Komatsu HD785-8R Dump Truck Shop Manual SEN06819-06 – PDF DOWNLOAD

Komatsu HD785-8R Dump Truck Shop Manual SEN06819-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD785-8R Dump Truck Shop Manual SEN06819-06 – PDF DOWNLOAD

Language : English
Pages : 4660
Downloadable : Yes
File Type : PDF
Size: 114 MB

TABLE OF CONTENTS:

Komatsu HD785-8R Dump Truck Shop Manual SEN06819-06 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00-1
FOREWORD, SAFETY, BASIC INFORMATION 00-21
HOW TO READ THE SHOP MANUAL 00-21
SAFETY NOTICE FOR OPERATION 00-23
PRECAUTIONS TO PREVENT FIRE 00-31
ACTIONS IF FIRE OCCURS 00-33
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 00-34
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-35
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 00-38
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 00-45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-48
PRACTICAL USE OF KOMTRAX 00-49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-64
STANDARD TIGHTENING TORQUE TABLE 00-65
CONVERSION TABLE 00-72
ABBREVIATION LIST 00-77
01 SPECIFICATION 01-1
CONTENTS 01-2
SPECIFICATIONS 01-3
SPECIFICATION DRAWING 01-3
SPECIFICATIONS 01-5
WEIGHT TABLE 01-10
FUEL, COOLANT, LUBRICANT 01-12
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
BOOT-UP SYSTEM 10-7
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-7
PRE-LUBRICATION SYSTEM 10-10
SYSTEM OPERATING LAMP SYSTEM 10-13
BATTERY DISCONNECT SWITCH 10-14
STARTING MOTOR DISCONNECT SWITCH 10-15
PREHEATING SYSTEM 10-16
ENGINE SHUTDOWN SECONDARY SWITCH 10-18
EMERGENCY ENGINE STOP SWITCH 10-19
ENGINE SYSTEM 10-20
LAYOUT DRAWING OF ENGINE SYSTEM 10-20
ENGINE CONTROL SYSTEM 10-22
ENGINE POWER MODE SELECTOR SYSTEM 10-24
AUTOMATIC IDLE STOP SYSTEM 10-25
ENGINE SYSTEM 10-27
COOLING SYSTEM 10-32
LAYOUT DRAWING OF COOLING SYSTEM 10-32
CONTROL SYSTEM 10-34
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 10-34
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
10-36
MACHINE MONITOR SYSTEM 10-38
REARVIEW MONITOR SYSTEM 10-40
INDEX 00 INDEX AND FOREWORD
00-2 HD785-8R
KOMTRAX Plus SYSTEM 10-41
PAYLOAD METER SYSTEM 10-48
AUTOMATIC SUSPENSION SYSTEM 10-56
CONTROL SYSTEM 10-59
HYDRAULIC SYSTEM 10-126
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-126
HYDRAULIC SYSTEM 10-127
POWER TRAIN SYSTEM 10-150
LAYOUT DRAWING OF POWER TRAIN SYSTEM 10-150
TRANSMISSION CONTROL SYSTEM 10-154
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 10-156
TRANSMISSION PROTECTION FUNCTION 10-158
GEAR SHIFT CONTROL SYSTEM 10-162
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10-165
TRAVEL SPEED LIMITATION SYSTEM 10-167
POWER TRAIN SYSTEM 10-171
WORK EQUIPMENT SYSTEM 10-223
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-223
HOIST CONTROL SYSTEM 10-225
WORK EQUIPMENT SYSTEM 10-228
STEERING SYSTEM 10-234
LAYOUT DRAWING OF STEERING SYSTEM 10-234
SECONDARY STEERING SYSTEM 10-235
STEERING COLUMN 10-236
STEERING LINKAGE 10-237
STEERING SYSTEM 10-238
BRAKE SYSTEM 10-253
LAYOUT DRAWING OF BRAKE SYSTEM 10-253
RETARDER CONTROL 10-256
ARSC SYSTEM 10-258
ABS 10-260
EXHAUST BRAKE 10-265
BRAKE SYSTEM 10-268
UNDERCARRIAGE AND FRAME 10-293
SUSPENSION 10-293
FRONT SUSPENSION 10-295
REAR SUSPENSION 10-296
FRONT SUSPENSION CYLINDER 10-297
REAR SUSPENSION CYLINDER 10-303
TIRE 10-305
WORK EQUIPMENT 10-306
STRUCTURE OF WORK EQUIPMENT 10-306
CAB RELATED PARTS 10-307
ROPS CAB 10-307
CAB MOUNT 10-308
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
STANDARD VALUE TABLE FOR ENGINE 20-3
STANDARD VALUE TABLE FOR ENGINE HD785-8R 20-3
STANDARD VALUE TABLE FOR MACHINE 20-8
STANDARD VALUE TABLE FOR MACHINE: HD785-8R 20-8
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 20-28
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING 30-6
TOOLS FOR TESTING AND ADJUSTING 30-6
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-17
ENGINE AND COOLING SYSTEM 30-18
00 INDEX AND FOREWORD INDEX
HD785-8R 00-3
TEST ENGINE SPEED 30-18
TEST BOOST PRESSURE 30-22
TEST EXHAUST GAS TEMPERATURE 30-26
TEST EXHAUST GAS COLOR 30-28
CHECK AND ADJUST VALVE CLEARANCE 30-32
TEST COMPRESSION PRESSURE 30-35
TEST BLOWBY PRESSURE 30-39
TEST ENGINE OIL PRESSURE 30-43
TEST FUEL PRESSURE 30-45
TEST FUEL RETURN RATE AND LEAKAGE 30-48
BLEED AIR FROM FUEL SYSTEM 30-55
TEST FUEL CIRCUIT FOR LEAKAGE 30-58
TEST LOW PRESSURE CIRCUIT DEVICES 30-59
NO-INJECTION CRANKING OPERATION 30-64
TEST MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 30-65
TEST INSTALLATION OF CYLINDER HEAD COVER AND MANIFOLDS 30-66
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 30-67
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 30-68
TEST AND ADJUST ALTERNATOR BELT TENSION 30-75
CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT 30-77
POWER TRAIN 30-79
TEST POWER TRAIN OIL PRESSURE 30-79
ADJUST SPEED SENSOR (TRANSMISSION) 30-100
CHECK AFTER ADJUSTMENT SPEED SENSOR (TRANSMISSION) 30-102
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 30-103
CLEAN MAGNET OF FINAL DRIVE CASE 30-105
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM 30-106
STEERING SYSTEM 30-113
TEST STEERING WHEEL 30-113
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 30-115
TEST OUTLET PRESSURE OF DEMAND VALVE 30-117
TEST OUTLET PRESSURE OF STEERING VALVE 30-119
BLEED AIR FROM STEERING CYLINDER CIRCUIT 30-122
BRAKE SYSTEM 30-124
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 30-124
TEST WHEEL BRAKE OIL PRESSURE 30-125
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 30-131
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 30-134
TEST BRAKE PERFORMANCE 30-144
BLEED AIR FROM BRAKE CIRCUIT 30-147
TEST RELEASING PRESSURE OF PARKING BRAKE 30-159
TEST OPERATING PRESSURE OF SECONDARY BRAKE 30-163
RELEASE PARKING BRAKE MANUALLY 30-164
TEST WEAR OF WHEEL BRAKE DISC 30-167
HYDRAULIC SYSTEM 30-169
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 30-169
TEST SOURCE PRESSURE OF HOIST CYLINDER 30-171
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 30-173
TEST AND ADJUST FRONT SUSPENSION CYLINDER 30-177
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)
30-182
TEST AND ADJUST REAR SUSPENSION CYLINDER 30-184
TEST OIL PRESSURE OF KTCS CIRCUIT 30-190
BLEED AIR FROM HYDRAULIC CIRCUIT 30-192
WORK EQUIPMENT 30-196
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 30-196
LOWER DUMP BODY MANUALLY 30-198
LIFT DUMP BODY MANUALLY 30-200
INDEX 00 INDEX AND FOREWORD
00-4 HD785-8R
CAB RELATED PARTS 30-201
ADJUST TILT LOCK LEVER OF STEERING WHEEL 30-201
ADJUST PLAY OF OPERATOR’S SEAT 30-203
ADJUST DOOR LOCK LINK 30-204
TEST AND ADJUST CLEARANCE OF ESCAPE DOOR 30-206
ELECTRICAL SYSTEM 30-207
SETTING AND ADJUSTMENT OF EACH EQUIPMENT 30-207
SET AND OPERATE MACHINE MONITOR 30-210
START UP KOMTRAX TERMINAL 30-360
STOP USE OF KOMTRAX TERMINAL 30-365
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL)
30-367
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 30-369
DEFAULT SETTING OF WIRELESS LAN MODEM 30-372
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 30-374
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 30-379
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 30-382
SETTING OF MOBILE COMMUNICATION TERMINAL 30-385
ADJUST REARVIEW CAMERA ANGLE 30-395
SET REGION OF Bluetooth® COMPATIBLE RADIO 30-396
ENGINE CONTROLLER VOLTAGE CIRCUIT 30-398
BATTERY DISCONNECT SWITCH 30-399
BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 30-401
TEST DIODES 30-403
Pm-CLINIC 30-404
PM CLINIC SERVICE 30-404
PERFORM QUICK PM 30-418
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
RELATED INFORMATION TO TROUBLESHOOT 40-15
GENERAL TROUBLESHOOTING POINTS 40-15
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-16
CHECKS BEFORE TROUBLESHOOTING 40-18
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-20
TEST IN ACCORDANCE WITH TESTING PROCEDURE 40-22
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 40-45
PROCEDURE FOR TROUBLESHOOTING 40-55
SYMPTOM AND TROUBLESHOOTING NUMBERS 40-58
INFORMATION DESCRIBED IN TROUBLESHOOTING 40-67
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE 40-70
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE (MACHINE WITH MOBILE COMMUNICATION
TERMINAL) 40-90
CONNECTOR LAYOUT 40-91
CONNECTOR CONTACT IDENTIFICATION 40-107
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-149
FUSE LOCATION TABLE 40-155
PREPARATION TO TROUBLESHOOT MACHINE MONITOR 40-160
HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 40-162
FAILURE CODE TABLE 40-167
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-191
FAILURE CODE [1500L0] 40-191
FAILURE CODE [15B0NX] 40-192
FAILURE CODE [15F0KM] 40-196
FAILURE CODE [15F0MB] 40-197
FAILURE CODE [15F7KM] 40-198
FAILURE CODE [15G0MW] 40-199
FAILURE CODE [15G7KM] 40-201
FAILURE CODE [15H0MW] 40-202
00 INDEX AND FOREWORD INDEX
HD785-8R 00-5
FAILURE CODE [15J0MW] 40-204
FAILURE CODE [15K0MW] 40-206
FAILURE CODE [15L0MW] 40-208
FAILURE CODE [15M0MW] 40-210
FAILURE CODE [15N0MW] 40-212
FAILURE CODE [15SBL1] 40-214
FAILURE CODE [15SBMA] 40-218
FAILURE CODE [15SCL1] 40-220
FAILURE CODE [15SCMA] 40-224
FAILURE CODE [15SDL1] 40-226
FAILURE CODE [15SDMA] 40-230
FAILURE CODE [15SEL1] 40-232
FAILURE CODE [15SEMA] 40-236
FAILURE CODE [15SFL1] 40-239
FAILURE CODE [15SFMA] 40-243
FAILURE CODE [15SGL1] 40-246
FAILURE CODE [15SGMA] 40-250
FAILURE CODE [15SHL1] 40-253
FAILURE CODE [15SHMA] 40-257
FAILURE CODE [15SJMA] 40-259
FAILURE CODE [2C4MNX] 40-261
FAILURE CODE [2F00KM] 40-265
FAILURE CODE [2G42ZG] 40-269
FAILURE CODE [2G43ZG] 40-271
FAILURE CODE [6014NX] 40-273
FAILURE CODE [879AKA] 40-276
FAILURE CODE [879AKB] 40-277
FAILURE CODE [879BKA] 40-278
FAILURE CODE [879BKB] 40-281
FAILURE CODE [879CKA] 40-284
FAILURE CODE [879CKB] 40-285
FAILURE CODE [879EMC] 40-286
FAILURE CODE [879FMC] 40-287
FAILURE CODE [879GKX] 40-288
FAILURE CODE [989D00] 40-291
FAILURE CODE [989L00] 40-293
FAILURE CODE [989M00] 40-294
FAILURE CODE [989N00] 40-295
FAILURE CODE [989X00] 40-296
FAILURE CODE [989Y00] 40-297
FAILURE CODE [AA10NX] 40-299
FAILURE CODE [AB00KE] 40-302
FAILURE CODE [AB00KY] 40-306
FAILURE CODE [B@BAZG] 40-308
FAILURE CODE [B@BAZK] 40-309
FAILURE CODE [B@BCNS] 40-312
FAILURE CODE [B@BCQA] 40-313
FAILURE CODE [B@BCZK] 40-316
FAILURE CODE [B@C6NS] 40-319
FAILURE CODE [B@C7NS] 40-322
FAILURE CODE [B@CENS] 40-325
FAILURE CODE [B@JANS] 40-328
FAILURE CODE [CA111] 40-331
FAILURE CODE [CA115] 40-333
FAILURE CODE [CA122] 40-334
FAILURE CODE [CA123] 40-336
FAILURE CODE [CA131] 40-337
FAILURE CODE [CA132] 40-340
INDEX 00 INDEX AND FOREWORD
00-6 HD785-8R
FAILURE CODE [CA135] 40-341
FAILURE CODE [CA141] 40-343
FAILURE CODE [CA144] 40-344
FAILURE CODE [CA145] 40-346
FAILURE CODE [CA153] 40-348
FAILURE CODE [CA154] 40-350
FAILURE CODE [CA187] 40-352
FAILURE CODE [CA212] 40-353
FAILURE CODE [CA213] 40-355
FAILURE CODE [CA221] 40-356
FAILURE CODE [CA222] 40-358
FAILURE CODE [CA227] 40-359
FAILURE CODE [CA234] 40-361
FAILURE CODE [CA238] 40-362
FAILURE CODE [CA263] 40-364
FAILURE CODE [CA265] 40-366
FAILURE CODE [CA271] 40-367
FAILURE CODE [CA272] 40-369
FAILURE CODE [CA273] 40-371
FAILURE CODE [CA274] 40-373
FAILURE CODE [CA322] 40-375
FAILURE CODE [CA323] 40-377
FAILURE CODE [CA324] 40-379
FAILURE CODE [CA325] 40-381
FAILURE CODE [CA331] 40-383
FAILURE CODE [CA332] 40-385
FAILURE CODE [CA351] 40-387
FAILURE CODE [CA352] 40-389
FAILURE CODE [CA386] 40-390
FAILURE CODE [CA431] 40-392
FAILURE CODE [CA432] 40-395
FAILURE CODE [CA441] 40-396
FAILURE CODE [CA442] 40-397
FAILURE CODE [CA449] 40-398
FAILURE CODE [CA451] 40-399
FAILURE CODE [CA452] 40-401
FAILURE CODE [CA553] 40-402
FAILURE CODE [CA554] 40-403
FAILURE CODE [CA559] 40-404
FAILURE CODE [CA689] 40-405
FAILURE CODE [CA691] 40-407
FAILURE CODE [CA692] 40-409
FAILURE CODE [CA731] 40-410
FAILURE CODE [CA757] 40-411
FAILURE CODE [CA778] 40-412
FAILURE CODE [CA781] 40-414
FAILURE CODE [CA1257] 40-416
FAILURE CODE [CA2185] 40-417
FAILURE CODE [CA2186] 40-419
FAILURE CODE [CA2249] 40-420
FAILURE CODE [CA2555] 40-421
FAILURE CODE [CA2556] 40-422
FAILURE CODE [CA9117] 40-424
FAILURE CODE [CB111] 40-425
FAILURE CODE [CB115] 40-427
FAILURE CODE [CB187] 40-428
FAILURE CODE [CB227] 40-429
FAILURE CODE [CB238] 40-431
00 INDEX AND FOREWORD INDEX
HD785-8R 00-7
FAILURE CODE [CB263] 40-433
FAILURE CODE [CB265] 40-435
FAILURE CODE [CB271] 40-436
FAILURE CODE [CB272] 40-438
FAILURE CODE [CB273] 40-440
FAILURE CODE [CB274] 40-442
FAILURE CODE [CB351] 40-444
FAILURE CODE [CB352] 40-446
FAILURE CODE [CB386] 40-447
FAILURE CODE [CB441] 40-449
FAILURE CODE [CB442] 40-450
FAILURE CODE [CB449] 40-451
FAILURE CODE [CB451] 40-452
FAILURE CODE [CB452] 40-454
FAILURE CODE [CB553] 40-455
FAILURE CODE [CB554] 40-456
FAILURE CODE [CB559] 40-457
FAILURE CODE [CB689] 40-458
FAILURE CODE [CB731] 40-460
FAILURE CODE [CB757] 40-461
FAILURE CODE [CB778] 40-462
FAILURE CODE [CB781] 40-464
FAILURE CODE [CB1257] 40-465
FAILURE CODE [CB1548] 40-466
FAILURE CODE [CB1549] 40-468
FAILURE CODE [CB1551] 40-470
FAILURE CODE [CB1552] 40-472
FAILURE CODE [CB1553] 40-474
FAILURE CODE [CB1622] 40-476
FAILURE CODE [CB2249] 40-478
FAILURE CODE [CB9117] 40-479
FAILURE CODE [D150KB] 40-480
FAILURE CODE [D150KZ] 40-483
FAILURE CODE [D164KY] 40-486
FAILURE CODE [D180KA] 40-489
FAILURE CODE [D180KB] 40-492
FAILURE CODE [D180KY] 40-495
FAILURE CODE [D19HKZ] 40-497
FAILURE CODE [D19JKZ] 40-500
FAILURE CODE [D19QKZ] 40-503
FAILURE CODE [D1EFKA] 40-506
FAILURE CODE [D1EFKB] 40-509
FAILURE CODE [D1EFKY] 40-512
FAILURE CODE [D1EHKA] 40-514
FAILURE CODE [D1EHKB] 40-517
FAILURE CODE [D1EHKY] 40-520
FAILURE CODE [D1EMKA] 40-522
FAILURE CODE [D1EMKB] 40-525
FAILURE CODE [D1EMKY] 40-528
FAILURE CODE [D1FBKB] 40-530
FAILURE CODE [D1J0KB] 40-533
FAILURE CODE [D5ZHL6] 40-536
FAILURE CODE [D862KA] 40-539
FAILURE CODE [DAF0KT] 40-542
FAILURE CODE [DAF0MB] 40-543
FAILURE CODE [DAF0MC] 40-544
FAILURE CODE [DAF3KK] 40-545
FAILURE CODE [DAF8KB] 40-550
INDEX 00 INDEX AND FOREWORD
00-8 HD785-8R
FAILURE CODE [DAFDKB] 40-553
FAILURE CODE [DAFGMC] 40-556
FAILURE CODE [DAFLKA] 40-557
FAILURE CODE [DAFLKB] 40-561
FAILURE CODE [DAFQKR] 40-564
FAILURE CODE [DAQ0KK] 40-577
FAILURE CODE [DAQ0KT] 40-581
FAILURE CODE [DAQ0MC] 40-583
FAILURE CODE [DAQ1KA] 40-584
FAILURE CODE [DAQ2KK] 40-587
FAILURE CODE [DAQ9KQ] 40-591
FAILURE CODE [DAQLKA] 40-593
FAILURE CODE [DAQLKB] 40-597
FAILURE CODE [DAQQKR] 40-600
FAILURE CODE [DAQRKR] 40-614
FAILURE CODE [DAQRMA] 40-628
FAILURE CODE [DAQV00] 40-630
FAILURE CODE [DAQW00] 40-632
FAILURE CODE [DAZ9KQ] 40-633
FAILURE CODE [DAZQKR] 40-635
FAILURE CODE [DB10KT] 40-648
FAILURE CODE [DB10MC] 40-649
FAILURE CODE [DB11KA] 40-650
FAILURE CODE [DB12KK] 40-653
FAILURE CODE [DB13KK] 40-657
FAILURE CODE [DB19KQ] 40-661
FAILURE CODE [DB1LKA] 40-663
FAILURE CODE [DB1LKB] 40-667
FAILURE CODE [DB1QKR] 40-670
FAILURE CODE [DB1QMA] 40-684
FAILURE CODE [DB1RKR] 40-686
FAILURE CODE [DB2QKR] 40-700
FAILURE CODE [DBC0KT] 40-718
FAILURE CODE [DBC0MC] 40-719
FAILURE CODE [DBC1KA] 40-720
FAILURE CODE [DBC2KK] 40-723
FAILURE CODE [DBC3KK] 40-727
FAILURE CODE [DBC9KQ] 40-731
FAILURE CODE [DBCLKA] 40-733
FAILURE CODE [DBCLKB] 40-737
FAILURE CODE [DBCQKR] 40-740
FAILURE CODE [DBCQMA] 40-754
FAILURE CODE [DBCRKR] 40-756
FAILURE CODE [DBP0KM] 40-769
FAILURE CODE [DBP0KT] 40-771
FAILURE CODE [DBP0NR] 40-774
FAILURE CODE [DBP5KP] 40-775
FAILURE CODE [DBPLKA] 40-779
FAILURE CODE [DBPLKB] 40-783
FAILURE CODE [DBPQKR] 40-786
FAILURE CODE [DBPRKR] 40-800
FAILURE CODE [DBPRMA] 40-814
FAILURE CODE [DBPUKR] 40-816
FAILURE CODE [DBPVKR] 40-826
FAILURE CODE [DBPWKR] 40-836
FAILURE CODE [DBPXKR] 40-838
FAILURE CODE [DBV0MC] 40-841
FAILURE CODE [DBV1KK] 40-842
00 INDEX AND FOREWORD INDEX
HD785-8R 00-9
FAILURE CODE [DBV6KB] 40-846
FAILURE CODE [DBV7KB] 40-851
FAILURE CODE [DBV8KB] 40-854
FAILURE CODE [DBVLKA] 40-857
FAILURE CODE [DBVLKB] 40-861
FAILURE CODE [DBVQKR] 40-864
FAILURE CODE [DBVRKR] 40-878
FAILURE CODE [DBVVKR] 40-892
FAILURE CODE [DBVWKR] 40-894
FAILURE CODE [DDAAL6] 40-896
FAILURE CODE [DDB4KX] 40-900
FAILURE CODE [DDD7KX] 40-904
FAILURE CODE [DDE2KB] 40-908
FAILURE CODE [DDE2L6] 40-911
FAILURE CODE [DDP6L4] 40-914
FAILURE CODE [DDTHKA] 40-918
FAILURE CODE [DDTJKA] 40-921
FAILURE CODE [DDTKKA] 40-924
FAILURE CODE [DDTLKA] 40-927
FAILURE CODE [DDTMKA] 40-930
FAILURE CODE [DDTNKA] 40-933
FAILURE CODE [DDTPKA] 40-936
FAILURE CODE [DF10KA] 40-939
FAILURE CODE [DF10KB] 40-945
FAILURE CODE [DGE5KX] 40-950
FAILURE CODE [DGF1KX] 40-954
FAILURE CODE [DGR2KB] 40-958
FAILURE CODE [DGR2L8] 40-961
FAILURE CODE [DGR4KB] 40-964
FAILURE CODE [DGR4L8] 40-967
FAILURE CODE [DGR6KB] 40-970
FAILURE CODE [DGR6L8] 40-973
FAILURE CODE [DGT1KX] 40-976
FAILURE CODE [DGTUKY] 40-980
FAILURE CODE [DGTUKZ] 40-984
FAILURE CODE [DGTVKY] 40-989
FAILURE CODE [DGTVKZ] 40-993
FAILURE CODE [DGTWKY] 40-998
FAILURE CODE [DGTWKZ] 40-1002
FAILURE CODE [DGTXKY] 40-1007
FAILURE CODE [DGTXKZ] 40-1011
FAILURE CODE [DHE5KY] 40-1016
FAILURE CODE [DHE5KZ] 40-1019
FAILURE CODE [DHP4KY] 40-1023
FAILURE CODE [DHP4KZ] 40-1026
FAILURE CODE [DHP5KY] 40-1030
FAILURE CODE [DHP5KZ] 40-1033
FAILURE CODE [DHP6KA] 40-1037
FAILURE CODE [DHP6KX] 40-1042
FAILURE CODE [DHP6KY] 40-1046
FAILURE CODE [DHP6KZ] 40-1049
FAILURE CODE [DHP7KA] 40-1053
FAILURE CODE [DHP7KX] 40-1058
FAILURE CODE [DHP7KY] 40-1063
FAILURE CODE [DHP7KZ] 40-1066
FAILURE CODE [DHQ2KX] 40-1070
FAILURE CODE [DHQ4KX] 40-1074
FAILURE CODE [DHQ6KX] 40-1078
INDEX 00 INDEX AND FOREWORD
00-10 HD785-8R
FAILURE CODE [DHT5KX] 40-1082
FAILURE CODE [DHT5L6] 40-1085
FAILURE CODE [DHT8KX] 40-1087
FAILURE CODE [DHT8ZG] 40-1091
FAILURE CODE [DHU2KX] 40-1094
FAILURE CODE [DHU3KX] 40-1098
FAILURE CODE [DHU6KX] 40-1102
FAILURE CODE [DHU7KX] 40-1106
FAILURE CODE [DHU8KX] 40-1110
FAILURE CODE [DHU9KX] 40-1114
FAILURE CODE [DHUBKX] 40-1118
FAILURE CODE [DHUCKX] 40-1122
FAILURE CODE [DHUDKX] 40-1126
FAILURE CODE [DHUHKX] 40-1130
FAILURE CODE [DHULKX] 40-1134
FAILURE CODE [DHUMKX] 40-1138
FAILURE CODE [DHUQKX] 40-1142
FAILURE CODE [DHUTKX] 40-1146
FAILURE CODE [DJF1KA] 40-1150
FAILURE CODE [DJG1KX] 40-1153
FAILURE CODE [DJG2KX] 40-1157
FAILURE CODE [DK30KX] 40-1161
FAILURE CODE [DK51L5] 40-1165
FAILURE CODE [DK52KX] 40-1173
FAILURE CODE [DK53L8] 40-1177
FAILURE CODE [DK54KX] 40-1180
FAILURE CODE [DK60KX] 40-1184
FAILURE CODE [DKD0L6] 40-1188
FAILURE CODE [DKH0KX] 40-1192
FAILURE CODE [DKH1KX] 40-1196
FAILURE CODE [DKR2KY] 40-1200
FAILURE CODE [DKR2KZ] 40-1203
FAILURE CODE [DLF1KA] 40-1206
FAILURE CODE [DLF1LC] 40-1209
FAILURE CODE [DLF2KA] 40-1213
FAILURE CODE [DLF2LC] 40-1216
FAILURE CODE [DLF6L3] 40-1220
FAILURE CODE [DLF7L3] 40-1224
FAILURE CODE [DLF8L3] 40-1228
FAILURE CODE [DLF8LC] 40-1233
FAILURE CODE [DLF9L3] 40-1237
FAILURE CODE [DLF9LC] 40-1242
FAILURE CODE [DLT3KA] 40-1246
FAILURE CODE [DLT3LC] 40-1248
FAILURE CODE [DPQ1KR] 40-1251
FAILURE CODE [DPQ1LD] 40-1257
FAILURE CODE [DPQ2KR] 40-1263
FAILURE CODE [DPQ3KR] 40-1269
FAILURE CODE [DPQ4KB] 40-1275
FAILURE CODE [DQ11KQ] 40-1278
FAILURE CODE [DQ11KR] 40-1283
FAILURE CODE [DQ11KT] 40-1286
FAILURE CODE [DQ11MA] 40-1289
FAILURE CODE [DQ11NR] 40-1294
FAILURE CODE [DQ12KQ] 40-1297
FAILURE CODE [DQ12KR] 40-1302
FAILURE CODE [DQ12KT] 40-1305
FAILURE CODE [DQ12MA] 40-1308
00 INDEX AND FOREWORD INDEX
HD785-8R 00-11
FAILURE CODE [DQ12NR] 40-1313
FAILURE CODE [DQ13KQ] 40-1316
FAILURE CODE [DQ13KR] 40-1321
FAILURE CODE [DQ13KT] 40-1324
FAILURE CODE [DQ13MA] 40-1327
FAILURE CODE [DQ13NR] 40-1332
FAILURE CODE [DQ14KQ] 40-1335
FAILURE CODE [DQ14KR] 40-1340
FAILURE CODE [DQ14KT] 40-1343
FAILURE CODE [DQ14MA] 40-1346
FAILURE CODE [DQ14NR] 40-1351
FAILURE CODE [DQ15KQ] 40-1354
FAILURE CODE [DQ15KR] 40-1359
FAILURE CODE [DQ15KT] 40-1362
FAILURE CODE [DQ15MA] 40-1365
FAILURE CODE [DQ15NR] 40-1370
FAILURE CODE [DQ16KQ] 40-1373
FAILURE CODE [DQ16KR] 40-1378
FAILURE CODE [DQ16KT] 40-1381
FAILURE CODE [DQ16MA] 40-1384
FAILURE CODE [DQ16NR] 40-1389
FAILURE CODE [DQ17KQ] 40-1392
FAILURE CODE [DQ17KR] 40-1397
FAILURE CODE [DQ17KT] 40-1400
FAILURE CODE [DQ17MA] 40-1403
FAILURE CODE [DQ17NR] 40-1408
FAILURE CODE [DQ18KQ] 40-1411
FAILURE CODE [DQ18KR] 40-1416
FAILURE CODE [DQ18KT] 40-1419
FAILURE CODE [DQ18MA] 40-1422
FAILURE CODE [DQ18NR] 40-1427
FAILURE CODE [DR10KA] 40-1430
FAILURE CODE [DR20KA] 40-1434
FAILURE CODE [DR30KA] 40-1438
FAILURE CODE [DR40KA] 40-1442
FAILURE CODE [DR50KA] 40-1446
FAILURE CODE [DR60KA] 40-1450
FAILURE CODE [DSJ0KR] 40-1454
FAILURE CODE [DUMBKB] 40-1466
FAILURE CODE [DV00KB] 40-1469
FAILURE CODE [DV01KB] 40-1472
FAILURE CODE [DW2AKA] 40-1475
FAILURE CODE [DW2AKB] 40-1478
FAILURE CODE [DW2AKY] 40-1481
FAILURE CODE [DW2AL1] 40-1483
FAILURE CODE [DW2ALH] 40-1486
FAILURE CODE [DW2BKA] 40-1489
FAILURE CODE [DW2BKB] 40-1492
FAILURE CODE [DW2BKY] 40-1495
FAILURE CODE [DW2BL1] 40-1497
FAILURE CODE [DW2BLH] 40-1500
FAILURE CODE [DW2CKA] 40-1503
FAILURE CODE [DW2CKB] 40-1505
FAILURE CODE [DW2CKY] 40-1508
FAILURE CODE [DW2CL1] 40-1510
FAILURE CODE [DW2CLH] 40-1513
FAILURE CODE [DW35KZ] 40-1516
FAILURE CODE [DW36KZ] 40-1519
INDEX 00 INDEX AND FOREWORD
00-12 HD785-8R
FAILURE CODE [DW4BK4] 40-1522
FAILURE CODE [DW4BMA] 40-1526
FAILURE CODE [DW71KB] 40-1530
FAILURE CODE [DW71KY] 40-1533
FAILURE CODE [DW71KZ] 40-1535
FAILURE CODE [DW72KZ] 40-1537
FAILURE CODE [DW73KA] 40-1540
FAILURE CODE [DW73KB] 40-1542
FAILURE CODE [DW73KY] 40-1545
FAILURE CODE [DW78KZ] 40-1547
FAILURE CODE [DW7NKZ] 40-1551
FAILURE CODE [DWNJKZ] 40-1554
FAILURE CODE [DWNMKZ] 40-1557
FAILURE CODE [DWPQKZ] 40-1560
FAILURE CODE [DWPQMA] 40-1563
FAILURE CODE [DWPRKZ] 40-1568
FAILURE CODE [DWPRMA] 40-1571
FAILURE CODE [DWPSKZ] 40-1576
FAILURE CODE [DWPSMA] 40-1579
FAILURE CODE [DWPTKZ] 40-1584
FAILURE CODE [DWPTMA] 40-1587
FAILURE CODE [DX13KA] 40-1592
FAILURE CODE [DX13KB] 40-1594
FAILURE CODE [DX13KY] 40-1597
FAILURE CODE [DX21KA] 40-1599
FAILURE CODE [DX21KB] 40-1601
FAILURE CODE [DX21KY] 40-1604
FAILURE CODE [DX21MA] 40-1606
FAILURE CODE [DX22KA] 40-1610
FAILURE CODE [DX22KB] 40-1612
FAILURE CODE [DX22KY] 40-1615
FAILURE CODE [DX22MA] 40-1617
FAILURE CODE [DX23KA] 40-1621
FAILURE CODE [DX23KB] 40-1623
FAILURE CODE [DX23KY] 40-1626
FAILURE CODE [DX23MA] 40-1628
FAILURE CODE [DX24KA] 40-1632
FAILURE CODE [DX24KB] 40-1634
FAILURE CODE [DX24KY] 40-1637
FAILURE CODE [DX24MA] 40-1639
FAILURE CODE [DX25MA] 40-1643
FAILURE CODE [DX26MA] 40-1645
FAILURE CODE [DX30K4] 40-1647
FAILURE CODE [DX30KA] 40-1650
FAILURE CODE [DX30KB] 40-1652
FAILURE CODE [DX30KY] 40-1655
FAILURE CODE [DX30MA] 40-1657
FAILURE CODE [DX33K4] 40-1660
FAILURE CODE [DX33KA] 40-1663
FAILURE CODE [DX33KB] 40-1665
FAILURE CODE [DX33KY] 40-1668
FAILURE CODE [DX33MA] 40-1670
FAILURE CODE [DX37K4] 40-1673
FAILURE CODE [DX37KA] 40-1676
FAILURE CODE [DX37KB] 40-1678
FAILURE CODE [DX37KY] 40-1681
FAILURE CODE [DX37MA] 40-1683
FAILURE CODE [DX38K4] 40-1686
00 INDEX AND FOREWORD INDEX
HD785-8R 00-13
FAILURE CODE [DX38KA] 40-1689
FAILURE CODE [DX38KB] 40-1691
FAILURE CODE [DX38KY] 40-1694
FAILURE CODE [DX38MA] 40-1696
FAILURE CODE [DX46KA] 40-1699
FAILURE CODE [DX46KB] 40-1702
FAILURE CODE [DX46KY] 40-1705
FAILURE CODE [DXH1KA] 40-1707
FAILURE CODE [DXH1KB] 40-1710
FAILURE CODE [DXH1KY] 40-1713
FAILURE CODE [DXH2KA] 40-1715
FAILURE CODE [DXH2KB] 40-1719
FAILURE CODE [DXH2KY] 40-1723
FAILURE CODE [DXH3KA] 40-1727
FAILURE CODE [DXH3KB] 40-1731
FAILURE CODE [DXH3KY] 40-1735
FAILURE CODE [DXH4KA] 40-1739
FAILURE CODE [DXH4KB] 40-1743
FAILURE CODE [DXH4KY] 40-1747
FAILURE CODE [DXH5KA] 40-1751
FAILURE CODE [DXH5KB] 40-1755
FAILURE CODE [DXH5KY] 40-1759
FAILURE CODE [DXH6KA] 40-1763
FAILURE CODE [DXH6KB] 40-1767
FAILURE CODE [DXH6KY] 40-1771
FAILURE CODE [DXH7KA] 40-1775
FAILURE CODE [DXH7KB] 40-1778
FAILURE CODE [DXH7KY] 40-1781
FAILURE CODE [DXHHKA] 40-1783
FAILURE CODE [DXHHKB] 40-1786
FAILURE CODE [DXHHKY] 40-1789
FAILURE CODE [DY30MA] 40-1793
FAILURE CODE [DY30MC] 40-1797
FAILURE CODE [DY30ME] 40-1804
FAILURE CODE [F@B3NR] 40-1807
FAILURE CODE [F@B3NS] 40-1809
FAILURE CODE [F@B4NR] 40-1811
FAILURE CODE [F@B4NS] 40-1813
FAILURE CODE [F@B5NR] 40-1815
FAILURE CODE [F@B5NS] 40-1817
FAILURE CODE [F@B6NR] 40-1819
FAILURE CODE [F@B6NS] 40-1821
FAILURE CODE [F@BBZL] 40-1823
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-1825
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-1825
E-2 MANUAL PREHEATING SYSTEM DOES NOT OPERATE 40-1837
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT OPERATE 40-1843
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING PILOT LAMP DOES NOT LIGHT UP
40-1847
E-5 NONE OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY ANYTHING
40-1850
E-6 LCD UNIT ON MACHINE MONITOR SHOWS NOTHING 40-1859
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OFF
OR FLICKERS) 40-1862
E-8 LCD SCREEN ON MACHINE MONITOR DOES NOT SHOW CORRECTLY 40-1865
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 40-1868
E-10 NIGHT MODE LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 40-1873
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 40-1877
INDEX 00 INDEX AND FOREWORD
00-14 HD785-8R
E-12 NIGHT MODE LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR
SWITCHES DOES NOT OPERATE CORRECTLY 40-1882
E-13 TWO SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT OPERATE
40-1887
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 40-1892
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT
SHOWN CORRECTLY 40-1897
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40-1898
E-17 REARVIEW MONITOR IMAGES ARE NOT SHOWN CLEARLY 40-1903
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40-1909
E-19 NIGHT MODE LAMP OF REARVIEW MONITOR IS ABNORMAL 40-1915
E-20 AIR CLEANER CLOGGING CAUTION LAMP DOES NOT LIGHT UP 40-1919
E-21 TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP DOES NOT LIGHT UP 40-1922
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 40-1926
E-23 REAR VIEW MONITOR IS NOT SHOWN IN CONJUNCTION WITH REVERS WHEN THE CONSTANT
DISPLAY SETTING IS DISABLE 40-1929
E-24 REAR VIEW MONITOR REFERENCE LINE IS NOT SHOWN WHEN THE REFERENCE LINE
DISPLAY SETTING IS TURNED ON 40-1932
E-25 FUEL GAUGE DOES NOT SHOW NORMALLY 40-1934
E-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT RISE OR TORQUE CONVERTER
OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 40-1937
E-27 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE OR HYDRAULIC OIL TEMPERATURE
CAUTION LAMP DOES NOT LIGHT UP 40-1940
E-28 SEATBELT CAUTION LAMP DOES NOT SHOW NORMALLY 40-1944
E-29 MACHINE MONITOR IS NOT ENABLED WHEN STARTING SWITCH IS NOT TURNED ON
40-1948
E-30 ALARM BUZZER DOES NOT MAKE SOUND 40-1952
E-31 ALARM BUZZER DOES NOT STOP 40-1954
E-32 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE CORRECTLY WHEN ENGINE
POWER MODE SELECTOR SWITCH IS OPERATED 40-1959
E-33 AISS FUNCTION DOES NOT OPERATE CORRECTLY 40-1963
E-34 DUMP (HOIST) CONTROL LEVER DOES NOT OPERATE CORRECTLY 40-1967
E-35 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 40-1970
E-36 TURN SIGNAL LAMP AND HAZARD LAMP DO NOT OPERATE CORRECTLY 40-1978
E-37 HORN DOES NOT MAKE SOUND 40-1986
E-38 HORN DOES NOT STOP 40-1990
E-39 NONE OF HEADLAMP, CLEARANCE LAMP, OR TAIL LAMP LIGHTS UP 40-1993
E-40 CLEARANCE LAMP DOES NOT LIGHT UP 40-1998
E-41 TAIL LAMP DOES NOT LIGHT UP 40-2001
E-42 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP 40-2004
E-43 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP 40-2008
E-44 HEADLAMP (LOW BEAM) AND (HIGH BEAM) DO NOT LIGHT UP 40-2012
E-45 PASSING LAMP DOES NOT LIGHT UP 40-2015
E-46 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-2018
E-47 DATA DOWNLOAD WITH WIRELESS LAN DOES NOT OPERATE 40-2020
E-48 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40-2021
E-49 KomVision MONITOR IMAGES ARE NOT SHOWN CLEARLY 40-2026
E-50 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40-2035
E-51 NIGHT MODE LAMP OF KomVision MONITOR IS ABNORMAL 40-2041
E-52 A PART OF CAMERA IMAGE OF KomVision MONITOR DOES NOT DISPLAY 40-2045
E-53 KomVision MONITOR DOES NOT DISPLAY NORMALLY AFTER CALIBRATION 40-2048
E-54 CANNOT ACCESS TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL
40-2050
E-55 CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL
BECAUSE THE LOG IN PASSWORD IS UNKNOWN 40-2057
E-56 KOMTRAX Plus CONTROLLER IS NOT DETECTED 40-2059
E-57 KOMTRAX Plus CONTROLLER DOES NOT BECOME ACTIVE 40-2061
00 INDEX AND FOREWORD INDEX
HD785-8R 00-15
E-58 COMMUNICATION BETWEEN MOBILE COMMUNICATION TERMINAL AND KOMTRAX Plus
SERVER FAILS 40-2062
E-59 DATA IS NOT SENT TO KOMTRAX Plus SERVER 40-2065
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-2067
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE) 40-2067
FAILURE MODE AND CAUSE TABLE 40-2068
H-1 MACHINE DOES NOT MOVE 40-2072
H-2 IT IS NOT SMOOTH DURING TRAVEL (HUNTING) 40-2079
H-3 LOCKUP IS NOT RELEASED 40-2084
H-4 STRONG SHOCK IS MADE WHEN YOU START MACHINE OR SHIFT GEARS 40-2085
H-5 SHIFTUP DOES NOT OPERATE 40-2088
H-6 TRAVEL SPEED IN ALL GEAR SPEED IS LOW OR POWER IS LOW DURING TRAVEL WITH
LOCKUP FUNCTION 40-2093
H-7 TRAVEL SPEED IS LOW OR POWER IS LOW DURING TRAVEL WITH TORQUE CONVERTER
40-2097
H-8 TRAVEL SPEED IS LOW OR POWER IS LOW IN SPECIFIED GEAR SPEED 40-2101
H-9 TIME LAG IS LARGE WHEN YOU START MACHINE OR SHIFT GEARS 40-2105
H-10 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 40-2110
H-11 TORQUE CONVERTER OIL PRESSURE IS LOW 40-2114
H-12 STEERING WHEEL IS HEAVY TO OPERATE 40-2118
H-13 STEERING WHEEL IS DISABLED 40-2122
H-14 STEERING WHEEL IS SHAKEN 40-2125
H-15 PARKING BRAKE DOES NOT OPERATE OR IS WEAK 40-2127
H-16 PARKING BRAKE IS NOT RELEASED OR DRAGS 40-2128
H-17 BRAKING OF FRONT BRAKE IS NOT SUFFICIENT 40-2130
H-18 BRAKING OF REAR BRAKE IS NOT SUFFICIENT 40-2133
H-19 SPEED IS LOW WHEN DUMP BODY IS RAISED 40-2136
H-20 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 40-2140
H-21 DUMP BODY IS DISABLED 40-2141
TROUBLESHOOTING OF ENGINE (S-MODE) 40-2145
METHOD OF USING TROUBLESHOOTING CHARTS 40-2145
S-1 STARTING PERFORMANCE IS POOR 40-2148
S-2 ENGINE DOES NOT START 40-2150
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 40-2156
S-4 ENGINE STOPS DURING OPERATIONS 40-2158
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 40-2160
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 40-2162
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 40-2164
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 40-2166
S-9 OIL BECOMES CONTAMINATED QUICKLY 40-2168
S-10 FUEL CONSUMPTION IS EXCESSIVE 40-2169
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-2171
S-12 OIL PRESSURE DROPS 40-2173
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL) 40-2175
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 40-2177
S-15 ABNORMAL NOISE IS MADE 40-2179
S-16 VIBRATION IS EXCESSIVE 40-2181
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-7
HOW TO READ THIS MANUAL 50-7
COATING MATERIALS LIST 50-9
SPECIAL TOOLS LIST 50-13
SKETCHES OF SPECIAL TOOLS 50-29
ENGINE AND COOLING SYSTEM 50-35
DRAIN AND ADD FUEL 50-35
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-38
INDEX 00 INDEX AND FOREWORD
00-16 HD785-8R
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-44
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-45
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ASSEMBLY 50-71
REMOVE AND INSTALL ENGINE REAR OIL SEAL ASSEMBLY 50-77
REMOVE AND INSTALL COOLING ASSEMBLY 50-82
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-126
DISASSEMBLE AND ASSEMBLE RADIATOR ASSEMBLY 50-144
REMOVE AND INSTALL ENGINE ASSEMBLY 50-163
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-192
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-201
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-206
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-213
REPLACE AND ADJUST FAN BELT 50-217
POWER TRAIN 50-221
DRAIN AND ADD TRANSMISSION OIL 50-221
REMOVE AND INSTALL DAMPER ASSEMBLY 50-223
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 50-231
REMOVE AND INSTALL FRONT DRIVE SHAFT 50-234
REMOVE AND INSTALL REAR DRIVE SHAFT 50-241
REMOVE AND INSTALL TORQUE CONVERTER AND PTO ASSEMBLY, AND TRANSMISSION ASSEMBLY
50-245
DISCONNECT AND CONNECT TORQUE CONVERTER AND PTO ASSEMBLY, AND TRANSMISSION
ASSEMBLY 50-279
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER AND PTO ASSEMBLY 50-300
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 50-325
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 50-374
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 50-384
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 50-423
DISASSEMBLE AND ASSEMBLE FINAL DRIVE AND REAR BRAKE ASSEMBLY 50-430
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 50-469
DISASSEMBLE AND ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 50-475
BRAKE SYSTEM 50-478
DRAIN AND ADD BRAKE OIL 50-478
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY 50-480
REMOVE AND INSTALL BRAKE ACCUMULATOR CHARGE VALVE ASSEMBLY 50-485
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY 50-490
DISASSEMBLE AND ASSEMBLE FRONT WHEEL HUB AND BRAKE ASSEMBLY 50-506
STEERING SYSTEM 50-525
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 50-525
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 50-536
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY 50-561
UNDERCARRIAGE AND FRAME 50-566
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 50-566
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 50-569
REMOVE AND INSTALL RIGHT FRONT SUSPENSION CYLINDER ASSEMBLY 50-576
REMOVE AND INSTALL LEFT FRONT SUSPENSION CYLINDER ASSEMBLY 50-609
DISASSEMBLE AND ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH
BUFFER RING) 50-650
REMOVE AND INSTALL KINGPIN 50-656
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 50-678
DISASSEMBLE AND ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH
BUFFER RING) 50-688
REMOVE AND INSTALL SLANTED LADDER ASSEMBLY 50-694
HYDRAULIC SYSTEM 50-698
DRAIN AND ADD HYDRAULIC OIL 50-698
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-700
REMOVE AND INSTALL STEERING AND HOIST PUMP ASSEMBLY 50-713
REMOVE AND INSTALL POWER TRAIN DUPLEX PUMP ASSEMBLY 50-729
00 INDEX AND FOREWORD INDEX
HD785-8R 00-17
REMOVE AND INSTALL REAR BRAKE COOLING AND BRAKE CHARGE TRIPLEX PUMP ASSEMBLY
50-746
REMOVE AND INSTALL COOLING FAN AND HOIST PUMP ASSEMBLY 50-761
REMOVE AND INSTALL DEMAND VALVE ASSEMBLY 50-769
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 50-779
REMOVE AND INSTALL HOIST CYLINDER ASSEMBLY 50-786
DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY 50-792
WORK EQUIPMENT 50-801
FIX AND RELEASE BODY RAISE POSITION 50-801
REMOVE AND INSTALL BODY ASSEMBLY 50-805
CAB RELATED PARTS 50-814
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 50-814
REMOVE AND INSTALL OPERATOR CAB GLASS 50-869
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-880
REMOVE AND INSTALL OPERATOR SEAT ASSEMBLY 50-897
REMOVE AND INSTALL SEATBELT 50-903
ELECTRICAL SYSTEM 50-906
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 50-906
REMOVE AND INSTALL ABS AND POWER LADDER CONTROLLER ASSEMBLY 50-909
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 50-913
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-916
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 50-922
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY 50-925
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL 50-929
REMOVE AND INSTALL DC-DC CONVERTER 50-932
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 50-934
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-945
REMOVE AND INSTALL REARVIEW CAMERA 50-948
REMOVE AND INSTALL KomVision CAMERA 50-950
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 50-963
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 50-967
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 60-3
ENGINE AND COOLING SYSTEM 60-5
MAINTENANCE STANDARD OF ENGINE MOUNT 60-5
MAINTENANCE STANDARD OF DAMPER 60-6
POWER TRAIN 60-8
MAINTENANCE STANDARD OF DRIVE SHAFT 60-8
MAINTENANCE STANDARD OF TORQUE CONVERTER, TRANSMISSION MOUNT 60-9
MAINTENANCE STANDARD OF TORQUE CONVERTER, PTO 60-10
MAINTENANCE STANDARD OF TRANSMISSION 60-14
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 60-22
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 60-23
MAINTENANCE STANDARD OF H, L, R, 1ST, 2ND, 3RD, 4TH CLUTCH ECMV 60-24
MAINTENANCE STANDARD OF VALVE ASSEMBLY (MAIN PRESSURE VARIABLE, TORQUE CONVERTER
RELIEF, MAIN FLOW RATE SELECT) 60-25
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATING OIL SELECTOR VALVE 60-27
MAINTENANCE STANDARD OF FRONT AXLE 60-29
MAINTENANCE STANDARD OF REAR AXLE 60-30
MAINTENANCE STANDARD OF DIFFERENTIAL 60-31
MAINTENANCE STANDARD OF FINAL DRIVE 60-33
STEERING SYSTEM 60-35
MAINTENANCE STANDARD OF STEERING COLUMN 60-35
MAINTENANCE STANDARD OF STEERING LINKAGE 60-36
MAINTENANCE STANDARD OF DEMAND VALVE 60-39
MAINTENANCE STANDARD OF STEERING CYLINDER 60-42
BRAKE SYSTEM 60-43
INDEX 00 INDEX AND FOREWORD
00-18 HD785-8R
MAINTENANCE STANDARD OF FRONT BRAKE, PARKING BRAKE 60-43
MAINTENANCE STANDARD OF REAR BRAKE, PARKING BRAKE 60-45
UNDERCARRIAGE AND FRAME 60-47
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 60-47
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 60-51
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 60-53
HYDRAULIC SYSTEM 60-55
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-55
MAINTENANCE STANDARD OF PUMP ASSEMBLY (STEERING, HOIST) 60-56
MAINTENANCE STANDARD OF SERVO VALVE OF PUMP ASSEMBLY (STEERING, HOIST) 60-58
MAINTENANCE STANDARD OF HOIST VALVE 60-59
WORK EQUIPMENT 60-61
MAINTENANCE STANDARD OF HOIST CYLINDER 60-61
CAB RELATED PARTS 60-62
MAINTENANCE STANDARD OF CAB MOUNT 60-62
80 OTHERS 80-1
CONTENTS 80-2
AIR CONDITIONER SYSTEM 80-4
PRECAUTIONS FOR REFRIGERANT 80-4
LAYOUT DRAWING OF AIR CONDITIONER SYSTEM 80-5
SPECIFICATIONS OF AIR CONDITIONER 80-7
STRUCTURE OF REFRIGERATION CYCLE 80-8
FUNCTION OF REFRIGERATION CYCLE 80-9
AIR CONDITIONER SYSTEM DIAGRAM 80-10
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-11
AIR CONDITIONER UNIT 80-14
AIR CONDITIONER CONTROLLER 80-17
COMPRESSOR 80-19
CONDENSER 80-21
AIR CONDITIONER RELATED SENSORS 80-23
PROCEDURE FOR TESTING AND TROUBLESHOOTING AIR CONDITIONER 80-24
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-26
LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 80-28
TEST AIR LEAKAGE (DUCT) 80-32
TEST AIR CONDITIONER WITH SELF-DIAGNOSIS FUNCTION 80-35
TEST VENT (MODE) CHANGEOVER 80-36
TEST FRESH/RECIRC AIR CHANGEOVER 80-38
TEST REFRIGERANT (DUAL) PRESSURE SWITCH 80-39
TEST RELAYS 80-40
SIMPLE CHECK OF REFRIGERANT LEVEL THROUGH SIGHT GLASS 80-41
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-43
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-45
INFORMATION DESCRIBED IN TROUBLESHOOTING 80-48
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 80-51
TROUBLESHOOTING OF AIR CONDITIONER SYSTEM (A-MODE) 80-66
TROUBLESHOOTING BY GAUGE PRESSURE 80-83
CONNECT SERVICE TOOL 80-86
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPINGS
80-88
COMPRESSOR OIL 80-90
REPLACE DESICCANT 80-92
KomVision SYSTEM 80-94
STRUCTURE AND OPERATION OF KomVision SYSTEM 80-94
TEST AND ADJUST KomVision SYSTEM 80-115
CAMERA CALIBRATION 80-136
TROUBLESHOOTING FOR KomVision SYSTEM 80-169
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
00 INDEX AND FOREWORD INDEX
HD785-8R 00-19
HOW TO READ THE CODES FOR ELECTRIC CABLE 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-7
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-7
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST 90-11
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (MACHINE WITH 2 PIECES OF FORCED
LOWER VALVES) 90-13
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE CONTROL 90-15
HYDRAULIC CIRCUIT DIAGRAM OF TRANSMISSION, BRAKE COOLING 90-17
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (AT REVERSE 1ST, RIGHT TURN, BRAKE
OPERATION) 90-19
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (MACHINE WITH 2 PIECES OF FORCED
LOWER VALVES) (AT REVERSE 1ST, RIGHT TURN, BRAKE OPERATION) 90-21
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE CONTROL (AT REVERSE 1ST, RIGHT TURN, BRAKE
OPERATION) 90-23
HYDRAULIC CIRCUIT DIAGRAM OF TRANSMISSION, BRAKE COOLING (REVERSE 1ST + RIGHT
TURN + BRAKE OPERATION) 90-25
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (AT HOIST RAISE, FORWARD 2ND OPERATION)
90-27
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (MACHINE WITH 2 PIECES OF FORCED
LOWER VALVES) (AT HOIST RAISE, FORWARD 2ND OPERATION) 90-29
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE CONTROL (AT RETARDER BRAKE OPERATION)
90-31
HYDRAULIC CIRCUIT DIAGRAM OF TRANSMISSION, BRAKE COOLING SYSTEM (AT HOIST
RAISE, FORWARD 2ND OPERATION) 90-33
ELECTRICAL CIRCUIT DIAGRAM 90-35
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 90-35
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (1/12) 90-39
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (2/12) 90-41
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (3/12) 90-43
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (4/12) 90-45
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (5/12) 90-47
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (6/12) 90-49
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (7/12) 90-51
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (8/12) 90-53
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (9/12) 90-55
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (10/12) 90-57
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (11/12) 90-59
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (12/12) 90-61
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/11) 90-63
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/11) 90-65
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/11) 90-67
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/11) 90-69
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/11) 90-71
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/11) 90-73
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/11) 90-75
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/11) 90-77
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/11) 90-79
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/11) 90-81
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/11) 90-83
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2) 90-85
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2) 90-87
INDEX 1

DESCRIPTION:

Komatsu HD785-8R Dump Truck Shop Manual SEN06819-06 – PDF DOWNLOAD

SERIAL NUMBERS 58001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

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