code A012:…1883
P-60 Monitor panel detects service code A000:…1883
ENGINE ELECTRONIC DIAGNOSTIC SYSTEM…1885
ENGINE ELECTRONIC DIAGNOSTIC SYSTEM…1887
SYSTEM DESCRIPTION…1887
Engine Shutdown Light (Stop Engine)…1888
Engine Maintenance Light (Check Engine)…1888
Engine Maintenance Light (Protect Engine)…1888
Fault Check Switch…1888
Fault Scroll Switch…1888
Determining Fault Codes…1889
EXITING THE DIAGNOSTICS MODE…1889
FAULT CODE INFORMATION (T01-001)…1890
ELECTRICAL SPECIFICATIONS…1893
SENSOR SPECIFICATIONS…1893
HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING…1895
HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING…1897
H-1 Truck does not move…1897
H-2 Truck does not travel smoothly (truck jerks)…1899
H-3 Lock-up clutch cannot be disengaged (engine stalls)…1899
H-4 Excessive shock when starting to move or shifting…1899
H-5 Transmission does not shift up…1900
H-6 Truck lacks power or speed when moving…1901
H-7 Time lag is excessive when starting to move, or shifting gear…1905
H-8 Torque converter oil temperature is high…1907
H-9 Torque converter oil pressure is low…1908
H-10 Front brakes are ineffective, or effective only on one side…1909
H-11 Rear brakes are ineffective, or effective on one side only…1910
H-12 Steering wheel is difficult to turn…1911
H-13 Steering wheel is inoperative…1912
H-14 Steering wheel vibrates…1912
H-15 Hoist cylinder lacks lifting force (lifting speed)…1913
H-16 Hoist cylinders do not operate…1915
H-17 Excessive dump body hydraulic drift…1917
H-18 Air pressure does not increase (low-pressure buzzer does not turn off. Air pressure does not increase to green range.)…1918
SECTION F TRANSMISSION…1919
TRANSMISSION…1921
TRANSMISSION…1923
TORQUE CONVERTER…1924
TORQUE CONVERTER VALVE…1926
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…1927
HYDRAULIC PUMP…1928
MAIN RELIEF VALVE…1929
Function…1929
Operation…1929
Actuating Pressure:…1929
TORQUE CONVERTER RELIEF VALVE…1929
Function…1929
Operation…1929
Actuating Pressure:…1929
LOCKUP SOLENOID VALVE…1930
LOCKUP VALVE…1931
Function…1931
Operation…1931
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE…1934
Testing Main Relief Pressure…1934
Testing Hydraulic Pressure At Torque Converter Inlet Port (Relief)…1934
Testing Hydraulic Pressure At Torque Converter Outlet Port (Regulator)…1934
TORQUE CONVERTER STALL SPEED CHECK…1935
Preparing For Stall Speed Check…1935
TRANSMISSION…1937
TRANSMISSION SHIFT VALVES…1938
ECMV (Electronic Control Modulation Valve)…1941
Pressure Control Valve…1941
Flow Sensor Valve…1941
ECMV and Proportional Solenoid…1941
ECMV and Fill Switch…1941
ECMV REPAIR PROCEDURE…1945
Filter Cleaning Procedure…1945
ECMV Removal…1946
Disassembly…1946
Reassembly…1947
CLUTCH PRESSURE CHECK & ADJUSTMENT…1949
LUBRICATION RELIEF VALVE…1951
Function…1951
Specifications…1951
TRANSMISSION…1952
Transmission Removal…1952
Transmission Installation…1954
TRANSMISSION FILTER…1956
Service…1956
TRANSMISSION OIL COOLER…1957
TRANSMISSION OIL COOLER…1959
Removal And Installation…1959
Repair…1959
TRANSMISSION STRAINER…1959
Removal…1959
Installation…1959
TORQUE CONVERTER CONTROL VALVE…1960
Removal…1960
Installation…1960
Disassembly…1960
Assembly…1961
DRIVELINES…1963
DRIVELINES…1965
FRONT DRIVELINE…1965
Removal…1965
Installation…1965
Disassembly…1965
Assembly…1965
REAR DRIVELINE…1966
Removal…1966
Installation…1966
Disassembly…1966
Assembly…1966
LUBRICATION…1966
AUTOMATIC SHIFT CONTROL SYSTEM…1967
AUTOMATIC SHIFT CONTROL SYSTEM…1969
GENERAL INFORMATION…1969
TRANSMISSION SHIFT CONTROLLER…1969
Power Mode…1969
Braking Mode…1969
Lock-up And Engine Overspeed…1969
Transmission Speeds Monitoring…1969
Self Diagnostics…1970
RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES…1972
TRANSMISSION OPERATION MODES…1972
Braking Mode:…1972
Power Mode:…1972
Economy Mode:…1973
AUTOMATIC GEAR SHIFTING…1973
Automatic Shifting Sequence…1973
Gear shifting time lag…1974
Safety Functions…1975
TRANSMISSION RANGE SELECTOR…1976
SENSORS, SWITCHES…1977
Transmission Speed Sensors…1977
Adjustment Procedure…1977
Transmission and Torque Converter Oil Temperature Sensors…1978
Oil Temperature Sensor Tests…1978
Insulation Resistance Test:…1978
Thermistor Resistance Calibration Test:…1978
Fill Switch…1980
Shift Limit Switch…1981
Power Mode Switch…1981
TRANSMISSION TROUBLESHOOTING PROCEDURES…1982
Clutch Combinations…1982
Solenoid Valves…1982
HARNESS CONNECTORS AND SIGNALS…1983
SECTION G DRIVE AXLE, SPINDLES AND WHEELS…1987
TIRES AND RIMS…1989
TIRES AND RIMS…1991
GENERAL INFORMATION AND RECOMMENDATIONS…1991
FRONT TIRES AND RIMS…1992
Removal…1992
Installation…1993
REAR TIRE AND RIM…1993
Removal…1993
Installation Of Rear Wheel Assembly…1994
TIRE MATCHING…1996
FRONT WHEEL HUB AND SPINDLE…1997
FRONT WHEEL HUB AND SPINDLES…1999
FRONT WHEEL HUB…1999
Removal…1999
DISASSEMBLY OF FRONT WHEEL HUB ASSEMBLY…2000
Inspection…2001
ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY…2001
Front Wheel Hub Bearing Adjustment…2001
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION…2002
SUSPENSION A-FRAME…2002
Removal…2002
Installation…2002
CENTER TIE ROD PIVOT…2003
Removal…2003
Inspection…2003
Installation…2003
FINAL DRIVE ATTACHMENTS…2005
FINAL DRIVE ATTACHMENTS…2007
FINAL DRIVE ANCHOR…2007
Lower Link Removal…2007
Inspection…2008
Installation…2008
DIAGONAL PANHARD ROD…2008
Removal…2008
Inspection…2009
Installation…2009
FINAL DRIVE CENTER CASE ASSEMBLY…2011
FINAL DRIVE CENTER CASE ASSEMBLY…2013
Specifications:…2013
OPERATION…2014
Straight-away-travel…2014
Turning…2015
To Check Oil Level…2015
Specifications:…2015
REAR AXLE…2015
Removal…2015
Installation…2016
DIFFERENTIAL ASSEMBLY…2017
Removal…2017
Installation…2018
DIFFERENTIAL ASSEMBLY…2018
Disassembly…2018
Disassembly of Pinion Carrier Assembly…2019
Differential Gear Unit…2020
Disassembly Of Differential Gear Unit…2020
ASSEMBLY of DIFFERENTIAL…2023
Differential Bearing…2023
Assembly Of Differential Gear Assembly…2023
Installation Of Differential Assembly…2025
Input Pinion and Carrier Assembly…2026
Adjusting Tooth Contact, Backlash…2029
FINAL DRIVE PLANETARIES AND WHEEL HUBS…2033
FINAL DRIVE PLANETARIES AND WHEEL HUBS…2035
FINAL DRIVE…2035
CARRIER ASSEMBLY…2036
Removal…2036
Installation…2037
FINAL DRIVE CARRIER…2037
Disassembly…2037
Assembly…2038
FINAL DRIVE ASSEMBLY…2038
Disassembly…2038
Assembly…2041
SECTION H SUSPENSIONS…2043
FRONT SUSPENSIONS…2045
SUSPENSION SYSTEM…2047
SUSPENSION SYSTEM OPERATION…2047
FRONT SUSPENSION…2048
Removal…2049
Installation…2051
SUSPENSION REBUILD…2052
Disassembly…2052
Inspection…2053
Assembly…2053
ATTENUATION VALVE (FIXED RATE)…2055
Disassembly…2055
Assembly…2055
REAR SUSPENSIONS…2057
REAR SUSPENSIONS…2059
SUSPENSION OPERATION…2059
Removal…2060
Installation…2060
SUSPENSION REBUILD…2061
Disassembly…2061
Cleaning and Inspection…2061
Assembly…2062
REAR SUSPENSION SPHERICAL BEARING REPAIR…2063
Disassembly…2063
Inspection…2063
Assembly…2063
OILING AND CHARGING PROCEDURES…2065
OILING AND CHARGING PROCEDURES…2067
GENERAL…2067
Equipment List…2067
FRONT SUSPENSION…2067
Front Suspension Oiling…2068
Front Suspension Nitrogen Charging…2069
REAR SUSPENSION…2071
Rear Suspension Oiling…2071
Rear Suspension Nitrogen Charging…2072
SECTION J BRAKE SYSTEM…2075
BRAKE CIRCUIT OPERATION…2077
BRAKE CIRCUIT OPERATION…2079
COMPONENT DESCRIPTION…2079
AIR TREADLE VALVE…2079
EMERGENCY RELAY (RE-6) VALVE…2080
HAND BRAKE VALVE (Retarder control valve)…2083
Function…2084
PARKING BRAKE PILOT VALVE…2085
Function…2085
Operation…2085
PARKING BRAKE RELAY VALVE…2086
Function…2086
BRAKE CHAMBER…2087
SLACK ADJUSTER…2088
Specifications…2088
Function…2089
PRESSURE SWITCH…2090
Function…2090
STOP LIGHT SWITCH…2090
Function…2090
PARKING BRAKE SWITCH…2091
Function…2091
AUTOMATIC RETARDER VALVE…2091
Function…2091
FRONT BRAKE CUT-OFF VALVE…2092
Function…2092
BRAKE COOLING VALVE (BCV)…2093
2-WAY AIR CONTROL VALVE…2094
Function…2094
EMERGENCY BRAKE CONTROL VALVE…2095
Function…2095
Operation…2096
BRAKE VALVE…2099
Function…2100
BRAKE CIRCUIT COMPONENT SERVICE…2103
BRAKE CIRCUIT COMPONENT SERVICE…2105
BRAKE TREADLE ASSEMBLY…2105
Removal…2105
Installation…2105
Disassembly…2106
Assembly…2107
FRONT BRAKE CHAMBER ASSEMBLY…2108
Removal…2108
Installation…2108
Disassembly…2108
Assembly…2111
REAR BRAKE CHAMBER ASSEMBLY…2112
Removal…2112
Installation…2112
Disassembly…2113
Assembly…2115
SLACK ADJUSTER…2116
Removal…2116
EMERGENCY BRAKE CONTROL VALVE…2119
Removal…2119
Installation…2119
Disassembly…2120
Inspection…2120
Assembly…2120
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…2123
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…2125
CHECKING FRONT BRAKE PAD WEAR…2125
TESTING BRAKE PRESSURE…2125
CHECKING WEAR OF REAR BRAKE DISCS…2126
BRAKE BLEEDING…2127
Rear Brakes…2127
Front Brakes…2127
TROUBLESHOOTING…2128
FRONT BRAKES…2131
FRONT BRAKES…2133
FRONT BRAKE CALIPER PAD…2133
Removal…2133
Installation…2133
BRAKE CALIPER ASSEMBLY…2133
Removal…2133
Installation…2134
Disassembly…2134
Assembly…2135
REAR WET DISC BRAKE ASSEMBLY…2137
REAR WET DISC BRAKE ASSEMBLY…2139
WET DISC BRAKE ASSEMBLY…2139
Removal…2139
Installation…2140
WET DISC BRAKE…2141
Disassembly…2141
Inspection…2142
Assembly…2142
PARKING BRAKE…2145
PARKING BRAKE…2147
Inspection…2147
Pad Removal…2147
Pad Installation…2147
PARKING BRAKE CALIPER…2147
Caliper Removal…2147
Caliper Installation…2148
Caliper Disassembly…2148
Caliper Assembly…2149
PARKING BRAKE SPRING CYLINDER…2149
Removal…2149
Installation…2149
Disassembly…2149
Assembly…2150
PARKING BRAKE ADJUSTMENT…2151
Testing…2151
Adjusting…2151
PARKING BRAKE DISC…2152
Driveshaft Removal…2152
Parking Brake Disc Removal…2152
Parking Brake Disc Installation…2153
Driveshaft Installation…2153
BRAKE RELEASE…2153
Release Of Parking Brake…2153
Release Of Emergency Brake…2154
SECTION K AIR SYSTEM…2155
AIR SYSTEM…2157
AIR SYSTEM…2159
GENERAL DESCRIPTION…2159
AIR DRYER…2160
Operation…2160
SAFETY VALVE…2163
AIR GOVERNORS…2163
AUTOMATIC DRAIN VALVE (HEATED)…2164
Function…2164
Operation…2164
HORN SOLENOID…2164
Function…2164
AIR SYSTEM COMPONENT REPAIR…2165
AIR SYSTEM COMPONENT REPAIR…2167
GENERAL PRECAUTIONS…2167
AIR DRYER…2167
Removal…2167
Installation…2167
Desiccant Cartridge Service…2168
Desiccant Cartridge Replacement…2168
Unloader Valve Service…2169
Unloader Valve Replacement…2169
Bleed Valve Service…2170
Bleed Valve Replacement…2170
Check Valve Service…2170
Operational Check…2170
Check Valve Replacement…2170
Turbo Valve Service…2171
Operational Check:…2171
Turbo Valve Replacement…2171
Heater Assembly Service…2171
Operational Checks…2171
Heater Assembly Replacement…2171
AIR DRYER TROUBLESHOOTING…2172
AIR DRYER TROUBLESHOOTING (Continued)…2173
AIR COMPRESSOR…2174
AIR GOVERNORS…2174
Removal…2174
Installation…2174
Disassembly…2175
Cleaning and Inspection…2175
Assembly…2175
Adjustment…2176
Primary Governor…2176
Secondary Governor…2176
RETARDER VALVE…2177
RETARDER VALVE…2179
RETARDER FUNCTION…2179
Removal…2179
Installation…2179
Disassembly…2181
Assembly…2181
SECTION L HYDRAULIC SYSTEM…2183
HYDRAULIC SYSTEM…2185
HYDRAULIC SYSTEM…2187
HYDRAULIC SYSTEM OPERATION…2187
COMPONENT DESCRIPTION…2187
Pump…2187
Tank…2188
HYDRAULIC SYSTEM COMPONENT REPAIR…2191
HYDRAULIC SYSTEM COMPONENT REPAIR…2193
HYDRAULIC PUMP…2193
Removal…2193
Installation…2194
HYDRAULIC TANK…2194
HYDRAULIC TANK FILTERS…2195
Filter Replacement…2195
HYDRAULIC TANK BREATHER…2195
Cleaning…2195
BRAKE COOLING OIL STRAINER…2196
Cleaning…2196
HIGH PRESSURE HYDRAULIC FILTERS…2196
Filter Assembly Removal…2196
Filter Assembly Installation…2197
Filter Element Replacement…2197
STEERING CIRCUIT…2199
STEERING CIRCUIT…2201
STEERING CIRCUIT OPERATION…2201
DEMAND VALVE…2202
STEERING CONTROL VALVE…2202
CROSSOVER RELIEF VALVE…2203
OPERATION OF DEMAND AND STEERING CONTROL VALVE…2204
EMERGENCY STEERING SYSTEM…2212
Flow Switch…2213
Operation…2213
Relay Timer…2213
STEERING VALVE ASSEMBLY…2215
STEERING VALVE ASSEMBLY…2217
Removal…2217
Installation…2217
Disassembly…2218
Preparation…2218
Assembly…2223
STEERING CIRCUIT COMPONENT REPAIR…2231
STEERING CIRCUIT COMPONENT REPAIR…2233
EMERGENCY STEERING MOTOR PUMP ASSEMBLY…2233
Removal…2233
Installation…2233
STEERING CYLINDER ASSEMBLY…2234
Removal…2234
Installation…2234
Disassembly…2235
Assembly…2237
DEMAND VALVE ASSEMBLY…2239
Removal…2239
Installation…2239
Disassembly…2240
Assembly…2240
RELIEF VALVE ASSEMBLY…2241
Disassembly…2241
Assembly…2241
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION…2243
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION…2245
HOIST CIRCUIT OPERATION…2245
HOIST CIRCUIT COMPONENT DESCRIPTION…2245
Hoist Cylinders…2245
Hydraulic Filter…2245
Hoist Valve…2245
RAISE…2246
HOLD…2247
POWER DOWN…2248
FLOAT…2249
HOIST CIRCUIT COMPONENT REPAIR…2251
HOIST CIRCUIT COMPONENT REPAIR…2253
HOIST VALVE ASSEMBLY…2253
Removal…2253
Installation…2253
Disassembly…2254
Assembly…2254
HOIST CYLINDER…2256
Removal…2256
Installation…2257
Disassembly…2258
Assembly…2258
HYDRAULIC CHECKOUT…2261
HYDRAULIC CHECKOUT…2263
DUMP BODY CONTROL…2263
ADJUSTING HOIST LEVER LINKAGE…2264
ADJUSTING HOIST LIMITER…2265
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…2266
Steering Circuit…2266
Hoist Circuit…2267
SECTION M OPTIONS AND SPECIAL TOOLS…2275
WIGGINS QUICK FILL FUEL SYSTEM…2277
WIGGINS QUICK FILL FUEL SYSTEM…2279
FUEL TANK BREATHER VALVE…2279
Removal…2279
Installation…2279
Disassembly…2279
Assembly…2279
FUEL RECEIVER…2279
FAN DRIVE CLUTCH…2281
FAN DRIVE CLUTCH…2283
GENERAL DESCRIPTION…2283
MAJOR COMPONENTS…2283
Input…2283
Output…2284
Stationary Components…2284
OPERATION MODES…2284
Fully Engaged…2284
Modulated Variable Speed…2285
Fully Released…2285
Lubricating & Cooling Oil…2286
MAINTENANCE…2287
TROUBLESHOOTING…2288
Basic Preliminary Checks…2288
FIELD CHECK DIAGNOSIS…2289
Preliminary Checks With Engine Off…2289
Off Truck Test…2292
TROUBLESHOOTING CHART…2293
FAN CLUTCH REBUILD…2295
DISASSEMBLY…2296
Preparation…2296
Cleaning And Inspection…2303
ASSEMBLY INSTRUCTIONS…2306
General Instructions…2306
Assembly…2306
FAN CLUTCH TEST…2316
Operational Test…2316
COOLANT AND OIL HEATERS…2321
COOLANT AND OIL HEATERS…2323
SYSTEM OPERATION…2323
ENGINE COOLANT HEATERS…2325
Troubleshooting…2325
OIL HEATERS…2326
Troubleshooting…2326
SPECIAL TOOLS…2329
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM…2339
GENERAL INFORMATION…2341
Haul Cycles…2341
LIGHTS, SWITCHES AND COMPONENTS…2342
TIPS FOR OPERATION…2343
EXTERNAL DISPLAY LIGHTS…2343
THEORY OF OPERATION…2344
Basic Description…2344
Inclinometer…2344
Linkage Factor…2344
Gain Factor…2345
Brake Lock…2345
Sources of Error…2345
Typical Data From Service Check Mode…2345
Example Calculation of Payload…2346
Viewing Payload Calculation Inputs…2346
Checking the Gain…2347
Adjusting the Gain…2347
TYPES OF DATA STORED…2348
Cycle Data…2348
Engine ON/OFF Data…2349
Fault Codes and Warning Data…2349
Engine Operation…2350
Total Payload and Total Number of Cycles…2350
Other Data…2350
OPERATOR FUNCTIONS…2351
Using the Operator Load Counter…2351
Viewing the Operator Load Counter…2351
Clearing the Operator Load Counter…2351
Dimming the Lights on the Display…2351
INITIAL SETUP OF PAYLOAD METER…2352
Switch Settings…2352
Checking the Operator Check Mode…2353
Checking the Service Check Mode…2353
Checking the Gt setting:…2354
Checking the Inclinometer Settings…2354
Calibrating a Truck…2354
DISPLAYS AT START-UP…2355
Normal Operation…2355
SETUP AND MAINTENANCE…2356
Setting The Speed Limit…2356
Setting the Option Code…2356
Setting The Machine I.D. Code…2357
Setting The Operator I.D. Code…2357
Setting The Time and Date…2357
DOWNLOAD OF INFORMATION…2358
DISPLAY OF FAULT CODES…2358
Monitoring Input Signals…2362
Service Check Mode…2362
UP FACTOR – PAYLOAD CALCULATION GAIN…2363
PL MODE -LOAD CALCULATION TIMING…2363
FINAL GEAR RATIO SELECTION…2364
BATTERY REPLACEMENT PROCEDURE…2365
Replacing the Battery…2365
After Replacing the Battery…2366
SUSPENSION PRESSURE SENSOR…2366
Removal…2366
Installation…2367
INCLINOMETER…2367
Removal…2367
Installation…2367
Adjustment…2367
PAYLOAD METER BACK PANEL…2368
CONNECTIONS…2369
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE…2370
PAYLOAD CIRCUIT NUMBERS…2371
TROUBLESHOOTING…2372
COMMON PROBLEMS…2372
Suspension Charging…2372
Symptom Table…2373
Missing Body-Up Signal…2373
Missing Speed Signal…2374
F-18: Alternator R-Terminal, Oil Pressure Signals…2374
Shorted 18v Sensor Power Supply (930E)…2374
FAULT TREE DIAGNOSIS…2375
Payload Lights Won't Illuminate…2375
Red, Amber or Green Payload Light Does Not Illuminate…2376
Cannot Download – PC Communications…2377
PC Communications Configuration…2378
F.CAL: Payload Meter Won't Calibrate…2379
F-20: Sensor Power Fault…2380
F-21, F-25: Left Front Pressure Sensor…2382
F-22, F-26: Right Front Pressure Sensor…2382
F-23, F-27: Left Rear Pressure Sensor…2382
F-24, F-28: Right Rear Pressure Sensor…2382
F-31, F-32: Inclinometer…2384
Body Up Input…2386
Brake Lock Input…2387
Speed Signal…2388
Adjusting the Speed Sensor…2388
CONNECTORS AND PRESSURE SENSORS…2390
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM…2393
Menu Functions…2396
Using Scope…2396
Log File Information…2396
Connections to Payload Meter II™…2397
USING SCOPE…2398
Monitoring Inputs Using Scope…2398
Monitoring Suspension Charging Using Scope…2398
Pressure Sensor Dummy Loads…2401
GAIN ADJUSTMENT WORKSHEET…2402
EXHAUST BRAKE…2403
EXHAUST BRAKE…2405
FUNCTION…2405
SYSTEM OPERATION…2406
SYSTEM COMPONENTS…2407
Exhaust Brake Pressure Switch…2407
Exhaust Brake Solenoid Valve…2407
Exhaust Brake Assembly…2408
MAINTENANCE…2409
1000 Hour Maintenance…2409
Gate Adjustment…2409
TROUBLESHOOTING…2410
Operational Characteristics…2410
System Component Checks…2411
AUTOMATIC SPIN REGULATOR (ASR) SYSTEM…2413
AUTOMATIC SPIN REGULATOR (ASR) SYSTEM…2415
ASR SYSTEM…2415
ASR SYSTEM DESCRIPTION…2416
Torque Control…2416
Compensation for Steering…2416
System Diagnostics…2416
System Components…2416
OPERATION…2418
ASR SYSTEM TROUBLESHOOTING…2420
GENERAL TROUBLESHOOTING INFORMATION…2420
Preliminary Troubleshooting Procedures…2420
Troubleshooting Specific Problems…2420
NORMAL SYSTEM OPERATION…2421
Clearing Fault Codes…2421
TROUBLESHOOTING SYSTEM COMPONENTS…2424
Stabilizing the AC System…2559
SYSTEM PERFORMANCE TEST…2559
SYSTEM LEAK TESTING…2560
Electronic leak detector…2560
Tracer dyes…2560
Soap and water…2560
SYSTEM REPAIR…2561
System Cleaning…2561
Hoses and Fittings…2561
Lines…2561
Expansion Valve…2561
Receiver-Drier…2562
Thermostat…2562
Compressor…2562
Clutch…2562
Servicing the Compressor Clutch…2563
Pulley Removal…2565
Clutch Coil Check…2565
Pulley Installation…2565
Clutch Assembly Installation…2566
RECOVERING AND RECYCLING THE REFRIGERANT…2567
Performing the Recovery Cycle…2567
Performing the Recycling Procedure…2567
Evacuating and Charging the AC System…2567
EVACUATING THE SYSTEM…2568
CHARGING THE AC SYSTEM…2569
TROUBLESHOOTING…2570
Pre-Diagnosis Checks…2570
Preparing For Diagnosis…2570
Preliminary Steps…2570
System Performance Test…2570
Diagnosis Of Gauge Readings And System Performance…2571
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM…2578
OPERATOR CAB AND CONTROLS…2579
OPERATOR CAB AND CONTROLS…2583
STEERING WHEEL AND CONTROLS…2583
Tilt Lever…2583
Turn Signal Lever Switch…2583
Horn…2583
Windshield Wiper / Washer Switch…2583
Headlights and Dimmer Switch…2584
Retard Control Lever…2584
BRAKE PEDAL…2584
THROTTLE PEDAL…2584
CENTER CONSOLE AND CONTROLS…2584
Transmission Range Selector…2584
Shift Limiter Switch…2586
Economy / Power Mode Switch…2586
Emergency Steering Switch…2586
Emergency Brake Lever…2587
Parking Brake Valve Lever…2587
ENGINE ELECTRONIC CONTROL SYSTEM…2588
Engine Shutdown Light (Stop Engine)…2588
Engine Maintenance Light (Check Engine)…2588
Engine Maintenance Light…2588
ENGINE DIAGNOSTICS…2589
Fault Check Switch…2589
Fault Scroll Switch…2589
Determining Fault Codes…2589
Exiting The Diagnostics Mode…2589
HOIST CONTROL…2590
Safety Lock…2590
ASR / ARSC (OPTIONAL)…2591
ASR SYSTEM CONTROLS…2591
System Switch…2592
ASR/ARSC Caution Lamp…2592
ASR Operation Lamp…2592
Central Warning Lamp…2592
Retarder Control Lever…2592
Accelerator Pedal…2592
Brake Pedal…2592
PRECAUTIONS WHEN USING THE ASR SYSTEM…2592
ARSC SYSTEM CONTROLS…2593
System Switch…2593
ARSC Set Lever…2593
Brake Pedal…2593
Accelerator Pedal…2593
ASR/ARSC Caution Lamp…2593
ARSC Standby Lamp…2593
Set Speed Display…2593
Retarder Control Lever…2593
Central Warning Lamp…2593
ARSC SYSTEM ACTUATION…2594
Traveling Again At Set Speed…2594
Relationship With Exhaust Brake…2595
Recommended Set Speed…2595
TROUBLESHOOTING THE ASR/ARSC SYSTEMS…2596
When a problem occurs in the system…2596
Model Selection, Tire Selection, And Failure Code Display…2596
Failure Codes…2596
INSTRUMENT PANEL AND INDICATORS…2599
WARNING & CAUTION LAMPS…2600
GAUGE AND MONITOR PANEL…2601
Air Pressure Monitor…2601
Air Pressure Gauge…2601
Coolant Temperature Monitor…2601
Engine Cooling Water Temperature Gauge…2601
Torque Converter Oil Temperature Monitor…2602
Torque Converter Oil Temperature Gauge…2602
Retarder Oil Temperature Monitor…2602
Retarder Oil Temperature Gauge…2602
High Beam Pilot Lamp…2602
Left Turn Signal Pilot Lamp…2602
Right Turn Signal Pilot Lamp…2602
Speedometer…2602
Tachometer…2602
Shift Limiter Pilot Lamp…2602
Lock-up Pilot Lamp…2603
Transmission Shift Position Pilot Lamp…2603
Shift Indicator…2603
Engine Controller Monitor…2603
Automatic Transmission Mechatronics Monitor…2603
Other Mechatronics Monitor (OPTIONAL)…2603
Fuel Level Monitor…2603
Fuel Gauge…2603
Service Meter…2604
Service Meter Indicator…2604
Odometer…2604
Power Mode Indicator…2604
INDICATORS AND CONTROLS PANEL…2604
Optional Equipment…2604
Coolant Level Monitor…2605
Engine Oil Pressure Monitor…2605
Charge Monitor…2605
Transmission Oil Filter Monitor…2605
Hazard Warning Lights…2605
Front Brake On/Off Switch…2605
Panel Dimmer Switch…2605
AISS/Auto Switch…2606
Manual Starting Aid Switch…2606
Starting Switch…2606
Pilot Lamp Bulb Check Switch…2606
Rear Brake Pilot Lamp…2606
Body Float Caution Monitor…2606
Parking Brake Monitor…2607
Emergency Steering Monitor…2607
Exhaust Brake (Optional)…2607
Cold Start…2607
Steering Oil Temperature…2607
Side Slope Warning (Optional)…2607
Rear Brake Caution Lamp…2607
Exhaust Brake Switch (Optional)…2608
Fog Light Switch (Optional)…2608
Central Warning Lamp (Red Convex Lens)…2608
HEATER/AIR CONDITIONER CONTROLS…2609
Temperature Adjustment Lever…2609
Blower Switch…2609
Air Selector Lever…2609
Vent Selector Lever…2609
Air Vent…2610
Glove Box Storage Compartment…2610
Air Conditioner Switch…2610
Correction Code Display…2610
SECTION P LUBRICATION AND SERVICE…2611
LUBRICATION AND SERVICE…2613
LUBRICATION AND SERVICE…2615
10 HOUR (DAILY) INSPECTION…2617
FLUID LEVELS & OTHER CHECKS…2617
10 HOUR (DAILY) INSPECTION (continued)…2619
ENGINE…2619
WHEELS AND TIRES…2619
Tires…2619
10 HOUR (DAILY) INSPECTION (continued)…2620
Wheels…2620
OPERATIONAL CHECKS…2621
250 HOUR SERVICE…2623
INITIAL 250 HOUR SERVICE…2623
EVERY 250 HOUR SERVICE…2623
500 HOUR SERVICE…2625
1000 HOUR SERVICE…2626
EVERY 2000 HOUR SERVICE…2627
EVERY 5000 HOUR SERVICE…2628
HYDRAULIC TANK SERVICE…2629
Filling Instructions (Hoist Oil Supply)…2629
Filling Instructions (Rear Brake Cooling Oil Supply)…2629
HYDRAULIC FILTERS…2630
Filter Replacement…2630
HYDRAULIC TANK BREATHER…2630
Cleaning…2630
HIGH PRESSURE HYDRAULIC FILTERS…2631
Filter Assembly Removal…2631
Filter Assembly Installation…2631
Filter Element Replacement…2632
TRANSMISSION FILTER…2633
Service…2633
PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES…2634
AUTOMATIC LUBRICATION SYSTEM…2635
AUTOMATIC LUBRICATION SYSTEM…2637
OPERATION…2637
COMPONENTS…2637
Component Location…2638
GENERAL INFORMATION…2640
Lubricant Required for System…2640
Air Pressure Regulator…2640
Initial Reservoir Fill…2640
System Priming…2640
SYSTEM CHECKOUT…2641
Lubrication Cycle Timer Check…2641
Timer Adjustment…2641
INJECTORS (SL-1 Series “H”)…2642
Injector Specifications…2642
Injector Adjustment…2642
Injector Operation…2643
TROUBLESHOOTING CHART…2644
ALPHABETICAL INDEX…2647
SECTION R SYSTEM SCHEMATICS…2651
HA207 AIR CIRCUIT DIAGRAM…2653
HA208 AIR SCHEMATIC…2654
HH345 HYDRAULIC SCHEMATIC…2655
HH346 HYDRAULIC PIPING…2656
KT-T01 TRANSMISSION…2657
HE482 ELECTRICAL SCHEMATIC…2658
Komatsu Dump Truck HD785-5LC Repair Service Manuals