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Komatsu HD785-3 HD985-3 Dump Truck Shop Manual SEBM05610311 – PDF DOWNLOAD
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Description
Komatsu HD785-3 HD985-3 Dump Truck Shop Manual
FILE DETAILS:
Komatsu HD785-3 HD985-3 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD785-3 HD985-3
Serial Number: HD785-3 – 2001, HD985-3 – 1001
Book Code: SEBM05610311
Language: English
Pages: 1023
DESCRIPTION:
Komatsu HD785-3 HD985-3 Dump Truck Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu HD785-3 HD985-3 Dump Truck Shop Manual
MAIN MENU............................................................................................................................ 0 COVER PAGE........................................................................................................................... 1 CONTENTS............................................................................................................................. 2 10 STRUCTURE AND FUNCTION........................................................................................................... 27 RADIATOR, TORQUE CONVERTER OIL COOLER............................................................................................ 29 BRAKE OIL COOLER................................................................................................................. 30 POWER TRAIN SKELETON............................................................................................................. 31 OUTPUT SHAFT..................................................................................................................... 32 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING............................................................................... 33 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...................................................................... 34 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS................................................................... 35 HYDRAULIC PUMP (SAR4-160)........................................................................................................ 36 TORQUE CONVERTER (HD785-3)....................................................................................................... 37 TORQUE CONVERTER (HD985-3)....................................................................................................... 857 TORQUE CONVERTER VALVE........................................................................................................... 39 LOCKUP SOLENOID VALVE............................................................................................................ 44 TRANSMISSION (HD785-3)........................................................................................................... 45 TRANSMISSION (HD985-3)........................................................................................................... 859 TRANSMISSION VALVE............................................................................................................... 47 ECMV (ELECTRONIC CONTROL MODULATION VALVE)....................................................................................... 48 LUBRICATION RELIEF VALVE......................................................................................................... 53 FRONT AXLE (HD785-3)............................................................................................................. 54 FRONT AXLE (HD985-3)............................................................................................................. 861 REAR AXLE (HD785-3).............................................................................................................. 55 REAR AXLE (HD985-3).............................................................................................................. 862 DIFFERENTIAL..................................................................................................................... 56 DIFFERENTIAL LOCK CONTROL........................................................................................................ 57 STRUCTURE OF SYSTEM.......................................................................................................... 58 DIFFERENTIAL LOCK SYSTEM DIAGRAM............................................................................................. 59 SWITCH....................................................................................................................... 59 DIFFERENTIAL LOCK SOLENOID VALVE............................................................................................. 60 FINAL DRIVE (HD785-3)............................................................................................................ 61 FINAL DRIVE (HD985-3)............................................................................................................ 863 FRONT BRAKE...................................................................................................................... 62 REAR BRAKE....................................................................................................................... 63 PARKING BRAKE.................................................................................................................... 64 WHEELS (HD785-3)................................................................................................................. 66 WHEELS (HD985-3)................................................................................................................. 864 AXLE SUPPORT (HD785-3)........................................................................................................... 67 AXLE SUPPORT (HD985-3)........................................................................................................... 865 STEERING SYSTEM (HD785-3)........................................................................................................ 68 STEERING SYSTEM (HD985-3)........................................................................................................ 866 STEERING WHEEL................................................................................................................... 69 STEERING LINKAGE................................................................................................................. 70 SUSPENSION SYSTEM................................................................................................................ 72 SUSPENSION CYLINDER.............................................................................................................. 74 FRONT SUSPENSION CYLINDER........................................................................................................ 76 REAR SUSPENSION CYLINDER (HD785-3)............................................................................................... 79 REAR SUSPENSION CYLINDER (HD985-3)............................................................................................... 867 AIR CIRCUIT DIAGRAM.............................................................................................................. 80 AIR PIPING....................................................................................................................... 84 AIR GOVERNOR..................................................................................................................... 86 SAFETY VALVE..................................................................................................................... 88 CHECK VALVE...................................................................................................................... 88 DOUBLE-CHECK VALVE............................................................................................................... 89 AUTO DRAIN VALVE................................................................................................................. 90 HAND BRAKE VALVE (RETARDER CONTROL VALVE)........................................................................................ 91 BRAKE VALVE...................................................................................................................... 93 2-WAY CONTROL VALVE (PARKING BRAKE VALVE, EMERGENCY BRAKE VALVE)................................................................. 96 EMERGENCY BRAKE CONTROL VALVE (VARIABLE CONTROL TYPE)............................................................................ 98 PARKING BRAKE PILOT VALVE........................................................................................................ 101 RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)....................................................................................... 102 PARKING BRAKE RELAY VALVE........................................................................................................ 105 QUICK-RELEASE VALVE.............................................................................................................. 107 BRAKE CHAMBER.................................................................................................................... 108 PARKING BRAKE CHAMBER............................................................................................................ 110 SLACK ADJUSTER................................................................................................................... 111 HYDRAULIC PIPING (STEERING AND HOIST, AND BRAKE COOLING)......................................................................... 113 HYDRAULIC CIRCUIT DIAGRAM (STEERING AND HOIST, AND BRAKE COOLING)............................................................... 114 DUMP BODY CONTROL................................................................................................................ 115 HYDRAULIC TANK AND BRAKE COOLING OIL TANK........................................................................................ 116 HYDRAULIC PUMP................................................................................................................... 117 BRAKE COOLING OIL CONTROL VAVLE (BCV)............................................................................................ 118 STEERING VALVE................................................................................................................... 119 CROSSOVER RELIEF VALVE........................................................................................................... 123 DEMAND VALVE..................................................................................................................... 124 HOIST VALVE...................................................................................................................... 128 STEERING CYLINDER................................................................................................................ 130 HOIST CYLINDER................................................................................................................... 130 DUMP BODY (HD785-3).............................................................................................................. 131 DUMP BODY (HD985-3).............................................................................................................. 869 MAIN FRAME (HD785-3)............................................................................................................. 131 MAIN FRAME (HD985-3)............................................................................................................. 869 PRESSURE SWITCH.................................................................................................................. 132 STOP LAMP SWITCH................................................................................................................. 132 HORN VALVE....................................................................................................................... 133 PARKING BRAKE SWITCH............................................................................................................. 133 FRONT BRAKE CUT-OFF VALVE........................................................................................................ 134 AUTOMATIC RETARDER VALVE......................................................................................................... 135 EXHAUST BRAKE VALVE.............................................................................................................. 135 TILT SWITCH...................................................................................................................... 136 AIR CONDITIONER.................................................................................................................. 137 PIPING DIAGRAM............................................................................................................... 137 ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 138 REFRIGERANT CIRCUIT DIAGRAM.................................................................................................. 138 CONDENSER.................................................................................................................... 139 COMPRESSOR................................................................................................................... 139 ENGINE CONTROL SYSTEM (MECHANICAL GOVERNOR TYPE)................................................................................. 140 ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 141 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................... 141 SERVO CYLINDER............................................................................................................... 142 AISS (AUTOMATIC IDLING SETTING SYSTEM)....................................................................................... 143 ENGINE CONTROL SYSTEM (ELECTRONIC GOVERNOR)...................................................................................... 144 SYSTEM DIAGRAM............................................................................................................... 144 ELECTRIC CIRCUIT DIAGRAM..................................................................................................... 145 FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR................................................................................. 146 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................... 147 AISS (AUTOMATIC IDLING SETTING SYSTEM)....................................................................................... 147 ENGINE CONTROLLER............................................................................................................ 148 SENSORS, SWITCHES............................................................................................................ 148 ACCELERATOR SENSOR........................................................................................................... 148 ENGINE SPEED SENSOR.......................................................................................................... 148 EXHAUST BRAKE.................................................................................................................... 149 SYSTEM DIAGRAM............................................................................................................... 149 AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................... 152 TRANSMISSION CONTROLLER...................................................................................................... 153 SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES..................................................................... 154 SHIFT LEVER SWITCH............................................................................................................... 157 SENSORS, SWITCHES................................................................................................................ 158 TRANSMISSION SPEED SENSOR.................................................................................................... 158 TRANSMISSION OIL TEMPERATURE SENSOR.......................................................................................... 158 FILL SWITCH.................................................................................................................. 159 ACCELERATOR SENSOR........................................................................................................... 159 SHIFT LIMIT SWITCH........................................................................................................... 160 MODE SELECTOR SWITCH......................................................................................................... 160 SHIFT INDICATOR SYSTEM........................................................................................................... 161 SHIFT INDICATOR.............................................................................................................. 162 AUTOMATIC EMERGENCY STEERING SYSTEM (HD785-3).................................................................................... 165 AUTOMATIC EMERGENCY STEERING SYSTEM (HD985-3).................................................................................... 870 ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 166 FLOW SWITCH.................................................................................................................. 167 RELAY TIMER.................................................................................................................. 169 AUTOMATIC SUSPENSION SYSTEM...................................................................................................... 170 AUTOMATIC SUSPENSION MODE SELECTION CONTROL.................................................................................. 172 SUSPENSION CONTROLLER........................................................................................................ 173 SENSORS, SWITCHES............................................................................................................ 174 STEERING ANGLE SENSOR........................................................................................................ 174 PRESSURE SENSOR.............................................................................................................. 174 PAYLOAD METER.................................................................................................................... 175 STRUCTURE OF SYSTEM.......................................................................................................... 175 ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 176 PRINCIPLE OF CALCULATION..................................................................................................... 177 FEATURES OF EQUIPMENT........................................................................................................ 179 ELECTRONIC MONITOR SYSTEM........................................................................................................ 184 ELECTRONIC MONITOR PANEL..................................................................................................... 185 ELECTRONIC MONITOR DISPLAYS, FUNCTIONS....................................................................................... 186 SENSORS, SWITCHES............................................................................................................ 189 ENGINE SPEED SENSOR.......................................................................................................... 189 ENGINE OIL PRESSURE SENSOR................................................................................................... 189 ENGINE WATER TEMPERATURE SENSOR.............................................................................................. 190 RETARDER OIL TEMPERATURE SENSOR.............................................................................................. 190 TORQUE CONVERTER OIL TEMPERATURE SENSOR...................................................................................... 190 AIR PRESSURE SENSOR.......................................................................................................... 190 FUEL LEVEL SENSOR............................................................................................................ 191 MAINTENANCE MONITOR SYSTEM................................................................................................... 192 SYSTEM DIAGRAM............................................................................................................... 192 MONITOR PANEL................................................................................................................ 193 MONITOR DISPLAY, FUNCTIONS.................................................................................................. 194 FUNCTIONS OF SWITCHES........................................................................................................ 196 SENSORS, SWITCHES................................................................................................................ 198 ENGINE OIL LEVEL SENSOR...................................................................................................... 198 RADIATOR WATER LEVEL SENSOR.................................................................................................. 198 TRANSMISSION OIL LEVEL SENSOR................................................................................................ 198 HYDRAULIC OIL LEVEL SENSOR................................................................................................... 199 RETARDER OIL LEVEL SENSOR.................................................................................................... 199 AIR FILTER CLOGGING SENSOR................................................................................................... 199 RETARDER BRAKE WEAR SENSOR................................................................................................... 200 HYDRAULIC FILTER SENSOR...................................................................................................... 200 RETARDER OIL FILTER SENSOR................................................................................................... 200 TRANSMISSION OIL FILTER SENSOR............................................................................................... 200 BATTERY ELECTROLYTE LEVEL SENSOR............................................................................................. 201 ABS/ACR SYSTEM................................................................................................................... 202 ABS/ASR CONTROLLER (ECU)......................................................................................................... 209 ABS PRESSURE CONTROL VALVE....................................................................................................... 210 ASR CONTROL VALVE................................................................................................................ 213 WHEEL SPEED SENSOR............................................................................................................... 215 20 TESTING AND ADJUSTING............................................................................................................ 216 STANDARD VALUE TABEL FOR ENGINE RELATED PARTS (HD785-3).......................................................................... 217 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS (HD985-3).......................................................................... 873 STANDARD VALUE TABLE FOR CHASSIS (HD785-3)....................................................................................... 218 STANDARD VALUE TABLE FOR CHASSIS (HD985-3)....................................................................................... 874 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....................................................................................... 223 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING................................................................................. 230 ADJUSTING VALVE CLEARANCE........................................................................................................ 232 MEASURING COMPRESSION PRESSURE................................................................................................... 233 MEASURING BLOWBY PRESSURE........................................................................................................ 234 CHECKING AND ADJUSTING FUEL INJECTION TIMING..................................................................................... 235 ADJUSTING ACCELERATOR PEDAL...................................................................................................... 240 ADJUSTING OF AISS LINKAGE........................................................................................................ 241 ADJUSTING ENGINE STOP MOTOR CABLE................................................................................................ 241 TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE............................................................................. 242 TESTING ECMV HYDRAULIC PRESSURE ................................................................................................. 243 TESTING TRANSMISSION LUBRICATION PRESSURE........................................................................................ 246 TESTING TORQUE CONVERTER STALL SPEED............................................................................................. 247 TESTING BRAKE PRESSURE........................................................................................................... 249 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................. 250 TESTING WEAR OF FRONT BRAKE PAD.................................................................................................. 251 TESTING WEAR OF REAR BRAKE DISC.................................................................................................. 251 ADJUSTING PARKING BRAKE.......................................................................................................... 252 TESTING BRAKE PERFORMANCE........................................................................................................ 253 TESTING AND ADJUSTING SUSPENSION CYLINDER........................................................................................ 254 TESTING AND ADJUSTING SUSPENSION AIR CYLINDER.................................................................................... 263 TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT................................................................................ 264 ADJUSTING HOIST LEVER LINKAGE.................................................................................................... 265 ADJUSTING BODY POSITIONER........................................................................................................ 266 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT.............................................................. 267 AIR BLEEDING FROM STEERING CYLINDER.............................................................................................. 269 ADJUSTING ENGINE SPEED SENSOR.................................................................................................... 270 ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER............................................................. 271 PROCEDURE FOR OPERATING SHIFT CHECKER AND MODULATION CHECKER..................................................................... 273 METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMISSION CONTROL SYSTEM OR ENGINE C.... 295 TROUBLESHOOTING.................................................................................................................. 298 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................... 299 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................ 300 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................... 301 HANDLING CONNECTORS.......................................................................................................... 308 CHECKS BEFORE TROUBLESHOOTING................................................................................................ 309 METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES............................................................................ 311 METHOD OF USING JUDGEMENT TABLE.............................................................................................. 315 EXPLANATION OF FUNCTIONS OF ELECTRICAL SYSTEM (CONTROL MECHANISM)............................................................ 319 METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND EACH CONTROLLER...................................................... 323 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (TRANSMISSION CONTROLLER SYSTEM).................................................. 329 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (SUSPENSION CONTROLLER SYSTEM).................................................... 335 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS (ENGINE CONTROLLER SYSTEM)........................................................ 336 TYPE AND LOCATION OF CONNECTOR, SENSOR (HD785-3)............................................................................. 338 TYPE AND LOCATION OF CONNECTOR, SENSOR (HD985-3)............................................................................. 879 CONNECTION TABLE FOR CONNECTOR............................................................................................... 355 TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (FOR ENGINES WITH MECHANICAL GOVERNOR)........................................... 366 G-1 ENGINE DOES NOT START (FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)....................................... 367 G-2 ENGINE DOES NOT STOP (FUEL INJECTION PUMP STOP LEVER STAYS AT FULL POSITION)........................................ 368 G-3 DEFECTIVE OPERATION OF AISS......................................................................................... 369 A) STAYS AT LOW IDLING (HIGH SPEED) WHEN AISS SWITCH IS ON.......................................................... 369 B) STAYS AT LOW IDLING (LOW SPEED) WHEN AISS SWITCH IS OFF.......................................................... 369 C) STAYS AT LOW IDLING (HIGH SPEED) WHEN AISS SWITCH IS OFF......................................................... 370 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START AND STOP..................................................................... 371 AISS ELECTRICAL CIRCUIT DIAGRAM.......................................................................................... 371 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) (HD785-3)................................. 372 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR) (HD985-3)................................. 888 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS........................................................... 374 G-1 ABNORMALITY IN POWER SOURCE SYSTEM.................................................................................. 375 G-2 ABNORMALITY IN CONTROLLER SYSTEM.................................................................................... 376 G-3(A) ABNORMALITY IN RIGHT BANK RACK SENSOR SYSTEM..................................................................... 377 G-3(B) ABNORMALITY IN LEFT BANK RACK SENSOR SYSTEM...................................................................... 378 G-4(A) ABNORMALITY IN RIGHT BANK GOVERNOR SOLENOID SYSTEM............................................................... 379 G-4(B) ABNORMALITY IN LEFT BANK GOVERNOR SOLENOID SYSTEM................................................................ 380 G-5(A) ABNORMALITY IN RIGHT BANK GOVERNOR RELAY SYSTEM.................................................................. 381 G-5(B) ABNORMALITY IN LEFT BANK GOVERNOR CUT RELAY SYSTEM............................................................... 382 G-6(A) ABNORMALITY IN RIGHT BANK PRE-STROKE SOLENOID SYSTEM............................................................. 383 G-6(B) ABNORMALITY IN LEFT BANK PRE-STROKE SOLENOID SYSTEM.............................................................. 384 G-7 ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM....................................................................... 385 G-8(A) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM...................................................................... 386 G-8(B) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM...................................................................... 387 G-9 ABNORMALITY IN ACCELERATOR SENSOR................................................................................... 388 G-10 ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM..................................................................... 390 G-11(A) ABNORMALITY IN RIGHT BANK GOVERNOR SERVO SYSTEM................................................................. 391 G-11(B) ABNORMALITY IN LEFT BANK GOVERNOR SERVO SYSTEM.................................................................. 391 G-12 ENGINE DOES NOT START.............................................................................................. 392 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM.................................................................. 395 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (HD785-3).................................................................. 396 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (HD985-3).................................................................. 912 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................... 398 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS.................................................. 399 A-1 ABNORMALITY IN POWER SOURCE......................................................................................... 400 A) (OFF) SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP....................................................... 400 B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED............................................................. 402 C) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED..................................................... 403 A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED...................................................................... 404 A-3 ABNORMALITY IN CONTROLLER SYSTEM.................................................................................... 405 A) ONLY DOT LIGHTS UP OR ABNORMALITY IN CONTROLLER DISPLAYED........................................................ 405 B) DOUBLE SYSTEM FOR CLUTCH IS DISPLAYED............................................................................ 406 A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED............................................................ 407 A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM IS DISPLAYED..................................................... 408 A-6 ABNORMALITY IN SPEED SENSOR SYSTEM.................................................................................. 410 A) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED.............................................................. 410 B) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED.................................................. 412 C) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR SYSTEM) DISPLAYED................... 413 A-7 SPEED SENSOR SYSTEM, CLUTCH SLIPPING................................................................................ 414 A) INPUT SHAFT SENSOR OR H.L. CLUTCH SYSTEM DISPLAYED............................................................... 414 B) TRAVEL SPEED SENSOR OR SPEED CLUTCH (1,2,3,4,R) SYSTEM DISPLAYED................................................. 415 A-8 ABNORMALITY IN MODEL SELECTION DISPLAYED............................................................................ 416 A-9 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM...................................................................... 417 A) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED........................................ 417 B) TRANSMISSION SHIFT LEVER POSITION SIGNAL DISPLAYS 2-SYSTEM ABNORMAL INPUT........................................ 418 C) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT............................................................ 423 A-10 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED........................................................................ 424 A-11 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED....................................................... 427 A-12 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM....................................................................... 428 A) FILL SIGNAL DISPLAYS ON REGARDLESS OF COMMAND.................................................................... 428 B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED........................................................ 429 1) WHEN 42.43 IS DISPLAYED...................................................................................... 431 2) WHEN 44-48 IS DISPLAYED...................................................................................... 431 A-13 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)......................................................... 432 A-14 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED.................................................. 433 OR A-14 DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED............................................... 433 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM............................................................... 435 TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM.............................................................................. 437 JUDGEMENT TABLE FOR SUSPENSION CONTROLLER, SUSPENSION RELATED PARTS...................................................... 438 S-1 ABNORMALITY IN POWER SOURCE SYSTEM.................................................................................. 439 S-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM....................................................................... 440 S-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM........................................................................ 442 S-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM........................................................................... 444 S-5 ABNORMALITY IN STEERING SENSOR SYSTEM............................................................................... 445 S-6 ABNORMALITY IN MODEL SELECTION SYSTEM............................................................................... 446 S-7 ABNORMALITY IN SOLENOID [1] SYSTEM.................................................................................. 447 S-8 ABNORMALITY IN SOLENOID [11] SYSTEM................................................................................ 448 S-9 ABNORMALITY IN SOLENOID [111] SYSTEM................................................................................ 449 S-10 ABNORMALITY IN CONTROLLER.......................................................................................... 450 ELECTRICAL CIRCUIT DIAGRAM FOR SUSPENSION CONTROL SYSTEM................................................................. 451 TROUBLESHOOTING OF PAYLOAD METER SYSTEM...................................................................................... 452 L-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY APPEARS........................................................... 453 L-2 AFTER THE STARTING SWITCH IS TURNED ON, THE DEMAND FOR CALIBRATION (CAL FLASHES) CONTINUES TO BE GIVEN.............. 453 L-3 CALIBRATION CANNOT BE CARRIED OUT................................................................................... 454 L-4 AFTER THE STARTING SWITCH IS TURNED ON, THE EXTERNAL DISPLAY LAMPS DO NOT ALL LIGHT UP.............................. 456 L-5 EXTERNAL DISPLAY LAMPS LIGHT UP EVEN WHEN IT IS NOT THE CONDITION FOR LIGHTING UP................................... 456 L-6 THE LEVEL OF LIGHTING UP OF THE EXTERNAL DISPLAY LAMPS IS NOT CORRECT............................................... 457 L-7 THERE IS ABNORMALITY IN THE DISPLAY LOGIC........................................................................... 458 A) EVEN WHEN THE DUMP BODY IS OPERATED, THE DISPLAY DOES NOT BECOME 0 TONS.......................................... 458 B) THE DISPLAY STAYS AT 0 TONS AND DOES NOT CHANGE.................................................................. 458 C) WHEN THE TRANSMISSION LEVER IS AT NEUTRAL, THE WEIGHT DISPLAY IS NOT GIVEN (TIME DISPLAY IS GIVEN)............... 459 D) WHEN THE TRANSMISSION LEVER IS AT A POSITION OTHER THAN NEUTRAL, THE TIME DISPLAY IS NOT GIVEN................... 461 L-8 E01-E04 IS DISPLAYED................................................................................................ 462 L-9 E11-E14 IS DISPLAYED................................................................................................ 463 L-10 E21-E28 IS DISPLAYED BY SENSOR CHECK............................................................................... 463 L-11 E31 IS DISPLAYED................................................................................................... 464 L-12 E32 IS DISPLAYED................................................................................................... 466 L-13 E41 IS DISPLAYED................................................................................................... 466 L-14 E42 IS DISPLAYED................................................................................................... 467 L-15 THE PRINTER DOES NOT PRINT ANYTHING (ONLY BLANK PAPER COMES OUT)................................................... 467 L-16 THE PRINTER ONLY PRINTS NO DATA.................................................................................... 468 L-17 EVEN WHEN THE [PRT] SWITCH IS PRESSED NOTHING IS PRINTED OUT....................................................... 468 L-18 PAPE FLASHES....................................................................................................... 469 L-19 THE TIME IS WRONG.................................................................................................. 469 L-20 E33 IS DISPLAYED................................................................................................... 469 RELATED ELECTRICAL CIRCUIT DIAGRAMS...................................................................................... 470 ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM..................................................................... 473 TROUBLESHOOTING OF PILOT LAMP SYSTEM......................................................................................... 474 F-1 ABNORMALITY IN LIGHTING UP OF REAR BRAKE LAMP....................................................................... 475 A) BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHTS UP............................................................. 475 B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN BRAKE IS APPLIED.......................................................... 476 F-2 ABNORMALITY IN LIGHTING UP OF BODY FLOAT PILOT LAMP................................................................. 478 A) HOIST LEVER IS AT FLOAT POSITION, BUT PILOT LAMP LIGHTS UP....................................................... 478 B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN HOIST LEVER IS OPERATED................................................... 479 F-3 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP.............................................................. 480 A) PARKING BRAKE IS NOT BEING APPLIED, BUT PILOT LAMP LIGHTS UP..................................................... 480 B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE IS APPLIED.................................................. 481 F-4 ABNORMAL LIGHTING UP OF EXHAUST BRAKE PILOT LAMP.................................................................... 482 A) PILOT LAMP LIGHTS UP EVEN WHEN EXHAUST BRAKE IS NOT BEING OPERATED............................................... 482 B) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN EXHAUST BRAKE IS BEING OPERATED........................................... 483 F-5 ABNORMAL ACTUATION OF AISS.......................................................................................... 484 A) WHEN AISS SWITCH IS ON, IT DOES NOT BECOME LOW IDLING (LOW SPEED)................................................ 484 B) WHEN AISS SWITCH IS ON, IT DOES NOT BECOME LOW IDLING (HIGH SPEED)............................................... 484 ELECTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP CIRCUIT........................................................................ 486 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (HD785-3)............................................................................ 487 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (HD985-3)............................................................................ 951 P-1 MONITOR PANEL DOES NOT WORK AT ALL.................................................................................. 489 P-2 PART OF MONITOR PANEL DOES NOT WORK................................................................................. 490 A) SPEEDOMETER DISPLAY DOES NOT WORK................................................................................ 490 B) SPEEDOMETER DISPLAY WORKS, BUT OTHER PARTS DO NOT WORK........................................................... 490 C) SUSPENSION DISPLAY DOES NOT WORK................................................................................. 490 D) (MECHATRONICS) CAUTION, FUEL GAUGE DISPLAYS DO NOT WORK.......................................................... 491 P-3 AUTOMATIC SHIFT DISPLAY (MECHATRONICS) FLASHES...................................................................... 492 P-4 SUSPENSION (MECHATRONICS) DISPLAY FLASHES........................................................................... 492 P-5 ABNORMALITY IN SUSPENSION DISPLAY................................................................................... 493 A) HARD DISPLAY DOES NOT LIGHT UP................................................................................... 493 B) MEDIUM DISPLAY DOES NOT LIGHT UP................................................................................. 493 C) SOFT DISPLAY DOES NOT LIGHT UP................................................................................... 494 D) SUSPENSION MODE DISPLAYS ALL LIGHT UP............................................................................ 494 P-6 ABNORMALITY IN SHIFT POSITION DISPLAY............................................................................... 495 A) R DISPLAY DOES NOT LIGHT UP...................................................................................... 495 B) N DISPLAY DOES NOT LIGHT UP...................................................................................... 495 C) D DISPLAY DOES NOT LIGHT UP...................................................................................... 496 D) 5 DISPLAY DOES NOT LIGHT UP...................................................................................... 496 E) 4 DISPLAY DOES NOT LIGHT UP...................................................................................... 497 F) 3 DISPLAY DOES NOT LIGHT UP...................................................................................... 497 G) L DISPLAY DOES NOT LIGHT UP...................................................................................... 498 P-7 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP............................................................................. 499 P-8 LOCK-UP DISPLAY DOES NOT LIGHT UP................................................................................... 499 P-9 HI BEAM DISPLAY DOES NOT LIGHT UP................................................................................... 500 P-10 ABNORMALITY IN TURN SIGNAL......................................................................................... 501 A) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP......................................................................... 501 B) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP.......................................................................... 501 P-11 ABNORMALITY IN SHIFT INDICATOR DISPLAY............................................................................. 502 A) WHEN 1,2,4,5,R IS DISPLAYED, DISPLAY CHANGES TO E................................................................ 502 B) WHEN 3,5,7 IS DISPLAYED, DISPLAY CHANGES TO E.................................................................... 502 C) WHEN 1 IS DISPLAYED, DISPLAY CHANGES TO E........................................................................ 503 D) WHEN 2, 3 IS DISPLAYED, DISPLAY CHANGES TO E..................................................................... 503 E) WHEN 4, 5 IS DISPLAYED, DISPLAY CHANGES TO E..................................................................... 504 F) WHEN 6, 7 IS DISPLAYED, DISPLAY CHANGES TO E..................................................................... 504 G) WHEN R IS DISPLAYED, DISPLAY CHANGES TO E........................................................................ 505 P-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY......................................................................... 506 P-13 TACHOMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................... 506 P-14 SERVICE METER DOES NOT WORK........................................................................................ 507 P-15 ODOMETER DOES NOT WORK............................................................................................. 507 P-16 ABNORMALITY IN ALARM BUZZER........................................................................................ 508 A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT SOUND........................................ 508 B) ALARM BUZZER CONTINUES TO SOUND.................................................................................. 508 P-17 ABNORMALITY IN WARNING LAMP........................................................................................ 509 A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT WARNING LAMP DOES NOT FLASH........................................ 509 B) WARNING LAMP STAYS ON............................................................................................ 509 P-18 CAUTION DISPLAY DOES NOT FLASH (DOES NOT LIGHT UP), BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS............... 510 A) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS..................................................................... 510 B) WARNING LAMP FLASHES WHEN ENGINE STOPS........................................................................... 510 C) WARNING LAMP FLASHES WHEN ENGINE IS RUNNING...................................................................... 510 P-19 ABNORMALITY IN AIR PRESSURE GAUGE.................................................................................. 511 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 511 B) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE.................................................................... 511 P-20 ABNORMALITY IN COOLANT TEMPERATURE GAUGE........................................................................... 512 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 512 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 512 P-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.............................................................. 513 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 513 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 513 P-22 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE...................................................................... 514 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 514 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 514 P-23 ABNORMALITY IN FUEL GAUGE.......................................................................................... 515 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 515 B) DISPLAY SHOWS FULL AND DOES NOT MOVE............................................................................. 515 P-24 ABNORMALITY IN NIGHT LIGHTING (ABNORMALITY ONLY IN NIGHT LIGHTING OF MONITOR PANEL)................................ 516 A) NONE OF PANEL LAMPS LIGHT UP..................................................................................... 516 B) SERVICE METER AND ODOMETER LIGHT UP, BUT OTHER PARTS DO NOT LIGHT UP............................................. 517 C) SERVICE METER AND ODOMETER DO NOT LIGHT UP....................................................................... 517 P-25 ENGINE (MECHATRONICS) DISPLAY FLASHES.............................................................................. 518 P-26 ABNORMALITY IN POWER MODE DISPLAY.................................................................................. 519 A) HIGH POWER DISPLAY DOES NOT LIGHT UP............................................................................. 519 B) ECONOMY DISPLAY DOES NOT LIGHT UP................................................................................ 519 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM...................................................................... 520 RELATED ELECTRICAL CIRCUIT DIAGRAMS...................................................................................... 522 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (HD785-3)..................................................................... 531 TROUBLESHOOTING MAINTENANCE MONITOR SYSTEM (HD985-3)......................................................................... 993 M-1 MAINTENANCE MONITOR DOES NOT WORK................................................................................... 532 A) WHEN NOTHING WORKS............................................................................................... 532 B) WHEN CHECK DISPLAY DOES NOT WORK................................................................................. 532 M-2 WHEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES............................................................ 533 M-3 WHEN ENGINE IS STOPPED, TRANSMISSION OIL LEVEL DISPLAY FLASHES...................................................... 534 M-4 WHEN ENGINE IS STOPPED HYDRAULIC OIL LEVEL DISPLAY FLASHES.......................................................... 535 M-5 WHEN ENGINE IS STOPPED RETARDER OIL LEVEL DISPLAY FLASHES........................................................... 536 M-6 WHEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES............................................................. 537 M-7 WHEN ENGINE IS STOPPED, BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES................................................... 538 M-8 AT NEUTRAL, RETARDER WEAR DISPLAY FLASHES........................................................................... 539 M-9 WHEN ENGINE IS RUNNING, AIR CLEANER CLOGGING DISPLAY FLASHES........................................................ 540 M-10 WHEN ENGINE IS RUNNING, FULL-FLOW FILTER CLOGGING DISPLAY FLASHES.................................................. 541 M-11 WHEN ENGINE IS RUNNING, TRANSMISSION FILTER CLOGGING DISPLAY FLASHES............................................... 542 M-12 WHEN ENGINE IS RUNNING, HYDRAULIC FILTER CLOGGING DISPLAY FLASHES.................................................. 543 M-13 WHEN ENGINE IS RUNNING, RETARDER FILTER CLOGGING DISPLAY FLASHES................................................... 544 M-14 MAINTENANCE TIMER DOES NOT WORK (TIME DOES NOT ADVANCE)............................................................ 545 M-15 MAINTENANCE TIMER IS NOT OH OR BELOW, BUT MAINTENANCE ITEM LIGHTS UP............................................... 545 M-16 ABNORMALITY IN SWITCH.............................................................................................. 546 A) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK............................................. 546 B) REPLACEMENT SWITCH, MISOPERATION CANCEL SWITCH DO NOT WORK....................................................... 546 M-17 NIGHT LIGHTING DOES NOT LIGHT UP (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP).......................... 547 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM................................................................ 548 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM........................................................................... 549 H-1 MACHINE DOES NOT MOVE............................................................................................... 550 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY.................................................................................... 552 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED................................................................................. 552 H-4 LARGE SHOCK WHEN STARTING OF SHIFTING............................................................................... 553 H-5 TRANSMISSION DOES NOT SHIFT UP...................................................................................... 553 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELLING........................................................................ 554 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR................................................................ 560 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH............................................................................ 562 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW................................................................................ 563 H-10 FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE................................................................... 564 H-11 REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE.................................................................... 565 H-12 STEERING WHEEL IS HEAVY............................................................................................ 566 H-13 STEERING WHEEL DOES NOT FUNCTION................................................................................... 567 H-14 STEERING WHEEL VIBRATES............................................................................................ 567 H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)................................................................. 568 H-16 HOIST CYLINDER DOES NOT WORK....................................................................................... 569 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY............................................................................. 570 H-18 AIR PRESSURE DOES NOT RISE......................................................................................... 571 30 DISASSEMBLY AND ASSEMBLY......................................................................................................... 572 METHOD OF USING MANUAL........................................................................................................... 574 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................... 575 SPECIAL TOOL LIST................................................................................................................ 577 TIGHTENING TORQUES AND STANDARD VALUES TABLE..................................................................................... 579 WEIGHT TABLE..................................................................................................................... 583 LUBRICANT AND COOLANT TABLE...................................................................................................... 584 STARTING MOTOR................................................................................................................... 585 REMOVAL...................................................................................................................... 585 INSTALLATION................................................................................................................. 585 ALTERNATOR....................................................................................................................... 585 REMOVAL...................................................................................................................... 585 INSTALLATION................................................................................................................. 585 ENGINE OIL COOLER................................................................................................................ 585 REMOVAL...................................................................................................................... 585 INSTALLATION................................................................................................................. 585 FUEL INJECTION PUMP (LEFT AND RIGHT)............................................................................................. 587 REMOVAL...................................................................................................................... 587 INSTALLATION................................................................................................................. 587 AIR COMPRESSOR................................................................................................................... 587 REMOVAL...................................................................................................................... 587 INSTALLATION................................................................................................................. 587 WATER PUMP ...................................................................................................................... 589 REMOVAL...................................................................................................................... 589 INSTALLATION................................................................................................................. 589 AFTER-COOLER..................................................................................................................... 589 REMOVAL...................................................................................................................... 589 INSTALLATION................................................................................................................. 589 TURBOCHARGER..................................................................................................................... 591 REMOVAL...................................................................................................................... 591 INSTALLATION................................................................................................................. 591 NOZZLE HOLDER ASSEMBLY........................................................................................................... 591 REMOVAL...................................................................................................................... 591 INSTALLATION................................................................................................................. 591 CYLINDER HEAD.................................................................................................................... 593 REMOVAL...................................................................................................................... 593 INSTALLATION................................................................................................................. 595 ENGINE........................................................................................................................... 596 REMOVAL...................................................................................................................... 596 INSTALLATION................................................................................................................. 600 RADIATOR, TORQUE CONVERTER OIL COOLER............................................................................................ 601 REMOVAL...................................................................................................................... 601 INSTALLATION................................................................................................................. 601 OUTPUT SHAFT..................................................................................................................... 603 REMOVAL...................................................................................................................... 603 INSTALLATION................................................................................................................. 603 DISASSEMBLY.................................................................................................................. 605 ASSEMBLY..................................................................................................................... 605 TORQUE CONVERTER, TRANSMISSION................................................................................................... 609 REMOVAL...................................................................................................................... 609 INSTALLATION................................................................................................................. 611 TORQUE CONVERTER CONTROL VALVE................................................................................................... 613 REMOVAL...................................................................................................................... 613 INSTALLATION................................................................................................................. 613 DISASSEMBLY.................................................................................................................. 615 ASSEMBLY..................................................................................................................... 615 TORQUE CONVERTER AND TRANSMISSION................................................................................................ 617 DISCONNECTION................................................................................................................ 617 CONNECTION................................................................................................................... 617 TORQUE CONVERTER, PTO............................................................................................................ 619 DISASSEMBLY.................................................................................................................. 619 ASSEMBLY..................................................................................................................... 625 PTO.............................................................................................................................. 631 DISASSEMBLY.................................................................................................................. 631 ASSEMBLY..................................................................................................................... 631 TRANSMISSION..................................................................................................................... 633 DISASSEMBLY.................................................................................................................. 633 ASSEMBLY..................................................................................................................... 647 TRANSMISSION CONTROL VALVE (ECMV)................................................................................................ 665 REMOVAL...................................................................................................................... 665 INSTALLATION................................................................................................................. 665 TRANSMISSION PUMP................................................................................................................ 665 REMOVAL...................................................................................................................... 665 INSTALLATION................................................................................................................. 665 ECMV............................................................................................................................. 667 DISASSEMBLY.................................................................................................................. 667 ASSEMBLY..................................................................................................................... 667 DIFFERENTIAL (FOR STANDARD)...................................................................................................... 671 REMOVAL...................................................................................................................... 671 INSTALLATION................................................................................................................. 671 DISASSEMBLY.................................................................................................................. 673 ASSEMBLY..................................................................................................................... 677 DIFFERENTIAL (FOR WITH DIFFERENTIAL LOCK)........................................................................................ 686 REMOVAL...................................................................................................................... 686 INSTALLATION................................................................................................................. 686 DISASSEMBLY.................................................................................................................. 688 ASSEMBLY..................................................................................................................... 692 CARRIER.......................................................................................................................... 703 REMOVAL...................................................................................................................... 703 INSTALLATION................................................................................................................. 703 DISASSEMBLY.................................................................................................................. 703 ASSEMBLY..................................................................................................................... 703 FINAL DRIVE...................................................................................................................... 705 DISASSEMBLY.................................................................................................................. 705 ASSEMBLY..................................................................................................................... 707 REAR WHEEL BRAKE................................................................................................................. 709 REMOVAL...................................................................................................................... 709 INSTALLATION................................................................................................................. 709 DISASSEMBLY.................................................................................................................. 709 ASSEMBLY..................................................................................................................... 711 PARKING BRAKE CALIPER............................................................................................................ 713 REMOVAL...................................................................................................................... 713 INSTALLATION................................................................................................................. 713 DISASSEMBLY.................................................................................................................. 713 ASSEMBLY..................................................................................................................... 713 PARKING BRAKE PAD................................................................................................................ 715 REMOVAL...................................................................................................................... 715 INSTALLATION................................................................................................................. 715 FRONT BRAKE CALIPER.............................................................................................................. 715 REMOVAL...................................................................................................................... 715 INSTALLATION................................................................................................................. 715 DISASSEMBLY.................................................................................................................. 717 ASSEMBLY..................................................................................................................... 717 FRONT BRAKE CALIPER PAD.......................................................................................................... 717 REMOVAL...................................................................................................................... 717 INSTALLATION................................................................................................................. 717 STEERING VALVE................................................................................................................... 719 REMOVAL (A HD785-3).......................................................................................................... 719 REMOVAL (BH985-3)............................................................................................................1012 INSTALLATION (A HD785-3)..................................................................................................... 719 INSTALLATION (B HD985-3).....................................................................................................1012 DISASSEMBLY.................................................................................................................. 721 ASSEMBLY..................................................................................................................... 727 FRONT WHEEL ..................................................................................................................... 737 REMOVAL...................................................................................................................... 737 INSTALLATION................................................................................................................. 737 REAR WHEEL ...................................................................................................................... 739 REMOVAL...................................................................................................................... 739 INSTALLATION................................................................................................................. 739 FRONT WHEEL HUB.................................................................................................................. 741 DISASSEMBLY.................................................................................................................. 741 ASSEMBLY..................................................................................................................... 743 FRONT SUSPENSION................................................................................................................. 747 REMOVAL...................................................................................................................... 747 INSTALLATION................................................................................................................. 747 VARIABLE DAMPER VALVE ........................................................................................................... 749 REMOVAL...................................................................................................................... 749 INSTALLATION................................................................................................................. 749 VARIABLE DAMPER SELECTOR VALVE................................................................................................... 751 DISASSEMBLY.................................................................................................................. 751 ASSEMBLY..................................................................................................................... 751 FIXED ATTENUATION VALVE.......................................................................................................... 753 DISASSEMBLY.................................................................................................................. 753 ASSEMBLY..................................................................................................................... 753 FRONT SUSPENSION CYLINDER........................................................................................................ 755 DISASSEMBLY.................................................................................................................. 755 ASSEMBLY..................................................................................................................... 755 REAR SUSPENSION CYLINDER......................................................................................................... 757 REMOVAL...................................................................................................................... 757 INSTALLATION................................................................................................................. 757 DISASSEMBLY.................................................................................................................. 759 ASSEMBLY..................................................................................................................... 759 PARKING BRAKE SPRING CYLINDER.................................................................................................... 763 REMOVAL...................................................................................................................... 763 INSTALLATION................................................................................................................. 763 DISASSEMBLY.................................................................................................................. 765 ASSEMBLY..................................................................................................................... 765 BRAKE VALVE...................................................................................................................... 767 REMOVAL...................................................................................................................... 767 INSTALLATION................................................................................................................. 767 DISASSEMBLY.................................................................................................................. 769 ASSEMBLY..................................................................................................................... 771 FRONT BRAKE CHAMBER.............................................................................................................. 773 REMOVAL...................................................................................................................... 773 INSTALLATION................................................................................................................. 773 DISASSEMBLY.................................................................................................................. 775 ASSEMBLY..................................................................................................................... 779 REAR BRAKE CHAMBER............................................................................................................... 773 REMOVAL...................................................................................................................... 773 INSTALLATION................................................................................................................. 773 DISASSEMBLY.................................................................................................................. 783 ASSEMBLY..................................................................................................................... 787 AIR GOVERNOR..................................................................................................................... 791 REMOVAL...................................................................................................................... 791 INSTALLATION................................................................................................................. 791 DISASSEMBLY.................................................................................................................. 791 ASSEMBLY..................................................................................................................... 791 SLACK ADJUSTER................................................................................................................... 793 REMOVAL...................................................................................................................... 793 INSTALLATION................................................................................................................. 793 DISASSEMBLY.................................................................................................................. 793 ASSEMBLY..................................................................................................................... 793 BRAKE COOLING PUMP............................................................................................................... 795 REMOVAL...................................................................................................................... 795 INSTALLATION................................................................................................................. 795 STEERING, HOIST PUMP............................................................................................................. 795 REMOVAL...................................................................................................................... 795 INSTALLATION................................................................................................................. 795 BRAKE COOLER..................................................................................................................... 795 REMOVAL...................................................................................................................... 795 INSTALLATION................................................................................................................. 795 DEMAND VALVE..................................................................................................................... 797 REMOVAL...................................................................................................................... 797 INSTALLATION................................................................................................................. 797 DISASSEMBLY.................................................................................................................. 799 ASSEMBLY..................................................................................................................... 799 RELIEF VALVE..................................................................................................................... 799 DISASSEMBLY.................................................................................................................. 799 ASSEMBLY..................................................................................................................... 799 EMERGENCY STEERING MOTOR PUMP.................................................................................................... 801 REMOVAL...................................................................................................................... 801 INSTALLATION................................................................................................................. 801 STEERING CYLINDER................................................................................................................ 801 REMOVAL...................................................................................................................... 801 INSTALLATION................................................................................................................. 801 DISASSEMBLY.................................................................................................................. 803 ASSEMBLY..................................................................................................................... 805 HOIST VALVE...................................................................................................................... 809 REMOVAL...................................................................................................................... 809 INSTALLATION................................................................................................................. 809 DISASSEMBLY.................................................................................................................. 811 ASSEMBLY..................................................................................................................... 811 HOIST CYLINDER................................................................................................................... 813 REMOVAL...................................................................................................................... 813 INSTALLATION................................................................................................................. 813 DISASSEMBLY.................................................................................................................. 815 ASSEMBLY..................................................................................................................... 817 BODY............................................................................................................................. 819 REMOVAL...................................................................................................................... 819 INSTALLATION................................................................................................................. 819 TRANSMISSION CONTROLLER.......................................................................................................... 821 REMOVAL...................................................................................................................... 821 INSTALLATION................................................................................................................. 821 40 MAINTENANCE STANDARD............................................................................................................. 823 OUTPUT SHAFT..................................................................................................................... 824 TORQUE CONVERTER VALVE........................................................................................................... 825 TORQUE CONVERTER................................................................................................................. 826 TRANSMISSION (HD785-3) (HD785-3)................................................................................................. 828 TRANSMISSION (HD985-3)...........................................................................................................1015 ECMV (ELECTRONIC CONTROL MODULATION VALVE)....................................................................................... 833 FRONT AXLE....................................................................................................................... 834 REAR AXLE SUPPORT (HD785-3)...................................................................................................... 835 REAR AXLE SUPPORT (HD985-3)......................................................................................................1020 DIFFERENTIAL..................................................................................................................... 836 FINAL DRIVE (HD785-3)............................................................................................................ 838 FINAL DRIVE (HD985-3)............................................................................................................1021 FRONT BRAKE...................................................................................................................... 839 REAR BRAKE....................................................................................................................... 840 PARKING BRAKE.................................................................................................................... 841 STEERING LINKAGE................................................................................................................. 842 FRONT SUSPENSION CYLINDER........................................................................................................ 844 REAR SUSPENSION CYLINDER (HD785-3)............................................................................................... 845 REAR SUSPENSION CYLINDER (HD 985-3)..............................................................................................1022 PARKING BRAKE CHAMBER............................................................................................................ 846 SLACK ADJUSTER................................................................................................................... 847 HYDRAULIC PUMP (SAR4-160)........................................................................................................ 848 DEMAND VALVE..................................................................................................................... 850 CROSS-OVER RELIEF VALVE.......................................................................................................... 850 HOIST VALVE...................................................................................................................... 851 STEERING CYLINDER................................................................................................................ 852 HOIST CYLINDER................................................................................................................... 853 90 OTHERS: CONTENTS (FOR HD985-3).................................................................................................. 854 10 STRUCTURE AND FUNCTION....................................................................................................... 855 TORQUE CONVERTER............................................................................................................. 857 TRANSMISSION................................................................................................................. 859 FRONT AXLE................................................................................................................... 861 REAR AXLE.................................................................................................................... 862 FINAL DRIVE.................................................................................................................. 863 WHEELS....................................................................................................................... 864 AXLE SUPPORT................................................................................................................. 865 STEERING WHEEL............................................................................................................... 866 REAR SUSPENSION CYLINDER..................................................................................................... 867 DUMP BODY.................................................................................................................... 869 MAIN FRAME................................................................................................................... 869 AUTOMATIC EMERGENCY STEERING SYSTEM.......................................................................................... 870 ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 871 20 TESTING AND ADJUSTING........................................................................................................ 872 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS................................................................................ 873 STANDARD VALUE TABLE FOR CHASSIS............................................................................................. 874 TYPE AND LOCATION OF CONNECTOR, SENSOR....................................................................................... 879 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (FOR ENGINES WITH ELECTRONIC GOVERNOR)........................................... 888 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS........................................................... 890 G-1 ABNORMALITY IN POWER SOURCE SYSTEM.................................................................................. 891 G-2 ABNORMALITY IN CONTROLLER SYSTEM.................................................................................... 892 G-3(A) ABNORMALITY IN RIGHT BANK RACK SENSOR SYSTEM..................................................................... 893 G-3(B) ABNORMALITY IN LEFT BANK RACK SESNOR SYSTEM...................................................................... 894 G-4(A) ABNORMALITY IN RIGHT BANK GOVERNOR SOLENOID SYSTEM............................................................... 895 G-4(B) ABNORMALITY IN LEFT BANK GOVERNOR SOLENOID SYSTEM................................................................ 896 G-5(A) ABNORMALITY IN RIGHT BANK GOVERNOR RELAY SYSTEM.................................................................. 897 G-5(B) ABNORMALITY IN LEFT BANK GOVERNOR CUT RELAY SYSTEM............................................................... 898 G-6(A) ABNORMALITY IN RIGHT BANK PRE-STROKE SOLENOID SYSTEM............................................................. 899 G-6(B) ABNORMALITY IN LEFT BANK PRE-STROKE SOLENOID SYSTEM.............................................................. 900 G-7 ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM...................................................................... 901 G-8(A) ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM...................................................................... 902 G-8(B) ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM...................................................................... 903 G-9 ABNORMALITY IN ACCELERATOR SENSOR................................................................................... 904 G-10 ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM..................................................................... 906 G-11(A) ABNORMALITY IN RIGHT BANK GOVERNOR SERVO SYSTEM................................................................. 907 G-11(B) ABNORMALITY IN LEFT BANK GOVERNOR SERVO SYSTEM.................................................................. 907 G-12 ENGINE DOES NOT START.............................................................................................. 908 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM.................................................................. 911 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM............................................................................ 912 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................... 914 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS.................................................. 915 A-1 ABNORMALITY INPOWER SOURCE.......................................................................................... 916 A) (OFF) SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP....................................................... 916 B) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED............................................................. 918 C) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED..................................................... 919 A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED...................................................................... 920 A-3 ABNORMALITY IN CONTROLLER SYSTEM.................................................................................... 921 A) ONLY DOT LIGHTS UP OR ABNORMALITY IN CONTROLLER DISPLAYED........................................................ 921 B) DOUBLE SYSTEM FOR CLUTCH IS DISPLAYED............................................................................ 922 A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED............................................................ 923 A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM DISPLAYED........................................................ 924 A-6 ABNORMALITY IN SPEED SENSOR SYSTEM.................................................................................. 926 A) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED.............................................................. 926 B) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED.................................................. 928 C) DISCONNECTION IN TRAVEL SPEED SENSOR (TRANSMISSION OUTPUT SHAFT SPEED SENSOR) DISPLAYED.......................... 929 A-7 SPEED SENSOR SYSTEM, CLUTCH SLIPPING................................................................................ 930 A) INPUT SHAFT SENSOR OR H.L. CLUTCH SYSTEM DISPLAYED............................................................... 930 B) TRAVEL SPEED SENSOR OR SPEED CLUTCH (1,2,3,4,R) SYSTEM DISPLAYED................................................. 931 A-8 ABNORMALITY IN MODEL SELECTION DISPLAYED............................................................................ 932 A-9 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM...................................................................... 933 A) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED........................................ 933 B) TRANSMISSION SHIFT LEVER POSITION SIGNAL DISPLAYS 2-SYSTEM ABNORMAL INPUT........................................ 934 C) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT............................................................ 939 A-10 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED........................................................................ 940 A-11 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED....................................................... 943 A-12 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM....................................................................... 944 A) ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM..................................................................... 944 B) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED........................................................ 945 1) WHEN 42.43 IS DISPLAYED...................................................................................... 947 2) WHEN 44-48 IS DISPLAYED...................................................................................... 947 A-13 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETECTOR VALVE SYSTEM)......................................................... 948 A-14 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED.................................................. 949 OR A-14 DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM IS DISPLAYED........................................... 949 TROUBLESHOOTING OF MONITOR PANEL SYSTEM...................................................................................... 951 P-1 MONITOR PANEL DOES NOT WORK AT ALL.................................................................................. 953 P-2 PART OF MONITOR PANEL DOES NOT WORK................................................................................. 954 A) SPEEDOMETER DISPLAY DOES NOT WORK................................................................................ 954 B) SPEEDOMETER DISPLAY WORKS, BUT OTHER PARTS DO NOT WORK........................................................... 954 C) SUSPENSION DISPLAY DOES NOT WORK................................................................................. 954 D) (MECHATRONICS) CAUTION FUEL GAUGE DISPLAYS DO NOT WORK........................................................... 955 P-3 AUTOMATIC SHIFT DISPLAY (MECHATRONICS) FLASHES...................................................................... 956 P-4 SUSPENSION (MECHATRONICS) DISPLAY FLASHES........................................................................... 956 P-5 ABNORMALITY IN SUSPENSION DISPLAY................................................................................... 957 A) HARD DISPLAY DOES NOT LIGHT UP................................................................................... 957 B) MEDIUM DISPLAY DOES NOT LIGHT UP................................................................................. 957 C) SOFT DISPLAY DOES NOT LIGHT UP................................................................................... 958 D) SUSPENSION MODE DISPLAYS ALL LIGHT UP............................................................................ 958 P-6 ABNORMALITY IN SHIFT POSITION DISPLAY............................................................................... 959 A) R DISPLAY DOES NOT LIGHT UP...................................................................................... 959 B) N DISPLAY DOES NOT LIGHT UP...................................................................................... 959 C) D DISPLAY DOES NOT LIGHT UP...................................................................................... 960 D) 5 DISPLAY DOES NOT LIGHT UP...................................................................................... 960 E) 4 DISPLAY DOES NOT LIGHT UP...................................................................................... 961 F) 3 DISPLAY DOES NOT LIGHT UP...................................................................................... 961 G) L DISPLAY DOES NOT LIGHT UP...................................................................................... 962 P-7 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP............................................................................. 963 P-8 LOCK-UP DISPLAY DOES NOT LIGHT UP................................................................................... 963 P-9 HI BEAM DISPLAY DOES NOT LIGHT UP................................................................................... 964 P-10 ABNORMALITY IN TURN SIGNAL......................................................................................... 965 A) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP......................................................................... 965 B) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP.......................................................................... 965 P-11 ABNORMALITY IN SHIFT INDICATOR DISPLAY............................................................................. 966 A) WHEN 1,2,4,6,R IS DISPLAYED, DISPLAY CHANGES TO E................................................................ 966 B) WHEN 3,5,7 IS DISPLAYED, DISPLAY CHANGES TO E.................................................................... 966 C) WHEN 1 IS DISPLAYED, DISPLAY CHANGES TO E........................................................................ 967 D) WHEN 2,3 IS DISPLAYED, DISPLAY CHANGES TO E...................................................................... 967 E) WHEN 4,5 IS DISPLAYED, DISPLAY CHANGES TO E...................................................................... 968 F) WHEN 6,7 IS DISPLAYED, DISPLAY CHANGES TO E...................................................................... 968 G) WHEN R IS DISPLAYED, DISPLAY CHANGES TO E........................................................................ 969 P-12 SPEEDOMETER DISPLY DOES NOT WORK NORMALLY.......................................................................... 970 P-13 TACHOMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................... 970 P-14 SERVICE METER DOES NOT WORK........................................................................................ 971 P-15 ODOMETER DOES NOT WORK............................................................................................. 971 P-16 ABNORMALITY IN ALARM BUZZER........................................................................................ 972 A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT ALARM BUZZER DOES NOT SOUND........................................ 972 B) ALARM BUZZER CONTINUES TO SOUND.................................................................................. 972 P-17 ABNORMALITY IN WARNING LAMP........................................................................................ 973 A) CAUTION DISPLAY IS FLASHING (LIGHTED UP), BUT WARNING LAMP DOES NOT FLASH........................................ 973 B) WARNING LAMP STAYS ON............................................................................................ 973 P-18 CAUTION DISPLAY DOES NOT FLASH (DOES NOT LIGHT UP), BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS............... 974 A) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS..................................................................... 974 B) WARNING LAMP FLASHES WHEN ENGINE STOPS........................................................................... 974 C) WARNING LAMP FLASHES WHEN ENGINE IS RUNNING...................................................................... 974 P-19 ABNORMALITY IN AIR PRESSURE GAUGE.................................................................................. 975 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 975 B) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE.................................................................... 975 P-20 ABNORMALITY IN COOLANT TEMPERATURE GAUGE........................................................................... 976 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 976 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 976 P-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.............................................................. 977 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 977 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 977 P-22 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE...................................................................... 978 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 978 B) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE..................................................................... 978 P-23 ABNORMALITY IN FUEL GAUGE.......................................................................................... 979 A) NO DISPLAY GIVEN IN DISPLAY AREA................................................................................. 979 B) DISPLAY SHOWS FULL AND DOES NOT MOVE............................................................................. 979 P-24 ABNORMALITY IN NIGHT LIGHTING (ABNORMALITY ONLY IN NIGHT LIGHTING OF MONITOR PANEL)................................ 980 A) NONE OF PANEL LAMPS LIGHT UP...................................................................................... 980 B) SERVICE METER AND ODOMETER LIGHT UP, BUT OTHER PARTS DO NOT LIGHT UP............................................. 981 C) SERVICE METER AND ODOMETER DO NOT LIGHT UP....................................................................... 981 P-25 ENGINE (MECHATRONICS) DISPLAY FLASHES.............................................................................. 982 P-26 ABNORMALITY IN POWER MODE DISPLAY.................................................................................. 983 A) HIGH POWER DISPLAY DOES NOT LIGHT UP............................................................................. 983 B) ECONOMY DISPLAY DOES NOT LIGHT UP................................................................................ 983 RELATED ELECTRICAL CIRCUIT DIAGRAMS...................................................................................... 984 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM................................................................................ 993 M-1 MAINTENANCE MONITOR DOES NOT WORK................................................................................... 994 A) WHEN NOTHING WORKS............................................................................................... 994 B) WHEN CHECK DISPLAY DOES NOT WORK................................................................................. 994 M-2 WHEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES............................................................ 995 M-3 WHEN ENGINE IS STOPPED, TRANSMISSION OIL LEVEL DISPLAY FLASHES...................................................... 996 M-4 WHEN ENGINE IS STOPPED, HYDRAULIC OIL LEVEL DISPLAY FLASHES......................................................... 997 M-5 WHEN ENGINE IS STOPPED, RETARDER OIL LEVEL DISPLAY FLASHES.......................................................... 998 M-6 WHEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES............................................................. 999 M-7 WHEN ENGINE IS STOPPED, BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES...................................................1000 M-8 AT NEUTRAL, RETARDER WEAR DISPLAY FLASHES...........................................................................1001 M-9 WHEN ENGINE IS RUNNING, AIR CLEANER CLOGGING DISPLAY FLASHES........................................................1002 M-10 WHEN ENGINE IS RUNNING, FULL-FLOW FILTER CLOGGING DISPLAY FLASHES..................................................1003 M-11 WHEN ENGINE IS RUNNING, TRANSMISSION FILTER CLOGGING DISPLAY FLASHES...............................................1004 M-12 WHEN ENGINE IS RUNNING, HYDRAULIC FILTER CLOGGING DISPLAY FLASHES..................................................1005 M-13 WHEN ENGINE IS RUNNING, RETARDER FILTER CLOGGING DISPLAY FLASHES...................................................1006 M-14 MAINTENANCE TIMER DOES NOT WORK (TIME DOES NOT ADVANCE)............................................................1007 M-15 MAINTENANCE TIMER IS NOT OH OR BELOW, BUT MAINTENANCE ITEM LIGHTS UP...............................................1007 M-16 ABNORMALITY IN SWITCH..............................................................................................1008 A) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK.............................................1008 B) REPLACEMENT SWITCH, MISOPERATION CANCEL SWITCH DO NOT WORK.......................................................1008 M-17 NIGHT LIGHTING DOES NOT LIGHT UP (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)..........................1009 30 DISASSEMBLY AND ASSEMBLY.....................................................................................................1010 STEERING VALVE (B)..........................................................................................................1012 REMOVAL (B)..............................................................................................................1012 INSTALLATION (B).........................................................................................................1012 40 MAINTENANCE STANDARD.........................................................................................................1014 TRANSMISSION.................................................................................................................1015 REAR AXLE SUPPORT............................................................................................................1020 FINAL DRIVE..................................................................................................................1021 REAR SUSPENSION CYLINDER.....................................................................................................1022
KOMATSU HD785-3 HD985-3 DUMP TRUCK SHOP MANUAL SEBM05610311 – PDF DOWNLOAD:
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