Komatsu Dump Truck HD785-8R service & repair manual

Description Komatsu Dump Truck HD785-8R service & repair manual

Komatsu Dump Truck HD785-8R pdf workshop service repair manual

Serial numbers:
58001 and up

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
Standard Tightening Torque Table
Conversion Table
Abbreviation List

Specifications
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
Pre-lubrication System
System Operating Lamp System
Battery Disconnect Switch
Starting Motor Disconnect Switch
Preheating System
Engine Shutdown Secondary Switch
Emergency Engine Stop Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Control System
Layout Drawing of Control System
Layout Drawing of Control System (Machine with Mobile Communication Terminal)
Machine Monitor System
Rearview Monitor System
KOMTRAX Plus System
Payload Meter System
Automatic Suspension System
Drowsiness Detection System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission Control System
Transmission Gear Shift Control System
Transmission Protection Function
Gear Shift Control System
Komatsu Traction Control System (KTCS)
Travel Speed Limitation System
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Hoist Control System
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Secondary Steering System
Steering Column
Steering Linkage
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Retarder Control
ARSC System
ABS
Exhaust Brake
Component Parts of Brake System
Undercarriage and Frame
Suspension
Front Suspension
Rear Suspension
Front Suspension Cylinder
Rear Suspension Cylinder
Tires
Work Equipment
Structure of Work Equipment
Function of Work Equipment
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Engine HD785-8R
Standard Value Table for Machine
Standard Value Table for Machine HD785-8R
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Low Pressure Circuit Devices
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine Muffler and Muffler Stack for Looseness and Damage
Examine Installation of Cylinder Head Cover and Manifolds
Examine Engine Piping for Damage and Looseness
Write Injector Compensation Value to Engine Controller
Examine and Adjust Alternator Belt
Examine and Adjust Air Conditioner Compressor Belt
Power Train
Examine Power Train Oil Pressure
Adjust Speed Sensor (Transmission)
Examine After You Adjust Speed Sensor (Transmission)
Flush Torque Converter and Transmission Hydraulic Circuit
Clean Magnet of Final Drive Case
Move Machine Which Has a Trouble in Electrical System
Steering System
Examine Steering Wheel
Examine and Adjust Steering Circuit Oil Pressure
Examine Outlet Pressure of Demand Valve
Examine Outlet Pressure of Steering Valve
Bleed Air from Steering Cylinder Circuit
Brake System
Release Remained Pressure in Brake Accumulator Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Brake Accumulator Charge Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
How to Release Nitrogen Gas When You Discard Accumulator
Examine Brake Performance
Bleed Air from Brake Circuit
Examine Releasing Pressure of Parking Brake
Examine Operating Pressure of Secondary Brake
Release Parking Brake Manually
Examine Wear of Wheel Brake Disc
Hydraulic System
Examine and Adjust Hoist Circuit Oil Pressure
Examine Hoist Cylinder Source Pressure
Examine Oil Pressure of Hoist EPC Valve Circuit
Examine and Adjust Front Suspension Cylinder
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification)
Examine and Adjust Rear Suspension Cylinder
Examine Oil Pressure of KTCS Circuit
Bleed Air from Hydraulic System
Work Equipment
Examine and Adjust Dump Body Positioner Sensor
Lower Dump Body Manually
Lift Dump Body Manually
CAB Related Parts
Adjust Tilt Lock Lever of Steering Wheel
Adjust Play of Operator Seat
Adjust Door Lock Link
Examine and Adjust Clearance of Escape Door
Electrical System
Set and Adjust Each Equipment
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal)
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem
Setting of Mobile Communication Terminal
Set Driver Status Monitor
Adjust Rearview Camera Angle
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Battery Disconnect Switch (Machine with Mobile Communication Terminal)
Examine Diodes
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Related Information for Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting
Connector and Wiring Harness Identification Table
Connector List (Machine with Mobile Communication Terminal)
Connector List (Machine with Drowsiness Detection System)
Connector Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Drain and Add Fuel
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install Cooler Assembly
Remove and Install Radiator Assembly
Disassemble and Assemble Radiator Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal Assembly
Remove and Install Engine Rear Oil Seal Assembly
Remove and Install Fuel Tank Assembly
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Replace and Adjust Fan Belt
Power Train
Drain and Add Transmission Oil
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install Front Drive Shaft
Remove and Install Rear Drive Shaft
Remove And Install Torque Converter and PTO Assembly, and Transmission Assembly
Disconnect And Connect Torque Converter and PTO Assembly, and Transmission Assembly
Disassemble and Assemble Torque Converter and PTO Assembly
Disassemble and Assemble Transmission Assembly
Remove and Install Differential Assembly
Disassemble and Assemble Differential Assembly
Remove and Install Final Drive and Rear Brake Assembly
Disassemble and Assemble Final Drive and Rear Brake Assembly
Remove and Install Final Drive Carrier Assembly
Disassemble and Assemble Final Drive Carrier Assembly
Brake System
Drain and Add Brake Oil
Remove and Install Slack Adjuster Assembly
Remove and Install Brake Accumulator Charge Valve Assembly
Remove and Install Front Wheel Hub and Brake Assembly
Disassemble and Assemble Front Wheel Hub and Brake Assembly
Steering System
Remove and Install Steering Valve Assembly
Remove and Install Steering Cylinder Assembly
Disassemble and Assemble Steering Cylinder Assembly
Undercarriage and Frame
Remove and Install Front Wheel Assembly
Remove and Install Rear Wheel Assembly
Remove and Install Right Front Suspension Cylinder Assembly
Remove and Install Left Front Suspension Cylinder Assembly
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)
Remove and Install Kingpin.
Remove and Install Rear Suspension Cylinder Assembly
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)
Remove and Install Slanted Ladder Assembly
Hydraulic System
Drain and Add Hydraulic Oil
Remove and Install Hydraulic Tank Assembly
Remove and Install Steering and Hoist Pump Assembly
Remove and Install Power Train Duplex Pump Assembly
Remove and Install Rear Brake Cooling and Brake Charge Triplex Pump Assembly
Remove and Install Cooling Fan and Hoist Pump Assembly
Remove and Install Demand Valve Assembly
Remove and Install Hoist Valve Assembly
Remove and Install Hoist Cylinder Assembly
Disassemble and Assemble Hoist Cylinder Assembly
Work Equipment
Fix and Release Body RAISE Position
Remove and Install Dump Body Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator CAB Glass
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly
How to Remove and Install Seat Belt
Electrical System
Remove and Install Retarder and Hoist Controller Assembly
Remove and Install ABS and Power Ladder Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Monitor Controller Assembly
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Mobile Communication Terminal
Remove and Install DC-DC Converter
Remove and Install Mobile Communication Terminal Wiring Harness
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Rearview Camera
Remove and Install KomVision Camera
Remove and Install KomVision Controller Assembly
Remove and Install Wireless LAN Unit Assembly
Remove and Install Driver Status Monitor
Remove and Install Translator Controller
Remove and Install Drowsiness Detection Camera
Remove and Install Drowsiness Alarm Buzzer
Remove and Install Drowsiness Detection Wiring Harness

Maintenance Standard
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Torque Converter and Transmission Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for H, L, R, 1st, 2nd, 3rd, 4th Clutch ECMV
Maintenance Standard for Valve Assembly (Main Pressure Variable, Torque Converter Relief, Main Flow Rate Select)
Maintenance Standard for Transmission Lubricating Oil Selector Valve
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Differential
Maintenance Standard for Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering Linkage
Maintenance Standard for Demand Valve
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Front Brake, Parking Brake
Maintenance Standard for Rear Brake, Parking Brake
Undercarriage and Frame
Maintenance Standard for Front Suspension Cylinder
Maintenance Standard for Rear Suspension Cylinder
Maintenance Standard for Rear Axle Support
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Pump Assembly (Steering, Hoist)
Maintenance Standard for Servo Valve of Pump Assembly (Steering, Hoist)
Maintenance Standard for Hoist Valve
Work Equipment
Maintenance Standard for Hoist Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Others
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Layout Drawing of Air Conditioner System
Specifications of Air Conditioner
Structure of Refrigeration Cycle
Function of Refrigeration Cycle
System Diagram of Air Conditioner
Component Parts of Air Conditioner System
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
Examine Refrigerant (Dual) Pressure Switch
Examine Relay
Simple Check of Refrigerant Level Through Sight Glass
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Air Conditioner System (A-Mode)
Troubleshooting by Gauge Pressure
Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant
KomVision System
Structure and Operation of KomVision System
Examine and Adjust KomVision System
Camera Calibration
Troubleshooting for KomVision System

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram of Steering, Hoist
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves)
Hydraulic Circuit Diagram of Brake Control
Hydraulic Circuit Diagram of Transmission, Brake Cooling System
Hydraulic Circuit Diagram of Steering, Hoist (at Reverse 1st, Right Turn, Brake Operation)
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Reverse 1st, Right Turn, Brake Operation)
Hydraulic Circuit Diagram of Brake Control (at Reverse 1st, Right Turn, Brake Operation)
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Reverse 1st, Right Turn, Brake Operation)
Hydraulic Circuit Diagram of Steering, Hoist (at Hoist Raise, Forward 2nd Operation)
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Hoist Raise, Forward 2nd Operation)
Hydraulic Circuit Diagram of Brake Control (at Retarder Brake Operation)
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Hoist Raise, Forward 2nd Operation)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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