Komatsu Dump Truck HD785-5 HD985-5 service & repair manual

Description Komatsu Dump Truck HD785-5 HD985-5 service & repair manual

Komatsu Dump Truck HD785-5, HD985-5 pdf workshop service repair manual

Serial numbers:
HD785-5 4001 and up
HD985-5 1021 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
SAFETY
SAFETY NOTICE

FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND COOLANT

STRUCTURE AND FUNCTION
RADIATOR, TORQUE CONVERTER COOLER
BRAKE OIL COOLER
POWER TRAIN SKELETON
OUTPUT SHAFT (HD785-5)
OUTPUT SHAFT (HD985-5)
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT SCHEMATICS
TORQUE CONVERTER
TORQUE CONVERTER VLAVE
LOCKUP SOLENOID VALVE
TRANSMISSION
TRANSMISSION VALVE
ECMV
LUBRICATION RELIEF VALVE
FRONT AXLE (HD785-5)
FRONT AXLE (HD985-5)
REAR AXLE (HD785-5)
REAR AXLE (HD985-5)
DIFFERENTIAL
DIFFERENTIAL LOCK CONTROL
DIFFERENTIAL LOCK SOLENOID VALVE
FINAL DRIVE (HD785-5)
FINAL DRIVE (HD985-5)
FRONT BRAKE
REAR BRAKE
PARKING BRAKE
WHEELS (HD785-5)
WHEELS (HD985-5)
AXLE SUPPORT (HD785-5)
AXLE SUPPORT (HD985-5)
STEERING SYSTEM
STEERING WHEEL (HD785-5)
STEERING WHEEL (HD985-5)
STEERING LINKAGE
SUSPENSION SYSTEM
SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
AIR PIPING
AIR CIRCUIT DIAGRAM
DESICCANT TYPE AIR DRIER (IF EQUIPPED)
AIR GOVERNOR
SAFETY VALVE
CHECK VALVE
DOUBLE CHECK VALVE
AUTO DRAIN VALVE
HAND BRAKE VALVE
BRAKE VALVE
EMERGENCY BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
PARKING BRAKE PILOT VALVE
RELAY VLAVE
PARKING BRAKE RELAY VALVE
QUICK-RELEASE VALVE
PARKING BRAKE CHAMBER
RATIO VALVE (FOR FRONT BRAKE)
FRONT BRAKE CHAMBER
REAR BRAKE CHAMBER
SLACK ADJUSTER
AIR DRIER (DESICCANT TYPE) (IF EQUIPPED)
HYDRAULIC PIPING
HYDRALUIC CIRCUIT DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD785-5)
HYDRAULIC TANK AND BRAKE COOLING OIL TANK (HD985-5)
BRAKE COOLING OIL CONTROL VALVE (BCV)
STEERING VALVE
DEMAND VALVE
HOIST VALVE
CROSSOVER RELIEF VALVE
STEERING CYLINDER
HOIST CYLINDER
ELECTRICAL CIRCUIT DIAGRAM
STOP LAMP SWITCH
EXHAUST BRAKE SWITCH
TILT SWITCH
FRONT BRAKE CUT-OFF VALVE
OVERRUN PREVENTION VALVE
EXHAUST BRAKE VALVE
HORN VALVE
PARKING BRAKE SWITCH
AIR CONDITIONER
ENGINE CONTROL SYSTEM
EXHAUST BRAKE
AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC EMERGENCY STEERING SYSTEM
AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION MODE SELECTION CONTROL
PAYLOAD METER (PRINTER TYPE) (OP)
PAYLOAD METER Ⅱ (CARD TYPE) (OP)
MACHINE MONITOR SYSTEM
PMC SYSTEM (MACHINE EQUIPPED WITH ELECTRONIC GOVERNOR) (OP)
MAINTENANCE MONITOR SYSTEM
ABS/ASR SYSTEM
ABS/ASR CONTROLLER (ECU)
ABS PRESSURE CONTROL VALVE
ASR CONTROL VALVE
WHEEL SPEED SENSOR
RELAY
ASR-II SYSTEM (IF EUQIPPED)
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)
AUTO-GREASING SYSTEM

TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE BELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOWBY PRESSURE
MEASURING BOOST PRESSURE
MEASURING EXHAUST TRMPERATURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING ALTERNATOR BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
ADJSUTING TRANSMISSION SPEED SENSOR
ADJUSTING ACCELERATOR PEDAL
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
TESTING ECMV HYDRAULIC PRESSURE
TESTING TRANSMISSION LUBRICATION PRESSURE
TESTING TORQUE CONVERTER STALL SPEED
TESTING BRAKE PRESSURE
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF REAR BRAKE DISC
ADJUSTING PARKING BRAKE
TESTING BRAKE PERFORMANCE
TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (WITH VARIABLE DAMPING FORCE SELECTOR VALVE)
TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER
TESTING AND ADJUSTING SUSPENSION AIR CYLINDER
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT
INSPECTION OF AIR DRIER (DESICCANT TYPE)
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING BODY POSITIONER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
AIR BLEEDING FROM STEERING CYLINDER
ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER,TACHOMETER MODULE)
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN REPLACING ENGINE CONTROLLER
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER
METHOD OF DELETING DATA FROM ENGINE CONTROLER,TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL)
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
PROCEDURE FOR OPERATING MODULATION CHECKER
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION)
PERFORMING PM CLINIC USING MANUAL SNAPSHOT (QUICK PM)
PM-CLINIC SERVICE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR PIN ALLOCATION CHART
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS
TABLE OF SERVICE CODES AND USER CODES
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ELECTRONIC GOVERNOR SPECIFICATION G MODE)
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)
TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM (SP MODE)
TROUBLESHOOTING OF PAYLOAD METER (PRINTER TYPE) SYSTEM (LP MODE)
TROUBLESHOOTING OF PAYLOAD METER Ⅱ (CARD TYPE) SYSTEM (LC MODE)
TROUBLESHOOTING OF ARSC [AUTOMATIC RETARDER SPEED CONTROLLER] SYSTEM (R MODE)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (P MODE)
TROUBLESHOOTING OF PMC SYSTEM (M MODE)
TROUBLESHOOTING OF ABS/ASR SYSTEM (OP)
TROUBLESHOOTING FOR MAINTENANCE MONITOR SYSTEM
TROUBLESHOOTING FOR AUTOMATIC SPIN REGULATOR (ASR-Ⅱ) SYSTEM (AS MODE)
VHMS MACHINE HEALTH DIAGNOSIS SYSTEM (OP)

DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARING MOTOR
ALTERNATOR
ENGINE OIL COOLER
LEFT BANK FUEL INJECTION PUMP
RIGHT BANK FUEL INJECTION PUMP ASSEMBKY (WITHOUT GOVERNOR)
AIR COMPRESSOR
WATER PUMP
AFTERCOOLER CORE
TURBOCHARGER
NOZZLE HOLDER
CYLINDER HEAD
EXHAUST BRAKE
ENGINE
ENGINE FRONT SEAL
ENGINE REAR SEAL
RADIATOR TORQUE CONVERTER COOLER
BRAKE COOLER
OUTPUT SHAFT
TORQUE CONVERTER, TRANSMISSION
PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TROQUE CONVERTER, TRANSMISSION ASSEMBLY
TORQUE CONVERTER, CONTROL VALVE
TORQUE CONVERTER AND TRANSMISSION
TORQUE CONVERTER, PTO
TRANSMISSION
ECMV
DIFFERENTIAL (FOR STANFARD DIFFERENTIAL)
DIFFERENTIAL (WITH DIFFERENTIAL LOCK)
FRONT WHEEL
REAR WHEEL
FRONT BRAKE CALIPER
FRONT BRAKE CALIPER PAD
FRONT WHEEL HUB
FINAL DRIVE CARRIER
FINAL DRIVE
REAR BRAKE
REAR WHEEL BRAKE
PARKING BRAKE PAD
PARKING BRAKE CALIPER
FRONT SUSPENDION CYLINDER
KING PIN
VARIBLE DAMPING SELECTIOR VALVE
REAR SUSPENSION CYLINDER
AIR GOVERNOR
BRAKE VALVE
PARKING VRAKE CHAMBER
REAR BRAKE VHAMBER
FRONT BRAKE CHAMBER
SLACK ADJUSTER
AIR DRIER (DESICCANT TYPE)
BRAKE COLLING PUMP
STEERING, HOIST PUMP
TORQUE CONVERTER, TRANSMISSION PUMP
EMERGENCY STEERING MOTOR PUMP
STEERING VALVE
BRAKE CONTROL VALVE (BCV)
DEMAND VALVE
RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER
BODY
CONTROLLER
AIR CONITIONER COMPRESSOR
RECEIVER TAKE
AIR CONDITIONER CONDENSER

MAINTENANCE STANDARD
OUTPUT SHAFT
TURQUE CONVERTER VALVE
TORQUE CONVERTER
TRANSMISSION
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
FRONT AXLE
FRONT AXLE (WITH ABS/ASR) (IF EQUIPPED)
REAR AXLE SUPPORT (HD785-5)
REAR AXLE SUPPORT (HD985-5)
DIFFERENTIAL
FINAL DRIVE (HD785-5)
FINAL DRIVE (HD985-5)
FRONT BRAKE
REAR BRAKE
REAR BRAKE (WITH ABS/ASR) (IF EQUIPPED)
PARKING BRAKE
STEERING LINKAGE
FRONT SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
PARKING BRAKE CHAMBER
SLACK ADJUSTER
HYDRAULIC PUMP (SAR-160) (FOR TORQUE CONVERTER AND TRANSMISSION)
HYDRAULIC PUMP (SAR4-180+180:FOR STEERING,WORK EQUIPMENT) (SAR4-285+285:FOR BRAKE COOLING)
DEMAND VALVE
CROSS-OVER RELIEF VALVE
HOIST VALVE
STEERING CYLINDER
HOIST CYLINDER

OTHERS
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SUSPENSION SYSTEM
PAYLOAD METER (PRINTER TYPE) (OP)
PAYLOAD METER II(CARD TYPE) (OP)
PMC SYSTEM (OP)
ASR-II SYSTEM (OP)
ELECTRICAL CIRCUIT DIAGRAM

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