Komatsu HD785-5LC Dump Truck (A10316 and up) Shop Manual – CEBM013800

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Komatsu HD785-5LC Dump Truck (A10316 and up) Shop Manual – CEBM013800

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This complete service repair workshop manual PDF download for the Komatsu HD785-5LC Dump Truck (SN: A10316 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model : HD785-5LC
Serial Numbers : A10316 and up

TABLE OF CONTENTS :

– GENERAL INFORMATION
– STRUCTURES
– ENGINE
– ELECTRICAL SYSTEM
– TRANSMISSION
– DRIVE AXLE, SPINDLES AND WHEELS
– SUSPENSIONS
– BRAKE CIRCUIT
– AIR SYSTEM
– HYDRAULIC SYSTEM
– OPTIONS AND SPECIAL TOOLS
– OPERATOR’S CAB
– LUBRICATION AND SERVICE
– ALPHABETICAL INDEX
– SYSTEM SCHEMATICS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM013800
Total Pages : 1152

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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GENERAL INFORMATION
MAJOR COMPONENTS AND SPECIFICATIONS
SPECIFICATIONS
GENERAL SAFETY AND OPERATING INSTRUCTIONS
GENERAL SAFETY
Safety Rules
Safety Features
Clothing And Personal Protective Items
Unauthorized Modification
Leaving The Operator’s Seat
Mounting And Dismounting
Fire Prevention For Fuel And Oil
Precautions When Handling At High Temperatures
Asbestos Dust Hazard Prevention
Prevention Of Injury By Work Equipment
Fire Extinguisher And First Aid Kit
Precautions When Using ROPS
Precautions For Attachments
PRECAUTIONS DURING OPERATION
BEFORE STARTING ENGINE
Safety At Worksite
Fire Prevention
In Operator’s Cab
Ventilation For Enclosed Areas
In Operator’s Cab – Before Starting Engine
OPERATING THE MACHINE
When Starting Engine
Truck Operation – General
Check When Traveling In Reverse
Traveling
Traveling On Slopes
Ensure Good Visibility
Operate Carefully On Snow
Avoid Damage To Dump Body
Do Not Go Close To High-voltage Cables
When Dumping
Working On Loose Ground
When Loading
Parking The Machine
TOWING
WORKING NEAR BATTERIES
Battery Hazard Prevention
Starting With Booster Cables
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
Warning Tag
Proper Tools
Stopping The Engine Before Service
Securing The Dump Body
DURING MAINTENANCE
Personnel
Attachments
Work Under The Machine
Keep The Machine Clean
Rules To Follow When Adding Fuel Or Oil
Radiator Water Level
Use Of Lighting
Precautions With The Battery
Handling High-Pressure Hoses
Precautions With High-Pressure Oil
Precautions When Carrying Out Maintenance At High Temperature Or High Pressure
Rotating Fan And Belt
Waste Materials
TIRES
Handling Tires
Storing Tires After Removal
ADDITIONAL JOB SITE RULES
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
At The Truck – Ground Level Walk Around Inspection
ENGINE START-UP SAFETY PRACTICES
Before Starting The Engine
Starting The Engine
Starting The Engine In Cold Weather
AFTER ENGINE HAS STARTED
MACHINE OPERATION SAFETY PRECAUTIONS
LOADING
HAULING
RETARDER OPERATION
Engine Overspeed
PASSING
DUMPING
To Raise dump body:
To Lower Body:
SAFE PARKING PROCEDURES
SHUTDOWN PROCEDURE
TOWING
BRAKE RELEASE
Release Of Parking Brake
Release Of Emergency Brake
WARNINGS AND CAUTIONS
STANDARD CHARTS AND TABLES
INDEX OF TABLES
Sealants and Adhesives
STANDARD VALUE TABLES

STRUCTURES
STRUCTURAL COMPONENTS INDEX
STRUCTURAL COMPONENTS
GRILLE AND HOOD
Removal
Installation
DECKS
LEFT DECK AND CAB
Removal
Installation
RIGHT DECK
Removal
Installation
CENTER DECK
Removal
Installation
DUMP BODY INDEX
DUMP BODY
Removal
Installation
BODY PAD
Removal
Installation
BODY PAD ADJUSTMENT (SIDE)
(With pads in place)
(With pads removed)
BODY PAD ADJUSTMENT (FRONT)
BODY GUIDE
BODY PIN
ROCK EJECTORS
Inspection
FUEL TANK INDEX
FUEL TANK
Removal
Installation
Cleaning
VENT
QUICK FUEL INSTALLATION (OPTION)

ENGINE
COOLING SYSTEM INDEX
COOLING SYSTEM
COOLING SYSTEM COMPONENTS
RADIATOR
Removal
Service
Installation
BRAKE OIL COOLER
Removal
Installation
FAN
Removal
Installation
FAN BELT
Fan Belt Replacement
Fan Belt Adjustment
ENGINE INDEX
ENGINE
GENERAL INSTRUCTIONS
PREPARATION FOR ENGINE REMOVAL
Removal
Installation
DRIVE LINE ADAPTER
Drive Line Adapter Removal
Drive Line Adapter Installation
Drive Line Adapter Damper Disassembly
Drive Line Adapter Damper Assembly
RECOMMENDED LUBRICANTS
AIR FILTRATION SYSTEM INDEX
AIR FILTRATION SYSTEM
AIR CLEANER
Service Checks
Filter Element Replacement
Main Filter Element Cleaning
Air Intake Troubleshooting

ELECTRICAL SYSTEM INDEX
24V ELECTRIC SUPPLY SYSTEM (WITH PRELUB STARTER) INDEX
24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
Service
Storage
Maintenance and Troubleshooting
Spillage
BATTERY DISCONNECT SWITCH (Optional)
BATTERY CHARGING CIRCUIT COMPONENTS
Battery Charging Alternator
Operation
Magnetizing The Rotor
ENGINE PRELUB SYSTEM
OPERATION
Pressure Switch
Check Valve
Timer Solenoid
MAINTENANCE
Prelub™ System Operation
Starter/Prelub Pump
Check Valve
Timer Solenoid
Troubleshooting Prelub Starter Circuit
24VDC ELECTRICAL SYSTEM COMPONENTS INDEX
24VDC ELECTRICAL SYSTEM COMPONENTS
VEHICLE MONITOR SYSTEM
General Description
Normal Mode
Service Mode
NETWORK SIGNALS
VEHICLE MONITOR PANEL
SENSORS, SWITCHES
Engine Water Temperature Sensor
Retarder Oil Temperature Sensor
Torque Converter Oil Temperature Sensor
Air Pressure Sensor
Fuel Level Sensor
Engine Speed Sensor
MONITOR PANEL DISPLAYS
INSTRUMENT PANEL INDICATORS, TEST SWITCH
ELECTRONIC ACCELERATOR PEDAL
Operation
AISS (Automatic Idling Setting System)
TRANSMISSION CONTROLLER
Outline
OPERATION:
INTRODUCTION TO ELECTRICAL TROUBLESHOOTING INDEX
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT
Handling Controller Boxes
POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPE AND LOCATION
CONNECTOR LOCATION (Chassis)
CONNECTOR LOCATION (Instrument Panel, Console)
CONNECTOR LOCATION (Transmission, Rear Cab Area)
CONNECTOR LOCATION (General Cab Area)
CONNECTOR TYPE IDENTIFICATION CHARTS
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM
SYSTEM FUNCTION
SELF-DIAGNOSTIC DISPLAY FUNCTIONS
CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)
LOCK-UP FUNCTION CHECK
OPTIONAL CONTROLLERS
MONITOR PANEL ACTION CODES AND SERVICE MODE
OUTLINE
ACTION CODE DISPLAY
Service Mode
SERVICE MODE OPERATION
Brake Air Pressure Sensor
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS
MONITOR PANEL
TRANSMISSION CONTROLLER
TABLE OF SERVICE CODES AND ACTION CODES
1. Table of service codes and action codes related to Monitor Panel
2. Table of service codes and action codes related to Transmission Controller
METHOD OF USING TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
ADJUSTING ELECTRONIC MONITOR
Adjustment procedure
SETTING ROTARY SWITCH
METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY
TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK
TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK
TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS
A-1 FAULTS IN POWER SOURCE SYSTEM
a) (OFF) Controller self-diagnostic display LED does not light up
b) Drop in voltage of controller power source is displayed
c) Drop in voltage of battery direct power source is displayed
d) Drop in voltage of main power source is displayed
e) Faults in transmission cut relay power source is displayed
A-2 FAULT IN NEUTRAL SAFETY SYSTEM DISPLAYED
A-3 DOUBLE ENGAGEMENT FOR CLUTCH DISPLAYED
A-4 FAULTS IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED
A-5 FAULTS IN REAR BRAKE SOLENOID CIRCUIT DISPLAYED
A-6 FAULTS IN EXHAUST BRAKE SOLENOID CIRCUIT IS DISPLAYED
A-7 FAULTS IN BCV VALVE SYSTEM
a) Short circuit with ground in BCV rear solenoid is displayed
b) Short circuit in BCV rear solenoid is displayed
c) Disconnection in BCV rear solenoid is displayed
A-8 FAULT IN SPEED SENSOR
a) Disconnection in engine speed sensor [B] is displayed on truck or Failure of engine speed sensor is displayed on truck
b) Disconnection in input shaft speed sensor is displayed or Failure of input shaft speed sensor is displayed
c) Disconnection in intermediate shaft speed sensor is displayed or Failure of intermediate shaft speed sensor is displayed
d) Disconnection in speed sensor (transmission output shaft speed sensor) is displayed or Failure of output shaft speed sensor is displayed
A-9 SPEED SENSOR, CLUTCH SLIPPING
a) Input shaft speed sensor or H,L clutch is displayed
b) Output shaft speed sensor or speed clutch (1,2,3,4,R) system is displayed
A-10 FAULT IN MODEL SELECTION (WIRING HARNESS) DISPLAYED
a) Fault in model selection (wiring harness) is displayed
b) Fault in model selection (rotary switch) is displayed
A-11 FAULT IN SHIFT LEVER CIRCUIT
a) Short circuit in shift lever assembly power source is displayed
b) Shift lever position signal input for 2 or more circuits is displayed
c) Shift lever position signal is not inputted
A-12 FAULT IN ACCELERATOR SIGNAL IS DISPLAYED
A-13 FAULT IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED
A-14 FAULT IN PRESSURE CONTROL VALVE
a) Fill switch (clutch ON) is displayed regardless of command
b) Fill switch signal is not input and clutch slipping is displayed
A-15 NO FILL SWITCH SIGNAL INPUT (FLOW DETECTOR VALVE)
A-16 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED or DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED
A-17 FAULT IN SENSOR CIRCUITS
a) Fault in torque converter oil temperature sensor is displayed
b) Fault in fuel level sensor is displayed
c) Fault in cooling water temperature sensor is displayed
d) Fault in air pressure sensor is displayed
e) Fault in retarder brake oil temperature sensor is displayed
A-18 WARNING DISPLAY
a) Transmission filter restricted warning displayed
b) Tilt warning is displayed
c) Drop in radiator water level warning is displayed
d) Battery charge warning is displayed
e) Steering oil temperature overheat warning is displayed
f) Drop in engine oil pressure warning is displayed
g) Rear brake oil pressure warning is displayed
A-19 FAULT IN ENGINE OIL PRESSURE SENSOR DISPLAYED
A-20 FAULT IN CONNECTOR CONNECTION DISPLAYED
A-21
a) Torque converter oil temperature overheat warning displayed
b) Engine water temperature overheat warning displayed
c) Air pressure drop warning displayed
d) Retarder brake oil temperature overheat warning displayed
e) Engine overrun actuated displayed
f) Engine overshoot actuated displayed
MONITOR PANEL TROUBLESHOOTING
MONITOR PANEL AND CONTROLLER SELF-DIAGNOSTIC DISPLAY
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON TRUCK
TROUBLESHOOTING
P-1 Check pattern for wiring harnesses between modules
P-2 Nothing on Monitor Panel Operates
P-3 LH, RH Module and fuel gauge do not operate
P-4 LH, RH Module and fuel gauge do not operate
P-5 RH Module does not operate
P-6 LH module does not operate
P-7 Odometer does not operate
P-8 Service meter does not operate correctly
P-9 Central Warning Lamp does not operate, or monitor panel detects fault code (monitor panel display) [A002]
P-10 Central warning lamp stays ON
P-11 Alarm buzzer does not operate. or Monitor Panel detects fault code A003:
P-12 Alarm buzzer continues to sound
P-13 All data from Shift Controller (speedometer, tachometer, shift indicator, etc.) is faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A013, or service code A0018:
P-14 Suspension mode, power/economy mode displays are faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A016:
P-15 Gauge displays are faulty (nothing is displayed or display does not change)
P-16 Cooling water level drop caution lamp does not operate, or Monitor Panel detects service code A001:
P-17 Cooling water level drop caution lamp stays ON
P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code A001:
P-19 Emergency steering pilot lamp stays ON
P-20 Engine oil pressure drop caution lamp does not operate, or monitor panel detects service code A001:
P-21 Engine oil pressure drop caution lamp stays ON.
P-22 Exhaust brake (Optional) pilot lamp does not operate, or monitor panel detects service code A001:
P-23 Exhaust brake pilot lamp stays ON (Optional)
P-24 Charging circuit fault caution lamp does not operate. or monitor panel detects service code A001:
P-25 Charging circuit fault caution lamp stays ON
P-26 Transmission filter clogging caution lamp does not operate, or monitor panel detects service code A001:
P-27 Transmission filter clogging caution lamp stays ON
P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code A001:
P-29 Brake stroke caution lamp stays ON
P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code A001:
P-31 Preheating switch pilot lamp stays ON.
P-32 Tilt warning lamp does not operate, or monitor panel detects service code A001:
P-33 Tilt warning lamp stays ON.
P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or monitor panel detects service code A001:
P-35 Body FLOAT (except FLOAT) pilot lamp stays ON.
P-36 Rear brake pilot lamp does not work, or monitor panel detects service code A001:
P-37 Rear brake pilot lamp stays ON
P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code A001:
P-39 Parking brake pilot lamp stays ON
P-40 Maintenance caution lamp does not operate, or monitor panel detects service code A001:
P-41 Maintenance caution lamp stays ON
P-42 Steering oil temperature caution lamp does not operate, or monitor panel detects service code A001:
P-43 Steering oil temperature caution lamp stays ON
P-46 High beam display does not light up
P-47 Turn signal lamp (right) does not light up
P-48 Turn signal lamp (left) does not light up
P-49 Lamp check switch does not operate
P-50 AISS switch does not operate
P-51 Exhaust brake switch does not operate (Optional)
P-52 Mode change switch (1) does not operate
P-53 Mode change switch (2) does not operate
P-54 KPH/MPH speedometer unit selector does not operate
P-55 Improper operation of all switch inputs
P-56 Monitor panel detects service codes A014 or A019:
P-58 Monitor panel detects service code A011:
P-59 Monitor panel detects service code A012:
P-60 Monitor panel detects service code A000:
ENGINE ELECTRONIC DIAGNOSTIC SYSTEM INDEX
ENGINE ELECTRONIC DIAGNOSTIC SYSTEM
SYSTEM DESCRIPTION
Engine Shutdown Light (Stop Engine)
Engine Maintenance Light (Check Engine)
Engine Maintenance Light (Protect Engine)
Fault Check Switch
Fault Scroll Switch
Determining Fault Codes
EXITING THE DIAGNOSTICS MODE
FAULT CODE INFORMATION (T01-001)
ELECTRICAL SPECIFICATIONS
SENSOR SPECIFICATIONS
HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING INDEX
HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING
H-1 Truck does not move
H-2 Truck does not travel smoothly (truck jerks)
H-3 Lock-up clutch cannot be disengaged (engine stalls)
H-4 Excessive shock when starting to move or shifting
H-5 Transmission does not shift up
H-6 Truck lacks power or speed when moving
H-7 Time lag is excessive when starting to move, or shifting gear
H-8 Torque converter oil temperature is high
H-9 Torque converter oil pressure is low
H-10 Front brakes are ineffective, or effective only on one side
H-11 Rear brakes are ineffective, or effective on one side only
H-12 Steering wheel is difficult to turn
H-13 Steering wheel is inoperative
H-14 Steering wheel vibrates
H-15 Hoist cylinder lacks lifting force (lifting speed)
H-16 Hoist cylinders do not operate
H-17 Excessive dump body hydraulic drift
H-18 Air pressure does not increase (low-pressure buzzer does not turn off. Air pressure does not increase to green range.)

TRANSMISSION
TRANSMISSION INDEX
TRANSMISSION
TORQUE CONVERTER
TORQUE CONVERTER VALVE
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
HYDRAULIC PUMP
MAIN RELIEF VALVE
Function
Operation
Actuating Pressure:
TORQUE CONVERTER RELIEF VALVE
Function
Operation
Actuating Pressure:
LOCKUP SOLENOID VALVE
LOCKUP VALVE
Function
Operation
TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE
Testing Main Relief Pressure
Testing Hydraulic Pressure At Torque Converter Inlet Port (Relief)
Testing Hydraulic Pressure At Torque Converter Outlet Port (Regulator)
Testing Torque Converter Lockup Pressure
TORQUE CONVERTER STALL SPEED CHECK
Preparing For Stall Speed Check
TRANSMISSION
TRANSMISSION SHIFT VALVES
ECMV (Electronic Control Modulation Valve)
Pressure Control Valve
Flow Sensor Valve
ECMV and Proportional Solenoid
ECMV and Fill Switch
ECMV REPAIR PROCEDURE
Filter Cleaning Procedure
ECMV Removal
Disassembly
Reassembly
CLUTCH PRESSURE CHECK & ADJUSTMENT
LUBRICATION RELIEF VALVE
Function
Specifications
TRANSMISSION
Transmission Removal
Transmission Installation
TRANSMISSION FILTER
Service
TRANSMISSION OIL COOLER INDEX
TRANSMISSION OIL COOLER
Removal And Installation
Repair
TRANSMISSION STRAINER
Removal
Installation
TORQUE CONVERTER CONTROL VALVE
Removal
Installation
Disassembly
Assembly
DRIVELINES INDEX
DRIVELINES
FRONT DRIVELINE
Removal
Installation
Disassembly
Assembly
REAR DRIVELINE
Removal
Installation
Disassembly
Assembly
LUBRICATION
AUTOMATIC SHIFT CONTROL SYSTEM INDEX
AUTOMATIC SHIFT CONTROL SYSTEM
GENERAL INFORMATION
TRANSMISSION SHIFT CONTROLLER
Power Mode
Braking Mode
Lock-up And Engine Overspeed
Transmission Speeds Monitoring
Self Diagnostics
RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES
TRANSMISSION OPERATION MODES
Braking Mode:
Power Mode:
Economy Mode:
AUTOMATIC GEAR SHIFTING
Automatic Shifting Sequence
Gear shifting time lag
Safety Functions
TRANSMISSION RANGE SELECTOR
SENSORS, SWITCHES
Transmission Speed Sensors
Adjustment Procedure
Transmission and Torque Converter Oil Temperature Sensors
Oil Temperature Sensor Tests
Insulation Resistance Test:
Thermistor Resistance Calibration Test:
Fill Switch
Shift Limit Switch
Power Mode Switch
TRANSMISSION TROUBLESHOOTING PROCEDURES
Clutch Combinations
Solenoid Valves
HARNESS CONNECTORS AND SIGNALS

DRIVE AXLE, SPINDLES AND WHEELS
TIRES AND RIMS INDEX
TIRES AND RIMS
GENERAL INFORMATION AND RECOMMENDATIONS
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRE AND RIM
Removal
Installation Of Rear Wheel Assembly
TIRE MATCHING
FRONT WHEEL HUB AND SPINDLE INDEX
FRONT WHEEL HUB AND SPINDLES
FRONT WHEEL HUB
Removal
DISASSEMBLY OF FRONT WHEEL HUB ASSEMBLY
Inspection
ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY
Front Wheel Hub Bearing Adjustment
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION
SUSPENSION A-FRAME
Removal
Installation
CENTER TIE ROD PIVOT
Removal
Inspection
Installation
FINAL DRIVE ATTACHMENTS INDEX
FINAL DRIVE ATTACHMENTS
FINAL DRIVE ANCHOR
Lower Link Removal
Inspection
Installation
DIAGONAL PANHARD ROD
Removal
Inspection
Installation
FINAL DRIVE CENTER CASE ASSEMBLY INDEX
FINAL DRIVE CENTER CASE ASSEMBLY
Specifications:
OPERATION
Straight-away-travel
Turning
To Check Oil Level
Specifications:
REAR AXLE
Removal
Installation
DIFFERENTIAL ASSEMBLY
Removal
Installation
DIFFERENTIAL ASSEMBLY
Disassembly
Disassembly of Pinion Carrier Assembly
Differential Gear Unit
Disassembly Of Differential Gear Unit
ASSEMBLY of DIFFERENTIAL
Differential Bearing
Assembly Of Differential Gear Assembly
Installation Of Differential Assembly
Input Pinion and Carrier Assembly
Adjusting Tooth Contact, Backlash
FINAL DRIVE PLANETARIES AND WHEEL HUBS INDEX
FINAL DRIVE PLANETARIES AND WHEEL HUBS
FINAL DRIVE
CARRIER ASSEMBLY
Removal
Installation
FINAL DRIVE CARRIER
Disassembly
Assembly
FINAL DRIVE ASSEMBLY
Disassembly
Assembly

SUSPENSIONS
FRONT SUSPENSIONS INDEX
SUSPENSION SYSTEM
SUSPENSION SYSTEM OPERATION
FRONT SUSPENSION
Removal
Installation
SUSPENSION REBUILD
Disassembly
Inspection
Assembly
ATTENUATION VALVE (FIXED RATE)
Disassembly
Assembly
REAR SUSPENSIONS INDEX
REAR SUSPENSIONS
SUSPENSION OPERATION
Removal
Installation
SUSPENSION REBUILD
Disassembly
Cleaning and Inspection
Assembly
REAR SUSPENSION SPHERICAL BEARING REPAIR
Disassembly
Inspection
Assembly
OILING AND CHARGING PROCEDURES INDEX
OILING AND CHARGING PROCEDURES
GENERAL
Equipment List
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
Rear Suspension Oiling
Rear Suspension Nitrogen Charging

BRAKE SYSTEM
BRAKE CIRCUIT OPERATION INDEX
BRAKE CIRCUIT OPERATION
COMPONENT DESCRIPTION
AIR TREADLE VALVE
EMERGENCY RELAY (RE-6) VALVE
HAND BRAKE VALVE (Retarder control valve)
Function
PARKING BRAKE PILOT VALVE
Function
Operation
PARKING BRAKE RELAY VALVE
Function
BRAKE CHAMBER
SLACK ADJUSTER
Specifications
Function
PRESSURE SWITCH
Function
STOP LIGHT SWITCH
Function
PARKING BRAKE SWITCH
Function
AUTOMATIC RETARDER VALVE
Function
FRONT BRAKE CUT-OFF VALVE
Function
BRAKE COOLING VALVE (BCV)
2-WAY AIR CONTROL VALVE
Function
EMERGENCY BRAKE CONTROL VALVE
Function
Operation
BRAKE VALVE
Function
BRAKE CIRCUIT COMPONENT SERVICE INDEX
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE TREADLE ASSEMBLY
Removal
Installation
Disassembly
Assembly
FRONT BRAKE CHAMBER ASSEMBLY
Removal
Installation
Disassembly
Assembly
REAR BRAKE CHAMBER ASSEMBLY
Removal
Installation
Disassembly
Assembly
SLACK ADJUSTER
Removal
EMERGENCY BRAKE CONTROL VALVE
Removal
Installation
Disassembly
Inspection
Assembly
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT INDEX
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT
CHECKING FRONT BRAKE PAD WEAR
TESTING BRAKE PRESSURE
CHECKING WEAR OF REAR BRAKE DISCS
BRAKE BLEEDING
Rear Brakes
Front Brakes
TROUBLESHOOTING
FRONT BRAKES INDEX
FRONT BRAKES
FRONT BRAKE CALIPER PAD
Removal
Installation
BRAKE CALIPER ASSEMBLY
Removal
Installation
Disassembly
Assembly
REAR WET DISC BRAKE ASSEMBLY INDEX
REAR WET DISC BRAKE ASSEMBLY
WET DISC BRAKE ASSEMBLY
Removal
Installation
WET DISC BRAKE
Disassembly
Inspection
Assembly
PARKING BRAKE INDEX
PARKING BRAKE
Inspection
Pad Removal
Pad Installation
PARKING BRAKE CALIPER
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
PARKING BRAKE SPRING CYLINDER
Removal
Installation
Disassembly
Assembly
PARKING BRAKE ADJUSTMENT
Testing
Adjusting
PARKING BRAKE DISC
Driveshaft Removal
Parking Brake Disc Removal
Parking Brake Disc Installation
Driveshaft Installation
BRAKE RELEASE
Release Of Parking Brake
Release Of Emergency Brake

AIR SYSTEM
AIR SYSTEM INDEX
AIR SYSTEM
GENERAL DESCRIPTION
AIR DRYER
Operation
SAFETY VALVE
AIR GOVERNORS
AUTOMATIC DRAIN VALVE (HEATED)
Function
Operation
HORN SOLENOID
Function
AIR SYSTEM COMPONENT REPAIR INDEX
AIR SYSTEM COMPONENT REPAIR
GENERAL PRECAUTIONS
AIR DRYER
Removal
Installation
Desiccant Cartridge Service
Desiccant Cartridge Replacement
Unloader Valve Service
Unloader Valve Replacement
Bleed Valve Service
Bleed Valve Replacement
Check Valve Service
Operational Check
Check Valve Replacement
Turbo Valve Service
Operational Check:
Turbo Valve Replacement
Heater Assembly Service
Operational Checks
Heater Assembly Replacement
AIR DRYER TROUBLESHOOTING
AIR COMPRESSOR
AIR GOVERNORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Adjustment
Primary Governor
Secondary Governor
RETARDER VALVE INDEX
RETARDER VALVE
RETARDER FUNCTION
Removal
Installation
Disassembly
Assembly

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
COMPONENT DESCRIPTION
Pump
Tank
HYDRAULIC SYSTEM COMPONENT REPAIR INDEX
HYDRAULIC SYSTEM COMPONENT REPAIR
HYDRAULIC PUMP
Removal
Installation
HYDRAULIC TANK
HYDRAULIC TANK FILTERS
Filter Replacement
HYDRAULIC TANK BREATHER
Cleaning
BRAKE COOLING OIL STRAINER
Cleaning
HIGH PRESSURE HYDRAULIC FILTERS
Filter Assembly Removal
Filter Assembly Installation
Filter Element Replacement
STEERING CIRCUIT INDEX
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
DEMAND VALVE
STEERING CONTROL VALVE
CROSSOVER RELIEF VALVE
OPERATION OF DEMAND AND STEERING CONTROL VALVE
EMERGENCY STEERING SYSTEM
Flow Switch
Operation
Relay Timer
STEERING VALVE ASSEMBLY INDEX
STEERING VALVE ASSEMBLY
Removal
Installation
Disassembly
Preparation
Assembly
STEERING CIRCUIT COMPONENT REPAIR INDEX
STEERING CIRCUIT COMPONENT REPAIR
EMERGENCY STEERING MOTOR PUMP ASSEMBLY
Removal
Installation
STEERING CYLINDER ASSEMBLY
Removal
Installation
Disassembly
Assembly
DEMAND VALVE ASSEMBLY
Removal
Installation
Disassembly
Assembly
RELIEF VALVE ASSEMBLY
Disassembly
Assembly
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION INDEX
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION
HOIST CIRCUIT OPERATION
HOIST CIRCUIT COMPONENT DESCRIPTION
Hoist Cylinders
Hydraulic Filter
Hoist Valve
RAISE
HOLD
POWER DOWN
FLOAT
HOIST CIRCUIT COMPONENT REPAIR INDEX
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE ASSEMBLY
Removal
Installation
Disassembly
Assembly
HOIST CYLINDER
Removal
Installation
Disassembly
Assembly
HYDRAULIC CHECKOUT INDEX
HYDRAULIC CHECKOUT
DUMP BODY CONTROL
ADJUSTING HOIST LEVER LINKAGE
ADJUSTING HOIST LIMITER
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT
Steering Circuit
Hoist Circuit

OPTIONS AND SPECIAL TOOLS
WIGGINS QUICK FILL FUEL SYSTEM INDEX
WIGGINS QUICK FILL FUEL SYSTEM
FUEL TANK BREATHER VALVE
Removal
Installation
Disassembly
Assembly
FUEL RECEIVER
FAN DRIVE CLUTCH INDEX
FAN DRIVE CLUTCH
GENERAL DESCRIPTION
MAJOR COMPONENTS
Input
Output
Stationary Components
OPERATION MODES
Fully Engaged
Modulated Variable Speed
Fully Released
Lubricating & Cooling Oil
MAINTENANCE
TROUBLESHOOTING
Basic Preliminary Checks
FIELD CHECK DIAGNOSIS
Preliminary Checks With Engine Off
Off Truck Test
TROUBLESHOOTING CHART
FAN CLUTCH REBUILD
DISASSEMBLY
Preparation
Cleaning And Inspection
ASSEMBLY INSTRUCTIONS
General Instructions
Assembly
FAN CLUTCH TEST
Operational Test
COOLANT AND OIL HEATERS INDEX
COOLANT AND OIL HEATERS
SYSTEM OPERATION
ENGINE COOLANT HEATERS
Troubleshooting
OIL HEATERS
Troubleshooting
SPECIAL TOOLS
PAYLOAD METER II
GENERAL INFORMATION
Haul Cycles
LIGHTS, SWITCHES AND COMPONENTS
TIPS FOR OPERATION
EXTERNAL DISPLAY LIGHTS
THEORY OF OPERATION
Basic Description
Inclinometer
Linkage Factor
Gain Factor
Brake Lock
Sources of Error
Typical Data From Service Check Mode
Example Calculation of Payload
Viewing Payload Calculation Inputs
Checking the Gain
Adjusting the Gain
TYPES OF DATA STORED
Cycle Data
Engine ON/OFF Data
Fault Codes and Warning Data
Engine Operation
Total Payload and Total Number of Cycles
Other Data
OPERATOR FUNCTIONS
Using the Operator Load Counter
Viewing the Operator Load Counter
Clearing the Operator Load Counter
Dimming the Lights on the Display
INITIAL SETUP OF PAYLOAD METER
Switch Settings
Checking the Operator Check Mode
Checking the Service Check Mode
Checking the Gt setting:
Checking the Inclinometer Settings
Calibrating a Truck
DISPLAYS AT START-UP
Normal Operation
SETUP AND MAINTENANCE
Setting The Speed Limit
Setting the Option Code
Setting The Machine I.D. Code
Setting The Operator I.D. Code
Setting The Time and Date
DOWNLOAD OF INFORMATION
DISPLAY OF FAULT CODES
Monitoring Input Signals
Service Check Mode
UP FACTOR – PAYLOAD CALCULATION GAIN
PL MODE -LOAD CALCULATION TIMING
FINAL GEAR RATIO SELECTION
BATTERY REPLACEMENT PROCEDURE
Replacing the Battery
After Replacing the Battery
SUSPENSION PRESSURE SENSOR
Removal
Installation
INCLINOMETER
Removal
Installation
Adjustment
PAYLOAD METER BACK PANEL
CONNECTIONS
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE
PAYLOAD CIRCUIT NUMBERS
TROUBLESHOOTING
COMMON PROBLEMS
Suspension Charging
Symptom Table
Missing Body-Up Signal
Missing Speed Signal
F-18: Alternator R-Terminal, Oil Pressure Signals
Shorted 18v Sensor Power Supply (930E)
FAULT TREE DIAGNOSIS
Payload Lights Won’t Illuminate
Red, Amber or Green Payload Light Does Not Illuminate
Cannot Download – PC Communications
PC Communications Configuration
F.CAL: Payload Meter Won’t Calibrate
F-20: Sensor Power Fault
F-21, F-25: Left Front Pressure Sensor
F-22, F-26: Right Front Pressure Sensor
F-23, F-27: Left Rear Pressure Sensor
F-24, F-28: Right Rear Pressure Sensor
F-31, F-32: Inclinometer
Body Up Input
Brake Lock Input
Speed Signal
Adjusting the Speed Sensor
CONNECTORS AND PRESSURE SENSORS
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM
Menu Functions
Using Scope
Log File Information
Connections to Payload Meter II™
USING SCOPE
Monitoring Inputs Using Scope
Monitoring Suspension Charging Using Scope
Pressure Sensor Dummy Loads
GAIN ADJUSTMENT WORKSHEET
EXHAUST BRAKE INDEX
EXHAUST BRAKE
FUNCTION
SYSTEM OPERATION
SYSTEM COMPONENTS
Exhaust Brake Pressure Switch
Exhaust Brake Solenoid Valve
Exhaust Brake Assembly
MAINTENANCE
1000 Hour Maintenance
Gate Adjustment
TROUBLESHOOTING
Operational Characteristics
System Component Checks
AUTOMATIC SPIN REGULATOR (ASR) SYSTEM INDEX
AUTOMATIC SPIN REGULATOR (ASR) SYSTEM
ASR SYSTEM
ASR SYSTEM DESCRIPTION
Torque Control
Compensation for Steering
System Diagnostics
System Components
OPERATION
ASR SYSTEM TROUBLESHOOTING
GENERAL TROUBLESHOOTING INFORMATION
Preliminary Troubleshooting Procedures
Troubleshooting Specific Problems
NORMAL SYSTEM OPERATION
Clearing Fault Codes
TROUBLESHOOTING SYSTEM COMPONENTS
AS-1: Fault Code 0.1 Abnormality in power source voltage
AS-2: Fault Code 1.0 Engine speed sensor, open circuit
AS-3: Fault Code 1.1 Right rear wheel speed sensor, open circuit
AS-4: Fault Code 1.2 Left rear wheel speed sensor, open circuit
AS-5: Fault Code 1.3 Transmission output speed sensor, open circuit
AS-6: Fault Code 1.6 Steering angle sensor failure
AS-7: Fault Code 1.7 Accelerator signal system fault
AS-8: Fault Code 4.3 ASR/ARSC caution lamp system, open circuit
AS-9: Fault Code 4.5 Central warning lamp and buzzer system, open circuit
AS-10: Fault Code 5.3 ASR/ARSC caution lamp system, short to ground
AS-11: Fault Code 5.5 Central warning lamp and buzzer system output, short to ground
AS-12: Fault Code 6.0 Engine speed system failure
AS-13: Fault Code 6.1 Right rear wheel speed sensor failure
AS-14: Fault Code 6.2 Left rear wheel speed sensor failure
AS-15: Fault Code 8.0 Left pressure control valve failure – valve does not open.
AS-16: Fault Code 8.1 Short to ground in right pressure control valve circuit
AS-17: Fault Code 8.2 Short to ground in left pressure control valve circuit
AS-18: Fault Code 8.3 Right pressure control valve system, open circuit
AS-19: Fault Code 8.4 Failure in right pressure control valve system – LH valve does not close.
AS-20: Fault Code 8.5 Right pressure control valve system failure (valve does not close)
AS-21: Fault Code 8.6 Left pressure control valve system failure (valve does not close)
AS-22: Fault Code 8.7 Right pressure control valve system failure (valve does not open)
AS-23: Fault Code 8.9 Short to ground in shut-off valve system
AS-24: Fault Code 9.0 Open circuit in shut-off valve system
AS-25: Fault Code 9.1 Failure in shut-off valve system – valve does not close
AS-26: Fault Code 9.2 Failure in shut-off valve system – valve does not open
AS-101: Nothing is displayed in the controller display window
AS-102: Fault code remains cleared (“–” is always displayed) or cannot be cleared in controller display window
AS-103 : Another controller has failed
Transmission Controller System
Payload Meter System
AS-104: Central warning lamp (buzzer) stays ON (or OFF)
AS-105: Open circuit in ASR system ON/OFF switch
AS-106: Short circuit to ground in ASR system ON/OFF switch
AS-107: ASR operation lamp does not light up
AS-108 ASR operation lamp remains On
AUTOMATIC RETARD SPEED CONTROL SYSTEM (ARSC) TROUBLESHOOTING INDEX
AUTOMATIC RETARD SPEED CONTROL SYSTEM (ARSC) TROUBLESHOOTING
PRELIMINARY TROUBLESHOOTING PROCEDURES
Troubleshooting Specific Problems
Set Travel Speed Display
NORMAL SYSTEM OPERATION
Clearing Fault Codes
TROUBLESHOOTING SYSTEM COMPONENTS
R-1: Fault Code 0.1 Power source voltage fault
R-2: Fault Code 1.0 Engine speed sensor, open circuit
R-3: Fault Code 1.3 Transmission output speed sensor, open circuit
R-4: Fault Code 1.5 Retarder oil temperature sensor system fault
R-5: Fault Code 1.7 Accelerator signal system fault
R-6: Fault Code 1.8 Left suspension pressure sensor system fault
R-7: Fault Code 1.9 Right suspension pressure sensor system fault
R-8: Fault Code 4.2 Exhaust brake selector signal, open circuit
R-9: Fault Code 4.3 ASR/ARSC caution lamp system, open circuit
R-10: Fault Code 4.4 ARSC operation (standby) lamp system, open circuit
R-11: Fault Code 4.5 Central warning lamp and buzzer system, open circuit
R-12: Fault Code 5.2 Exhaust brake selector signal output system, short to ground
R-13: Fault Code 5.3 ASR/ARSC caution lamp system, short to ground
R-14: Fault Code 5.4 Short to ground in ARSC operation (standby) lamp output circuit
R-15: Fault Code 5.5 Central warning lamp and buzzer system output, short to ground
R-16: Fault Code 6.0 Engine speed system failure
R-17: Fault Code 7.1 Travel speed display system UP output, open circuit
R-18: Fault Code 7.1 Travel speed display system DOWN output, open circuit
R-19: Fault Code 7.2 Travel speed display system CLEAR output, open circuit
R-20: Fault Code 7.3 Travel speed display system UP output, short to ground
R-21: Fault Code 7.4 Travel speed display system DOWN output, short to ground
R-22: Fault Code 7.5 Travel speed display system CLEAR output, short to ground
R-23: Fault Code 8.1 Pressure control valve system, short to ground
R-24: Fault Code 8.3 Pressure control valve system, open circuit
R-25: Fault Code 8.5 Pressure control valve failure (valve remains open)
R-26: Fault Code 8.7 Pressure control valve failure (valve fails to open)
R-27: Fault Code 8.9 Shut-off valve system, short to ground
R-28: Fault Code 9.0 Shut-off valve system, open circuit
R-29: Fault Code 9.1 Shut-off valve system failure (valve remains open)
R-30: Fault Code 9.2 Shut-off valve system failure (valve fails to open)
R-31: Fault Code 9.3 ARSC system switch, open circuit
R-32: Fault Code 9.4 ARSC system switch, short to ground
R-33: Fault Code 9.5 Travel speed setting switch, open circuit or short to ground
R-101: Set speed cannot be set
R-102: No failure code displayed on controller (display always shows “- -”) or failure cannot be cleared
R-103: Retarding effort excessive when empty or ineffective when truck is loaded
R-104: Fault appears in another controller
R-105: No retarder control when traveling downhill even when set speed is exceeded
R-106: Central warning lamp (or buzzer) stays on (or off).
R-107: STANDBY (READY) lamp does not light (or remains lit)
R-108: Exhaust brake does not work properly
R-109: Travel speed value and machine value model do not agree
R-110: Retarder lamp does not light or remains lit
R-111: Travel speed always displayed or no display at all

OPERATOR’S CAB
TRUCK CAB INDEX
TRUCK CAB
Removal
Installation
CAB COMPONENTS INDEX
CAB COMPONENTS
WINDSHIELD WIPER /WASHER
Operation
Removal
Installation
WINDSHIELD WASHER
Operation
Service
AIR CLEANER INDICATOR GAUGE
BODY DUMP CONTROL LINKAGE
STEERING COLUMN SERVICE
Removal
Installation
OPERATOR COMFORT INDEX
OPERATOR COMFORT
OPERATOR SEAT
Removal
Installation
OPERATOR SEAT ASSEMBLY REPAIR
HEATER AND AIR CONDITIONER UNIT
Removal
Installation
HEATER AND AIR CONDITIONER CORE REPLACEMENT
Disassembly
Assembly
FILTER MAINTENANCE
Cab Fresh Air Filter
Service (Cab Air Fresh Air Intake)
Heater/Air Conditioner Air Filter
Service (Inside Air Filter)
DASH LEVER CONTROLS
Removal
Installation
DASH PANEL
Removal
Installation
AIR CONDITIONING SYSTEM
Environmental Impact
OPERATOR CAB AIR CONDITIONING
PRINCIPLES OF REFRIGERATION
Air Conditioning
Refrigeration – The Act Of Cooling
The Refrigeration Cycle
AIR CONDITIONER SYSTEM COMPONENTS
Compressor (Refrigerant Pump)
Service Valves
Condenser
Expansion Block Valve
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
SYSTEM SERVICING
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Replacing Oil After Servicing the System
Setting Up a New Compressor
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Leak Detector
Service Valves
Vacuum Pump
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air From Service Hoses
Stabilizing the AC System
SYSTEM PERFORMANCE TEST
SYSTEM LEAK TESTING
Electronic leak detector
Tracer dyes
Soap and water
SYSTEM REPAIR
System Cleaning
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
RECOVERING AND RECYCLING THE REFRIGERANT
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the AC System
EVACUATING THE SYSTEM
CHARGING THE AC SYSTEM
TROUBLESHOOTING
Pre-Diagnosis Checks
Preparing For Diagnosis
Preliminary Steps
System Performance Test
Diagnosis Of Gauge Readings And System Performance
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM
OPERATOR CAB AND CONTROLS INDEX
OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
Tilt Lever
Turn Signal Lever Switch
Horn
Windshield Wiper / Washer Switch
Headlights and Dimmer Switch
Retard Control Lever
BRAKE PEDAL
THROTTLE PEDAL
CENTER CONSOLE AND CONTROLS
Transmission Range Selector
Shift Limiter Switch
Economy / Power Mode Switch
Emergency Steering Switch
Emergency Brake Lever
Parking Brake Valve Lever
ENGINE ELECTRONIC CONTROL SYSTEM
Engine Shutdown Light (Stop Engine)
Engine Maintenance Light (Check Engine)
Engine Maintenance Light
ENGINE DIAGNOSTICS
Fault Check Switch
Fault Scroll Switch
Determining Fault Codes
Exiting The Diagnostics Mode
HOIST CONTROL
Safety Lock
ASR / ARSC (OPTIONAL)
ASR SYSTEM CONTROLS
System Switch
ASR/ARSC Caution Lamp
ASR Operation Lamp
Central Warning Lamp
Retarder Control Lever
Accelerator Pedal
Brake Pedal
PRECAUTIONS WHEN USING THE ASR SYSTEM
ARSC SYSTEM CONTROLS
System Switch
ARSC Set Lever
Brake Pedal
Accelerator Pedal
ASR/ARSC Caution Lamp
ARSC Standby Lamp
Set Speed Display
Retarder Control Lever
Central Warning Lamp
ARSC SYSTEM ACTUATION
Traveling Again At Set Speed
Relationship With Exhaust Brake
Recommended Set Speed
TROUBLESHOOTING THE ASR/ARSC SYSTEMS
When a problem occurs in the system
Model Selection, Tire Selection, And Failure Code Display
Failure Codes
INSTRUMENT PANEL AND INDICATORS
WARNING & CAUTION LAMPS
GAUGE AND MONITOR PANEL
Air Pressure Monitor
Air Pressure Gauge
Coolant Temperature Monitor
Engine Cooling Water Temperature Gauge
Torque Converter Oil Temperature Monitor
Torque Converter Oil Temperature Gauge
Retarder Oil Temperature Monitor
Retarder Oil Temperature Gauge
High Beam Pilot Lamp
Left Turn Signal Pilot Lamp
Right Turn Signal Pilot Lamp
Speedometer
Tachometer
Shift Limiter Pilot Lamp
Lock-up Pilot Lamp
Transmission Shift Position Pilot Lamp
Shift Indicator
Engine Controller Monitor
Automatic Transmission Mechatronics Monitor
Other Mechatronics Monitor (OPTIONAL)
Fuel Level Monitor
Fuel Gauge
Service Meter
Service Meter Indicator
Odometer
Power Mode Indicator
INDICATORS AND CONTROLS PANEL
Optional Equipment
Coolant Level Monitor
Engine Oil Pressure Monitor
Charge Monitor
Transmission Oil Filter Monitor
Hazard Warning Lights
Front Brake On/Off Switch
Panel Dimmer Switch
AISS/Auto Switch
Manual Starting Aid Switch
Starting Switch
Pilot Lamp Bulb Check Switch
Rear Brake Pilot Lamp
Body Float Caution Monitor
Parking Brake Monitor
Emergency Steering Monitor
Exhaust Brake (Optional)
Cold Start
Steering Oil Temperature
Side Slope Warning (Optional)
Rear Brake Caution Lamp
Exhaust Brake Switch (Optional)
Fog Light Switch (Optional)
Central Warning Lamp (Red Convex Lens)
HEATER/AIR CONDITIONER CONTROLS
Temperature Adjustment Lever
Blower Switch
Air Selector Lever
Vent Selector Lever
Air Vent
Glove Box Storage Compartment
Air Conditioner Switch
Correction Code Display

LUBRICATION AND SERVICE
LUBRICATION AND SERVICE INDEX
LUBRICATION AND SERVICE
10 HOUR (DAILY) INSPECTION
FLUID LEVELS & OTHER CHECKS
ENGINE
WHEELS AND TIRES
Tires
Wheels
OPERATIONAL CHECKS
250 HOURS SERVICE
INITIAL 250 HOURS SERVICE ONLY
EVERY 250 HOURS SERVICE
500 HOUR SERVICE
1000 HOUR SERVICE
EVERY 2000 HOUR SERVICE
EVERY 5000 HOUR SERVICE
HYDRAULIC TANK SERVICE
Filling Instructions (Hoist Oil Supply)
Filling Instructions (Rear Brake Cooling Oil Supply)
HYDRAULIC FILTERS
Filter Replacement
HYDRAULIC TANK BREATHER
Cleaning
HIGH PRESSURE HYDRAULIC FILTERS
Filter Assembly Removal
Filter Assembly Installation
Filter Element Replacement
TRANSMISSION FILTER
Service
PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES
AUTOMATIC LUBRICATION SYSTEM INDEX
AUTOMATIC LUBRICATION SYSTEM
OPERATION
COMPONENTS
Component Location
GENERAL INFORMATION
Lubricant Required for System
Air Pressure Regulator
Initial Reservoir Fill
System Priming
SYSTEM CHECKOUT
Lubrication Cycle Timer Check
Timer Adjustment
INJECTORS (SL-1 Series “H”)
Injector Specifications
Injector Adjustment
Injector Operation
TROUBLESHOOTING CHART

ALPHABETICAL INDEX

SYSTEM SCHEMATICS
HA207 AIR PIPING SCHEMATIC
HA208 AIR SYSTEM SCHEMATIC
HH345 HYDRAULIC SCHEMATIC
HH346 HYDRAULIC PIPING
KT-T01 TRANSMISSION
HE482 ELECTRICAL SCHEMATIC
HE482 – PAGE 1 – CAB WIRING
HE482 – PAGE 2 – CAB WIRING
HE482 – PAGE 3 – CAB WIRING
HE483 – PAGE 4 – CAB WIRING
HE482 – PAGE 5 – CAB WIRING
HE482 – PAGE 6 – CHASSIS WIRING
HE482 – PAGE 7 – CHASSIS WIRING
HE482 – PAGE 8 – SHIFT CONTROL WIRING
HE482 – PAGE 9 – SHIFT CONTROL WIRING
HE482 – PAGE 10 – PAYLOAD METER II WIRING

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Komatsu HD785-5LC Dump Truck (A10316 and up) Shop Manual – CEBM013800.pdf

 

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