Komatsu HD785-3,HD985-3 Dump Truck Shop Manual SEBM05610311 PDF

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Komatsu HD785-3,HD985-3 Dump Truck Shop Manual SEBM05610311 –  PDF DOWNLOAD

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Komatsu HD785-3,HD985-3 Dump Truck Shop Manual SEBM05610311 –  PDF DOWNLOAD

Language : English
Pages : 1023
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD785-3,HD985-3 Dump Truck Shop Manual SEBM05610311 –  PDF DOWNLOAD

Serial Number

• HD785-3 – 2001 and up
• HD985-3  1001  and up

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

DESCRIPTION:

Komatsu HD785-3,HD985-3 Dump Truck Shop Manual SEBM05610311 –  PDF DOWNLOAD

Serial Number

• HD785-3 – 2001 and up
• HD985-3  1001  and up

G.B 27/12/24