Dump Truck

SEBM013916
MACHINE MODEL SERIAL NUMBER

HD785-5 4001 and up
HD985-5 1021 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.
• HD785-5 and HD985-5 mount the SA12V140-1 engine.

For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2005 1
All Rights Reserved 00-1
Printed in Japan 07-05(02) (16)
CONTENTS
No. of page
01 GENERAL ............................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ........................................................... 10-1
20 TESTING AND ADJUSTING ................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ............................................................................................................... 90-1
00-2 HD785-5
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tions be taken to these pages according to the table c Page to be newly added Add
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20-1544 (13) 30-40 (2) 30-94 (10) 30-146 (2) c 30-185-8 (16)
20-1545 (15) 30-41 (2) 30-95 (2) 30-147 (2) c 30-185-9 (16)
20-1546 (15) 30-42 (2) 30-96 (15) 30-148 (2) c 30-185-10(16)
20-1547 (13) 30-43 (2) 30-97 (15) 30-149 (2) c 30-185-11(16)
20-1548 (13) 30-44 (2) 30-98 (2) 30-150 (12) c 30-185-12(16)
20-1549 (13) 30-45 (2) 30-99 (2) 30-150-1 (12) c 30-185-13(16)
20-1550 (13) 30-46 (2) 30-100 (15) 30-150-2 (12) c 30-185-14(16)
20-1551 (13) 30-47 (2) 30-101 (2) 30-152 (2) c 30-185-15(16)
20-1552 (14) 30-48 (2) 30-102 (15) 30-153 (15) c 30-185-16(16)
20-1553 (15) 30-49 (2) 30-103 (15) 30-154 (13) c 30-185-17(16)
20-1554 (15) 30-50 (2) 30-104 (15) 30-155 (15) c 30-185-18(16)
20-1555 (14) 30-51 (2) 30-105 (15) 30-155-1 (13) 30-186 (15)
20-1556 (14) 30-52 (10) 30-106 (15) 30-155-2 (13) 30-187 (2)
HD785-5 00-2-5
(16)
30-188 (2) 40-16

30-189 (2) 40-17 (12)
30-190 (2) 40-17-1 (12)
30-191 (2) 40-17-2 (12)
30-192 (2) 40-17-3 (12)
30-193 (2) 40-17-4 (12)
30-194 (2) 40-18
30-195 (2) 40-19 (12)
30-196 (2) 40-20 (12)
30-197 (2) 40-20-1 (12)
30-198 (2) 40-20-2 (12)
30-199 (2) 40-21
30-200 (2) 40-22
30-201 (2) 40-23
30-202 (2) 40-24
30-203 (2) 40-25 (1)
30-204 (15) 40-26
30-205 (2) 40-27
30-206 (2) 40-28
30-208 (2) 40-29
30-209 (15) 40-30
30-210 (2) 40-31
30-211 (2) 40-32
30-212 (2) 40-33
30-213 (2)
30-214 (2) 90-1 (13)
30-215 (2) 90-3 (13)
30-216 (2) 90-5 (13)
30-217 (2) 90-7 (13)
30-218 (2) 90-9 (13)
30-219 (2) 90-11 (13)
30-220 (2) 90-13 (13)
30-221 (2) 90-15 (13)
30-222 (2) 90-17 (13)
30-223 (2) 90-19 (13)
30-224 (2) 90-21 (13)
90-23 (13)
40-1 (12) 90-25 (13)
40-2 90-27 (13)
40-3 (15) 90-29 (13)
40-4 (10) 90-31 (13)
40-5 90-33 (13)
40-6 90-35 (13)
40-7 90-37 (13)
40-8 90-39 (13)
40-9 90-41 (13)
40-10 90-43 (13)
40-11 90-201 (13)
40-12 (12) 90-203 (13)
40-13 (12) 90-205 (13)
40-13-1 (12) 90-207 (14)
40-14 (1)
40-14-1 (1)
40-15
00-2-6 HD785-5
(16)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
! The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
! The adapter can be pushed in about 3.5
mm.
! Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
! Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
! Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
! When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

! In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
General assembly drawing ............................ 01-2

Specifications ................................................. 01-3
Weight table .................................................... 01-6
List of lubricant and coolant .......................... 01-7
HD785-5 01-1
(15)
GENERAL SPECIFICATIONS
SPECIFICATIONS
HD785-5 HD985-5
Machine model
With standard tires 64 m3 body
(27.00R49flfl) (30.00R51 E3 tires)
Serial No. 4001 and up 1021 and up
Empty kg 66,930 73,700

Rated load kg 91,000 105,000
Gross kg 158,005 178,775
Weight
Empty (front) kg 31,460 (47%) 34,640 (47%)

distribution
Weight
(rear) kg 35,470 (53%) 39,060 (53%)

Gross (front) kg 52,140 (33%) 57,345 (33%)
(rear) kg 105,865 (67%) 116,430 (67%)
Struck m3 40 45
Dump body capacity
3
Heaped (2 :1) m 60 64
Performance
Max. travel speed km/h 65 70

Gradeability (sin θ ) % 35 35
Min. turning radius m 9.9 12.5
Dumping angle ˚ 48 47
Overall length mm 10,490 10,610

Overall width mm 5,660 5,865
Overall height mm 5,050 5,120
Dimensions
Wheel base mm 4,950 4,950
Front wheel mm 4,230 4,420

Tread
Rear wheel mm 3,500 3,720
Ground clearance mm 810 875
Model KOMATSU SA12V140 KOMATSU SA12V140

4-cycle, water-cooled, 4-cycle, water-cooled,
V-type 12-cylinder, direct V-type 12-cylinder, direct
Type injection, with turbocharger injection, with turbocharger
and after-cooler and after-cooler
No. of cylinders – Bore x sroke mm 12 – 140 × 165 12 – 140 × 165
Piston desplacement ¬ {cc} 30.5 {30,480} 30.5 {30,480}
Engine
Rated output kW/rpm {HP/rpm} 783/2,000 {1,050/2,000} 753/2,100 {1,010/2,100}

Max. torque Nm/rpm {kgm/rpm} 4,168/1,400 {425/1,400} 4,168/1,500 {425/1,500}
Fuel consumption (Min.) g/kW h {g/HP h} 205 {153} 205 {153}
Stating motor 24V, 7.5 kW × 2 24V, 7.5 kW × 2
Alternator 24V,75A 24V,75A
Battery 12V,170Ah × 4 12V,170Ah × 4
HD785-5 01-3
(15)
GENERAL LIST OF LUBRICANT AND COOLANT
LIST OF LUBRICANT AND COOLANT
AMBIENT TEMPERATURE CAPACITY

RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104°F
Specified (¬) Refill (¬)
–30 –20 –10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 135 117/130
SAE 15W-40
 when full-flow 
Oil pan only,
SAE 10W-30
filter is replaced
SAE 30
Tsmission case 125 102
SAE 10W
Front brake oil tank 2 2

Engine oil
Hydraulic tank
• Steering hoist oil 248 153

SAE 10W
• Rear brake cooling 366 246
Front suspension 20.0 (each) —
Rear suspension 17.5 (each) —
Differeneial case 132 132

SAE 30
Final drive case 59 (each) 59 (each)
ASTM D975 No. 2

Fuel tank Diesel fuel 1,250 —
ª
Cooling system Coolant Add antifreeze 228 —
ª ASTM D975 No. 1
Fuel and oil fl The specified capacity means the total amount
Select fuel and oil according to the above table. of oil including oil for components and oil in
piping. The refill capacity means the amount
Coolant of oil needed to refill the system during nor-
Since Komatsu genuine Supercoolant (AF-ACL) mal inspection and maintenance.
is added to the cooling water, the latter does not
need to be replaced while the atmospheric tem- fl When starting the engine in an atmospheric
perature is above – 10˚C. If the atmospheric tem- temperature of lower than 0˚C, be sure to use
perature drops below – 10˚C, adjust the concen- engine oil of SAE10W, SAE 10W-30 or
tration and meintenance manual. SAE15W-34, even through the atmospheric
temperature goes up to 10˚C or above during
the day.
HD785-5 01-7
(15)
10 STRUCTURE AND FUNCTION
Radiator, torque converter cooler ............... 10- 4 Air piping .................................................... 10- 56
Brake oil cooler ............................................. 10- 5 Air circuit diagram ...................................... 10- 58
Power train skeleton .................................... 10- 6 Desiccant type air drier ............................. 10-59-1
Output shaft (HD785-5) ................................ 10- 7 Air governor ................................................ 10- 60
Output shaft (HD985-5) ............................... 10-7-1 Safety valve ................................................ 10- 60
Torque converter and transmission Check valve ................................................. 10- 61
hydraulic piping ......................................... 10- 8 Double check valve .................................... 10- 61
Torque converter and transmission Auto drain valve ......................................... 10- 62
hydraulic circuit diagram ........................... 10- 9 Hand brake valve ........................................ 10- 63
Torque converter and transmission Brake valve .................................................. 10- 64
hydraulic circuit schematics ...................... 10-10 Emergency brake control valve ................. 10- 65
Torque converter .......................................... 10-12 Parking brake control valve ....................... 10- 68
Torque converter valve ................................ 10-14 Parking brake pilot valve ........................... 10- 69
Lockup solenoid valve ................................. 10-18 Relay valve .................................................. 10- 70
Transmission ................................................ 10-19 Parking brake relay valve ........................... 10- 71
Transmission valve ...................................... 10-22 Quick-release valve .................................... 10- 72
ECMV ............................................................. 10-23 Parking brake chamber .............................. 10- 72
Lubrication relief valve ................................ 10-28 Ratio valve (For front brake) ...................... 10- 73
Front axle (HD785-5) .................................... 10-29 Front brake chamber .................................. 10- 74
Front axle (HD985-5) ................................. 10-29-1 Rear brake chamber ................................... 10- 75
Rear axle (HD785-5) ...................................... 10-30 Slack adjuster ............................................. 10- 78
Rear axle (HD985-5) ...................................... 10-31 Air drier (Desiccant type) ........................... 10- 79
Differential .................................................... 10-32 Hydraulic piping ......................................... 10- 80
Differential lock control ................................ 10-34 Hydraulic circuit diagram .......................... 10- 82
Differential lock solenoid valve ................... 10-36 Dump body control .................................... 10- 83
Final drive (HD785-5) .................................... 10-37 Hydraulic tank and brake cooling
Final drive (HD985-5) ................................. 10-37-1 oil tank (HD785-5) ..................................... 10- 84
Front brake .................................................... 10-38 Hydraulic tank and brake cooling
Rear brake ..................................................... 10-39 oil tank (HD985-5) .................................... 10-84-1
Parking brake ................................................ 10-41 Brake cooling oil control valve (BCV) ....... 10- 85
Wheels (HD785-5) ......................................... 10-42 Steering valve ............................................. 10- 86
Wheels (HD985-5) ...................................... 10-42-1 Demand valve ............................................. 10- 90
Axle support (HD785-5) ............................. 10-42-2 Hoist valve .................................................. 10- 94
Axle support (HD985-5) ................................ 10-43 Crossover relief valve ................................ 10- 96
Steering system ............................................ 10-44 Steering cylinder ........................................ 10- 97
Steering wheel (HD785-5) ............................ 10-45 Hoist cylinder .............................................. 10- 97
Steering wheel (HD985-5) ......................... 10-45-1 Electrical circuit diagram ........................... 10- 99
Steering linkage ............................................ 10-46 Stop lamp switch ........................................ 10-102
Suspension system ...................................... 10-48 Exhaust brake switch ................................. 10-102
Suspension cylinder ..................................... 10-50 Tilt switch .................................................... 10-102
HD785-5 10-1
(16)
Front brake cut-off valve ............................ 10-103 Self-diagnostic function ........................ 10-147
Overrun prevention valve .......................... 10-104 Payload meter (Printer type)(OP) .............. 10-148
Exhaust brake valve ................................... 10-104 Electrical circuit diagram ......................... 10-149
Horn valve ................................................... 10-105 Principle of calculation ............................ 10-150
Parking brake switch .................................. 10-105 Features of equipment ............................. 10-152
Air conditioner ............................................ 10-106 1. Payload meter .................................... 10-155
Piping diagram ......................................... 10-106 2. Pressure sensor .................................. 10-156
Electrical circuit diagram ......................... 10-108 3. Clinometer .......................................... 10-156
Refrigerant circuit diagram ..................... 10-110 4. Lamp drive relay ................................ 10-156
Unit ............................................................ 10-111 Self-diagnostic function ........................... 10-157
Receiver dryer .......................................... 10-111 Payload meter II (card type)(OP) .............. 10-158
Condenser ................................................. 10-112 Structure of system .................................. 10-158
Compressor .............................................. 10-112 Electrical circuit diagram ......................... 10-159
Engine control system ............................... 10-113 Payload meter block diagram ................. 10-159
System drawing ....................................... 10-113 Principle of measurement ....................... 10-160
Electrical circuit diagram ......................... 10-115 Features of each device ......................... 10-161
Fuel injection pump electronic governor 10-116 1. Payload meter II ................................. 10-161
Hydraulic circuit diagram ........................ 10-117 2. Pressure sensor .................................. 10-189
Aiss ............................................................ 10-117 3. Clinometer .......................................... 10-190
Sensors, switches .................................... 10-118 4. Lamp drive relay ................................ 10-190
Exhaust brake ............................................. 10-119 5. Self-diagnostic function .................... 10-192
System diagram ....................................... 10-119 Machine monitor system ........................... 10-198
System diagram ....................................... 10-120 System drawing ....................................... 10-198
Automatic shift control system ................. 10-122 Monitor panel diagram ............................ 10-200
System diagram ....................................... 10-122 Machine monitor normal display
Electrical circuit diagram ......................... 10-124 functions ................................................. 10-201
Transmission controller ........................... 10-125 Self-diagnostic function when starting
Connector signals .................................... 10-126 switch is operated .................................. 10-208
Shift lever positions and automatic Travel speed compensation
gear shifting ranges ................................. 10-127 Rotary switch .......................................... 10-208
Automatic gear shift line graph .............. 10-128 Sensors, switches .................................... 10-209
Shift lever switch ...................................... 10-130 Engine speed sensor ............................. 10-209
Sensors, switches .................................... 10-131 Transmission speed sensor ................... 10-209
Transmission oil temperature sensor ... 10-131 Engine oil pressure ............................... 10-210
Fill switch ................................................ 10-132 Engine coolant temperature sensor ..... 10-211
Accelerator sensor ................................. 10-133 Retarder oil temperature sensor ........... 10-211
Shift limit switch .................................... 10-134 Torque converter oil
Mode selector switch ............................. 10-134 temperature sensor ............................... 10-211
Self-diagnostic function ........................ 10-135 Air pressure sensor ................................ 10-211
Automatic emergency steering system .... 10-136 Fuel level sensor ................................... 10-212
System diagram ....................................... 10-136 Transmission oil filter sensor ................ 10-213
Electrical circuit diagram ......................... 10-137 Radiator coolant level sensor ............... 10-213
Flow switch ............................................... 10-138 Steering oil temperature sensor ........... 10-214
Relay timer ................................................ 10-140 Brake stroke sensor ............................... 10-214
Automatic suspension system .................. 10-141 PMC system
System diagram ....................................... 10-141 (machine equipped with electronic
Structure of system .................................. 10-142 governor) (OP) .......................................... 10-215
System circuit diagram ............................ 10-143 System diagram ....................................... 10-215
Automatic suspension mode selection Electric circuit diagram ............................ 10-217
control ..................................................... 10-144 Power train management
Suspension controller .............................. 10-145 controller (PMC) ..................................... 10-218
Sensors, switches .................................... 10-146 Message display (MOM) .......................... 10-220
Steering angle sensor .............................. 10-146 Sensors, switches .................................... 10-222
Pressure sensor ........................................ 10-146 Engine speed sensor ............................ 10-222
10-2 HD785-5
(16)
Transmission speed sensor ................... 10-222
Accelerator sensor ..................................... 10-223
Suspension pressure sensor ..................... 10-224
Sensors, switches ....................................... 10-225
Engine oil level sensor .............................. 10-225
Brake oil level sensor ................................. 10-225
Hydraulic oil level sensor .......................... 10-226
Retarder oil level sensor ............................ 10-226
Air cleaner clogging sensor ....................... 10-226
Retarder brake wear sensor ..................... 10-227
Hydraulic filter sensor ............................... 10-227
Retarder oil filter sensor ............................ 10-227
Full-flow filter sensor ................................ 10-228
Battery electrolyte level sensor ................. 10-228
Maintenance monitor system ................ 10-228-1
System diagram .................................... 10-228-1
Monitor panel ........................................ 10-228-2
Monitor display, functions .................... 10-228-3
Functions of switches ........................... 10-228-5
Sensors, switches ................................. 10-228-7
Engine oil level sensor ....................... 10-228-7
Radiator coolant level sensor ............ 10-228-7
Transmission oil level sensor ............. 10-228-7
Hydraulic oil level sensor ................... 10-228-8
Retarder oil level sensor ..................... 10-228-8
Air filter clogging sensor .................... 10-228-8
Retarder brake wear sensor ............... 10-228-9
Hydraulic filter sensor ........................ 10-228-9
Retarder oil filter sensor ..................... 10-228-9
Transmission oil filter sensor ............. 10-228-9
Battery electrolyte level sensor ....... 10-228-10
Torque converter oil temperature
switch ................................................ 10-228-10
Retarder oil temperature switch ...... 10-228-10
ABS/ASR system ........................................ 10-229
System circuit diagram ............................ 10-229
Principle of operation .............................. 10-231
When ABS is actuated ............................. 10-232
When ASR is actuated ............................. 10-233
System structure diagram ....................... 10-234
ABS/ASR electrical circuit diagram ........ 10-236
ABS/ASR controller (ECU) ......................... 10-238
ABS pressure control valve ....................... 10-240
ASR control valve ....................................... 10-243
Wheel speed sensor ................................... 10-245
Relay ............................................................ 10-245
ASR-II system (If equipped) ....................... 10-247
System diagram ....................................... 10-247
Basic operation ......................................... 10-248
System configuration .............................. 10-248
Controller of automatic spin regulator ... 10-251
Hydraulic tank pressurizing system
(High altitude specification) ..................... 10-252
Electrical circuit diagram of hydraulic
tank pressurizing system ....................... 10-254
HD785-5 10-3
(16)
STRUCTURE AND FUNCTION RADIATOR, TORQUE CONVERTER COOLER
RADIATOR, TORQUE CONVERTER COOLER
1. Upper tank SPECIFICATIONS

2. Shroud Radiator
3. Net Core type: CD-5
4. Lower tank Total radiation surface: 151.82 m2
(torque converter oil cooler built in)
5. Core Oil cooler
6. Pick-up for radiator coolant level sensor Element type: Multiple plate
7. Pressure cap Radiation surface: 3.12 m2
A: Oil outlet
B: Oil inlet
10-4 HD785-5
(15)
STRUCTURE AND FUNCTION BRAKE OIL COOLER
BRAKE OIL COOLER
1. Cooler element OIL COOLER SPECIFICATIONS

2. Cover Element type : Multiple plate
3. Flange Radiation surface : 9.92 m2
4. Case Pressure resistance (oil side) : 2.9 MPa {30 kg/cm2}
A: Oil outlet
B: Oil inlet
C: Coolant outlet
D: Coolant inlet
HD785-5 10-5
(15)
STRUCTURE AND FUNCTION ECMV
2) When the clutch is filled with oil, the flow

of oil from pump port D to clutch port C
stops. The size of areas receiving pres-
sure on the left and right sides of flow
sensor valve spool (3) is different (the area
on the left side is larger), so when the pres-
sure on both sides becomes the same, the
spool is moved by hydraulic force to the
right. When this happens, pump port D
and clutch port C are closed. Because of
this difference in area on the left and right
sides, and the force of return spring (2) of
the pressure control valve, flow sensor
valve (3) compresses fill switch spring (4)
and is pushed to the right. It then con-
tacts fill switch (5) and transmits the clutch
filling completed signal to the shift con-
troller. At this point, the current for the
initial pressure level is flowing to propor-
tional solenoid (6), so the hydraulic pres-
sure is set to the initial pressure by pres-
sure control valve spool (7).
4. Regulating (D range of graph)

When current is sent to proportional solenoid
(6), the solenoid generates a force propor-
tional to the current. This propulsion force of
the solenoid, and the sum of the propulsion
force by the hydraulic pressure at the clutch
port applied to load piston (8), and the reac-
tion force of pressure control valve spring (9)
are regulated so that they are in balanced.
The difference in hydraulic pressure applied
to both sides of flow sensor valve spool (3)
pushes the spool to the right, and the fill sig-
nal continues to be sent to the transmission
controller.
HD785-5 10-27
STRUCTURE AND FUNCTION LUBRICATING RELIEF VALVE
LUBRICATION RELIEF VALVE
1. Valve body FUNCTION

2. Lubrication relief spool • This valve is installed to the left side of the
transmission and prevents abnormal pressure
a. Lubrication pressure measurement plug in the transmission lubrication circut.
Cracking pressure : 0.26 MPa {2.7 kg/cm2}
10-28 HD785-5
(14)
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
HD785-5 Serial No.: 4001 – 4253
1. Parking brake SPECIFICATIONS

2. Differential Reducation ratio
3. Axle housing Differential: 3.467
4. Brake Final drive: 6.500
5. Final drive Oil
Differential: EO30-CD (130 liters)
Final drive: EO30-CD (64 liters each side)
Tire size: 27.00 R49
Rim size: 19.50-49
10-30 HD785-5
B
HD785-5 Serial No.: 4254 and up

5. Final drive Oil
Tire size: 27.00 R49
Rim size: 19.50-49
HD785-5 10-30-1
B

5. Final drive Oil
Tire size: 30.00 R51flfl
Rim size: 22.00 × 51
10-30-2 HD785-5
B
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
HD785-5 Serial No.: 4001 – 4253
1. Carrier SPECIFICATIONS
2. Planetary gear shaft Type: Planetary gear, splash-type lubrication
3. Planetary gear (No. of teeth: 39) Reduction tatio: 6.50
4. Sun gear (No. of teeth: 18) Oil: EO30-CD (64 liters each side)
5. Button
6. Cover
7. Ring gear (No. of teeth: 99)
8. Spacer
9. Holder
10. Inner hub
11. Drive shaft
12. Wheel hub
HD785-5 10-37
(15)
5. Button
6. Cover
8. Spacer
9. Holder
10. Inner hub
11. Tube
12. Wheel hub
13. Drive shaft
10-37-1 HD785-5
(15)
HD985-5
5. Button
6. Cover
8. Spacer
9. Holder
10. Inner hub
11. Drive shaft
12. Wheel hub
HD785-5 10-37-2
(15)
STRUCTURE AND FUNCTION REAR BRAKE
1. Inner gear SPECIFICATIONS

2. Floating seal Type: Air over hydraulic, oil-cooled, multipledisc
3. Floating seal brake (acts also as retarder)
4. Hub Oil: Brake oil EO10-CD
5. Plate Cooling oil EO10-CD
6. Disc
7. Outer gear
8. Piston
9. Cylinder
10-40 HD785-5
B
STRUCTURE AND FUNCTION REAR BRAKE
1. Spacer SPECIFICATIONS
2. Sensor Model: Air-over-hydraulic oil-cooled multiple disc
3. Retainer brake (acting also as retarder)
4. Inner gear Oil: Brake oil EO10-CD
5. Floating seal Cooling oil EO10-CD
6. Floating seal
7. Hub
8. Plate
9. Disc
10. Outer gear
11. Piston
12. Cylinder
10-40-2 HD785-5
B
STRUCTURE AND FUNCTION AXLE SUPPORT
AXLE SUPPORT
HD785-5 Serial No.: 4001 – 4253
1. Rod
2. Rod
3. Axle
4. Suspension cylinder
10-42-2 HD785-5
B
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
1. Cylinder
2. Ball
3. Flange
4. Retainer
5. Rod
6. Valve
(for bleding air and mounting pressure sensor)
7. Feed valve
HD785-5 10-53
(15)
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER

Structure and operation
The suspension cylinder has the function of both
a shock absorber and spring.
When a fixed amount of oil is sent from oil cham-
ber (6) through orifices (4) and (5) to cavity (2),
the oil is throttled by the orifices and a shock-ab-
sorbing effect is obrained.
a) Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rob is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (7) is compressed, the oil in cham-
ber (6) is sent through both orifices (4) and
(5) to cavity (2), and cavity (2) is filled more
quickly than when extending.
b) Extending action
When the machine has passed any pump or
object on the road surface, the cylinder rod is
pushed up by the weith of the wheels and axle
and the pressure of the nitrogen inside cham-
ber (7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil
remaining in cavity (2).
This pressurized oil closes orifice (4) with
check ball (3), and is sent to chamber (6)
through only orifice (5), so the flow of oil pass-
ing through the orifice is controlled so that it
is less than during retraction.
In this way, the amount of oil returning to
chamber (6) is restricted to provide a shock
absorbing effect.
1. Feed valve
2. Cavity
3. Check ball
4. Orifice
5. Orifice
6. Oil chamber
7. Nitrogen gas chamber
8. Cylinder rod
9. Cylinder
10. Valve
(for bleeding air and mounting pressure sensor)
a: When extending
b: When retracting
10-54 HD785-5
(15)
STRUCTURE AND FUNCTION DESICCANT TYPE AIR DRIER
DESICCANT TYPE AIR DRIER

(IF EQUIPPED)
1. Air governor
2. Wet air tank
3. Air drier (Desiccant type)
4. Cool tank
5. Air compressor
10-59-1 HD785-5
(16)
STRUCTURE AND FUNCTION AIR CIRCUIT DIAGRAM, SAFETY VALVE
AIR GOVERNOR
1. Exhaust port
2. Spring
3. Piston
4. Unloader port
5. Exhaust stem
6. Inlet valve
7. Tank port
8. Filter
SPECIFICATIONS
• Cut-out pressure:
814 ± 29 kPa {8.3 ± 0.3 kg/cm2}
• Cut-in pressure:
686 ± 29 kPa {7.0 ± 0.3 kg/cm2}
OUTLINE
• The air governor is installed in the air circuit
between the wet tank and the compressor. It
acts to maintain the pressure in the circuit
within the air pressure set range.
SAFETY VALVE
1. Valve seat
2. Ball
3. Release pin
4. Spring
5. Spring gauge
6. Adjustment nut
7. Locknut
FUNCTION
• The safety valve is installed to the wet air tank,
and if a pressure of more than 932 ± 39 kPa
{9.5 ± 0.4 kg/cm2} is generated in the air cir-
cuit, it acts to release the compressed air in-
side the air tank to the atmosphere in order
to ensure safety in the air circuit.
10-60 HD785-5
(16)
STRUCTURE AND FUNCTION RELAY VALVE
OPERATION
1. When not operated (compressed air supplied
to dry air tank)
When the emergency brake valve is at the
TRAVELING position and the brake pedal is
not being depressed, the compressed air in
the wet air tank passes through filter (1),
pushes down check valve (2), and is supplied
to the dry air tank. The pressure in the dry air
tank rises until it is almost the same as the
pressure in the wet air tank.
At the same time, emergency position (3) is
pushed down by the compressed air from the
emergency brake valve.
The air is supplied directly from the wet air
tank to the dry tank.
2. When brake pedal is depressed

Compressed air enters top position A of the
relay piston and pushes the piston down. Ex-
haust valve seat (4) closes exhaust port C and
pushes valve (5) open.
When the valve opens, the compressed air
from the dry air tank and emergency brake
valve passes through the valve and is sup-
plied to the brake chamber.
3. When pedal is kept in same position

(balanced condition)
The pressure at top position A and bottom
position B of the piston becomes equal, so
piston return spring (6) moves and relay pis-
ton (7) is pushed up. Moreover, in this posi-
tion, exhaust port C remains closed, so the
pressure at bottom portion B is maintained
at the same pressure.
4. When pedal is released

The compressed air at top position A of the
piston is released from the brake valve. When
the pressure at position A goes down, relay
position (7) is pushed up by the compressed
air in bottom position B, the exhaust port
opens, and the air in position B is released.
HD785-5 10-70-1
(13)
STRUCTURE AND FUNCTION RELAY VALVE
5. When emergency brake is actuated

(1) Automatic operation
i) If there is damage to the air circuit and
the pressure at the emergency brake
valve end (wet air tank end) drops
below approx. 0.31MPa {3.2kg/cm2},
emergency piston return spring (8) is
actuated, and emergency piston (3) is
pushed up, so exhaust valve seat (5)
closes exhaust port C and opens valve
(4). When the valve opens, com-
pressed air from the dry air tank
passes through the valve and is sup-
plied to the brake chamber. In this
way, if the pressure in the emergency
brake valve air circuit goes below
0.31MPa {3.2kg/cm2}, the emergency
brake starts to be applied.
ii) If the air pressure in the emergency
brake valve air circuit is between
approx. 0.46 MPa {4.7kg/cm 2}, and
0.31MPa {3.2kg/cm2}, the emergency
brake is not applied automatically.
However, in this condition, if the brake
valve is depressed, even if the brake
valve is kept in the same position, the
remaining pressure inside the brake
valve causes the emergency brake to
be actuated.
iii) To release the emergency brake, open
the drain valve of the air tank, or raise
the air pressure in the wet air tank to
above 0.55MPa {5.6kg/cm2}.
(2) Manual operation

i) If the emergency brake valve is moved
from the TRAVELING position to the
BRAKING position, the compressed
air between the emergency brake
valve and the emergency relay valve
is released to the atmosphere.
If this happens, the circuit is set to the
same condition as in i) above, so the
emergency relay valve is actuated.
ii) To release the emergency brake, set
the emergency brake valve to the
TRAVELING position.
10-70-2 HD785-5
(13)
STRUCTURE AND FUNCTION PARKING BRAKE RELAY VALVE
PARKING BRAKE RELAY VALVE
1. Cover FUNCTION
2. Relay piston • The parking brake relay valve is in the park-
3. Valve body ing brake circuit. When the parking brake
4. Exhaust cover valve is set to PARKING, the parking brake
relay valve is actuated, the air in the parking
A: From parking brake pilot valve brake chamber is released, and the machine
B: From air tank is stopped from moving.
C: To parking brake chamber
HD785-5 10-71
(13)
STRUCTURE AND FUNCTION PARKING BRAKE RELAY VALVE
FUNCTION
1. When the parking brake valve in
“TRAVELING”
Pressurized air will enter A, the upper section
of the relay piston, causing the piston to lower.
Then, the exhaust valve seat (1) will close the
exhaust port C and open the valve (2).
If the valve is opened, the pressurized air will
be fed to the parking brake chamber through
the valve.
2. When the parking brake valve in “PARKING”

The pressurized air in the piston upper sec-
tion A will be exhausted through the parking
brake valve, reducing the pressure A.
Consequently, the relay piston will be thrusted
up by the pressurized air in the section B, caus-
ing the exhaust port to open. Thus, the air in
the section B will be exhaled.
10-71-1 HD785-5
(13)
STRUCTURE AND FUNCTION QUICK-RELEASE VALVE, PARKING BRAKE CHAMBER
QUICK-RELEASE VALVE
FUNCTION
The quick-release valve serves to let the pressur-
ized air in the pilot line for retarder flow out
quickly.
1. Body
2. Diaphragm
3. Diaphragm valve
4. Cover
5. O-ring
PARKING BRAKE CHAMBER
1. Spring FUNCTION
2. Piston The air pressure from the parking brake valve
3. Cylinder pushes the spring (1) and compresses it to release
4. Boot the parking brake.
5. Rod Usually the parking brake is kept applied by spring
(1), so the machine is prevented from moving.
10-72 HD785-5
(13)
STRUCTURE AND FUNCTION REAR BRAKE CHAMBER
REAR BRAKE CHAMBER
1. Air cylinder SPECIFICATIONS

2. Air piston 1. Air cylinder
3. Spring Cylinder bore: 180 mm
4. Rod Stroke: 133.5 mm
5. Breather Cylinder capacity: 3,600 cc
6. Piston
2. Master cylinder
7. Master cylinder
Cylinder bore: 68 mm
8. Piston valve
Stroke: 132.5 mm
9. Body
Cylinder capacity: 472 cc
10. Brake line failure sensor
3. Boosting ratio: 7.0 : 1
HD785-5 10-75
(15)
OPERATION
Brake operated
When the brake pedal is depressed, compressed
air is supplied from the brake valve to the brake
chamber. Air piston (2) moves rod (4) and pushes
piston (6) of master cylinder (7) to the right. Brake
oil is sent by piston (6) to the brake piston to ac-
tuate the brake.
Brake held in position

When the brake pedal is kept depressed at a con-
stant force, the hydraulic pressure is kept con-
stant, so the brake is kept applied.
Brake released
When the operating force on the brake pedal is
partly released, the compressed air supplied to
the back of piston (2) of the brake chamber is re-
leased from the brake valve, and the hydraulic
pressure inside master cylinder (7) drops.
If the brake pedal is released further, the brake oil
set to the piston of the brake is sent back to the
inside of master cylinder (7) by the force of the
brake return spring.
10-76 HD785-5
(15)
OPERATION OF BRAKE LINE FAILURE SENSOR
When air piston (1) moves more than 93% of its

stroke, it pushes brake line failure pin (2), and
brake line failure sensor (3) is actuated.
When brake line failure sensor (3) is actuated,
the rear brake caution lamp inside the cab lights
up. At the same time, the central warning lamp
flashes and the alarm buzzer sounds intermit-
tently.
HD785-5 10-77
(15)
STRUCTURE AND FUNCTION AIR DRIER (DESICCANT TYPE)
AIR DRIER (DESICCANT TYPE)

(IF EQUIPPED)
1. Purge chamber
2. Spring
3. Check valve
4. Drier cylinder
5. Drying agent (Desiccant)
6. Oil filter
7. Valve
8. Piston
9. Body
10. Heater
A. From compressor
B. To air tank
C. From air governor
HD785-5 10-79
(16)
STRUCTURE AND FUNCTION AIR DRIER (DESICCANT TYPE)
OPERATION
1. Dehumidifying
While the compressor is working, air from the
compressor enters port A of the air drier. The
air is cooled on the walls of the body and the
condensed water and oil are accumulated on
the bottom of the body. Then, the air passes
through oil filter (6) which is fitted with an oil
mist separator, where the fine drops of oil and
particles of dust are removed before the air
enters the drier cylinder. Any water still in-
cluded in the air is removed by drying agent
(5). When the air reaches the top of the drier
cylinder, it is completely dry. This dry air
passes through check valve (3) and the purge
chamber (1) and is sent to the air tank.
2. Restoring drying agent

When the air pressure in the circuit reaches
the set pressure, the command from the gov-
ernor sets the compressor in the unloading
mode. The same command is also sent to
the control ports of the air drier. Drain valve
(7) opens and the air in drier cylinder (4) is
released to the atmosphere. Following this
sudden drop in pressure, the dried air in the
purge chamber (1) passes through orifice “a”.
Because of the drop in pressure, the dry air
expands and becomes super-dry air. As it
flows back through the drier cylinder (4), it
picks up water from drying agent (5) and car-
ries it out to the atmosphere.
When the loading cycle starts again, the drain
valve (7) closes according to the command
from the governor, and the cylinder returns
to dehumidifying action.
10-79-1 HD785-5
(16)
STRUCTURE AND FUNCTION STOP LAMP SWITCH, EXHAUST BRAKE SWITCH, TILT SWITCH
STOP LAMP SWITCH

EXHAUST BRAKE SWITCH
FUNCTION
When the brake pedal is depressed or exhaust
brake is applied, air pressure acts on the switch
to light up the lamp.
1. Terminal (A)
2. Terminal (B)
3. Spring
4. Plate
5. Block
6. Diaphragm
7. Body
TILT SWITCH
1. Magnet FUNCTION
2. Plate • If the chassis tilts to the right or left, the disc
3. Gasket magnet moves to the right or left. If the chas-
4. Print card sis tilts into the overturn danger range, either
5. Bracket the right or left switch is turned OFF. If the
6. Plate dump lever is set in the RAISE position under
7. Plate this condition, the lamp lights up and the
8. Plate buzzer sounds to warn of the danger.
9. Connector
10-102 HD785-5
(15)
STRUCTURE AND FUNCTION AIR CONDITIONER
REFRIGERANT CIRCUIT DIAGRAM
10-110 HD785-5
(15)
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
1. Self-diagnostic display window

2. Connector
3. Case
4. Printboard
5. Model selection switch
(rotary switch 1)
6. Network connection switch
(rotary switch 2)
OUTLINE
• This transmission controller is designed to 6. It receives the input of model selection data
control the system, so it has a built-in com- (what machine the controller is mounted on)
puter. and network data (what controller is con-
It has the following features and functions. nected to the network), and contacts the other
1. It has a high-power mode and economy mode controllers through the network. (For details
and it changes the shift pattern. (Machines of the method of setting, see TESTING, AD-
not equipped with an electronic governor JUSTING, AND TROUBLESHOOTING.)
have only the high-power mode.) 7. It has finely divided self-diagnostic functions
2. The braking mode is the mode when the brake for both the input and output systems.
is used. The gear shifting point is raised and 8. The content of the self-diagnostic display is
the brake cooling pump speed is also in- shown with 2-digit numbers.
creased to improve the cooling effect for the 9. When any failure is detected, it sends details
retarder. At the same time it also enables the to the network, and displays this on the other
braking force of the engine to be used effec- display panels.
tively. 10. The content of the self-diagnosis is recorded
3. It drives and controls the torque converter in memory, so even when the main switch is
lock-up solenoid valve, overrun prevention so- turned off it is possible to check details of fail-
lenoid valve, exhaust brake solenoid valve, ures.
and BCV solenoid valve. 11. It sends the trouble data to the network, and
4. Speed sensors are located at three points displays this on the other display panels.
(transmission input shaft, intermediate shaft, 12. The location of any existing failure is dis-
and output shaft) to make it possible to de- played on the monitor panel.
tect any slipping of the transmission clutches. 13. It has an emergency travel function for use if
It also acts to protect the transmission when there is any failure in the electrical system.
there is any abnormality in the hydraulic sys- 14. It is located separately from the gearshift le-
tem. ver.
5. It is connected to the network and makes vari-
ous data common with other controllers.
HD785-5 10-125
B
CONNECTOR SIGNALS
ATC1 ATC3A ATC4 ATC5A
1 L/C SOL 1 Connector check 1 RS422 TX (+) 1 Connector check
2 — Transmission input 2 RS422 RX (+) 2 Rear brake signal
2
3 — shaft speed 3 RS232C TX 3 Body FLOAT signal
3 Transmission output
4 Overrun SOL (+) shaft speed 4 RS232C RX 4 Body seated signal
5 Exhaust brake SOL (+) 4 — 5 RS485 (+) 5 Machine tilt angle
6 AISS relay 5 Throttle correction 6 S-NET (+) 6 Transmission filter clogging
7 Battery direct power source 6 Potentiometer power 7 RS422 TX (–) 7 —
8 GND source 5V 8 FLASH switch 8 Brake stroke signal
9 Power source 24 V 7 — 9 RS422 RX (–) 9 —
10 — 8 — 10 GND (serial) 10 Fill switch L
11 BCV 9 — 11 RS485 (–) 11 Fill switch 4th
12 — 10 Emergency escape switch 12 S-NET (–) 12 Fill switch H
13 Overrun SOL (–) 11 Steering oil temperature 13 Fill switch 1st
14 Exhaust brake SOL (–) Transmission intermedi- 14 Fill switch 2nd
12
ate shaft speed
15 Transmission cut relay 15 Fill switch 3rd
13 Engine speed
16 GND 16 Fill switch R
14 GND (pulse)
17 Power source 24 V 17 —
15 —
18 Start signal
16 GND (analog)
19 Emergency steering
17 —
20 Heater relay ON/OFF
18 —
19 —
20 —
ATC2 ATC3A ATC5B

1 Proportional SOL power 1 Alternator terminal R 1 Exhaust brake ON/OFF
source 24 V 2 Brake air pressure 2 Shift lever R signal
2 ECMV 1st (+)
3 — 3 Shift lever N signal
3 ECMV 3rd (+)
4 Fuel level 4 Shift lever D signal
4 ECMV 2nd(+)
5 Engine coolant temperature 5 Shift lever 5 signal
5 ECMV R (+)
6 — 6 Shift lever 4 signal
6 —
7 Torque converter oil 7 Shift lever 3 signal
7 ECMV L (+) temperature 8 Shift lever L signal
8 ECMV 4th (+) 8 Retarder oil temperature
9 Shift limit switch
9 ECMV H (+) 9 Transmission valve inlet
port oil temperature 10 Model selection 1
10 —
10 — 11 Model selection 2
11 —
11 Accelerator angle 12 Model selection 3
12 Proportional SOL power
source 24 V 12 Engine oil pressure 13 Model selection 4
13 ECMV 1st, 3rd (–) 13 — 14 Parking brake ON/OFF
14 Sensor power source 12 V 14 — 15 Coolant level
15 ECMV 2nd, R (–) 15 Differential lock switch 16 Mode switch
16 — 16 —
17 ECMV L (–)
18 ECMV 4th (–)
19 ECMV H (–)
20 —
21 GND
10-126 HD785-5
(15)
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
• This is installed under the operator’s cab. The
accelerator pedal and accelerator sensor are
connected by a link. When the accelerator
pedal is depressed, the movement is passed
through the link and rotates the shaft of the
potentiometer inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 - 3
pins of the potentiometer. A voltage signal
corresponding to the angle of the accelerator
pedal is sent from the No. 2 pin to the trans-
mission controller.
Idling validation signal (only machines

equipped with electronic governor)
• This is installed under the operator’s cab.
When the accelerator pedal is released, sig-
nal 2 (No. 5 pin) is connected to the ground;
when the accelerator pedal is depressed, sig-
nal 3 (No. 6 pin) is connected to the ground.
The engine controller then detects the condi-
tion.
HD785-5 10-133
(15)
STRUCTURE AND FUNCTION PAYLOAD METER II (Card type)(OP)
ii) Measuring empty weight (calibration)

The weight of the machine when empty is
measured and this is used as the calibration
data.
These data are retained even when the power
is turned OFF.
iii) Normal operation display (for details, see the
Operation and Maintenance Manual)
See the Normal operation display.
iv) External display lamp drive
(estimated display)
The chart on the right shows the payload dis-
play level for the external display lamps dur-
ing the normal operation display.
The estimated display shows the estimation
of the total payload when one more load is
added. The applicable lamp flashes to pre-
vent overload.
Normal operation display

Shift lever Dump lever
Condition of the machine position position Payload meter display External display lamps
Stopped N FLOAT Payload display (*1) Payload display

Empty
Traveling Except N FLOAT Time display OFF
During load- Stopped Payload display and

N FLOAT Payload display
ing, before estimated display
reaching 50%
of correct pay-
load Traveling Except N FLOAT Payload display OFF
Payload display and

During load- Stopped N FLOAT Payload display
ing, after estimated display
reaching 50% Travel distance displayed
of correct pay- Traveling Except N FLOAT in units of m from 0 – 160 OFF
load m (each 5 m)
Traveling Except N FLOAT After completion, OFF

changes to time display
Loaded
Stopped N FLOAT Payload display Payload display
FLOAT → Aggregate payload

When dumping (*2) N RAISE→LOWER OFF
→ FLOAT display (*3)
Abnormality, warning (Error code displayed in See Operation and

generated — — order of priority) Maintenance Manual
(*1) When load is less than 50% of correct payload, display shows 0 ton.
(*2) For details of conditions taken as dumping, see v) Content of memory (1).
(*3) The aggregate payload display is shown in units of 100 ton. (Rounded to the nearest 100)
HD785-5 10-165
(15)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS

1. Monitor panel gauge and gauge caution display
Display
Symbol Display item category Display range, conditions Display method
Air pressure Gauge 7-level display

One place lights up to show level.
No. 1
Caution When below 0.51 MPa OFF when normal

{5.2 kg/cm2} When there is any abnormality,
lamp flashes, central warning
lamp lights up, and alarm buzzer
sounds.
Engine coolant Gauge 7-level display

temperature One place lights up to show level.
No. 2
SAP00527
Caution When above 102˚C OFF when normal

When there is any abnormality,
sounds.
Torque Gauge 7-level display
converter oil One place lights up to show level.
temperature
No. 3
Caution When above 102˚C OFF when normal

When there is any abnormality,
sounds.
HD785-5 10-201
(15)
6. Lamps inside dashboard (caution items)

Display
Symbol Display item category Display range, conditions Display method
No. 21 Radiator Caution When coolant level drops OFF when normal.
coolant level When there is any abnormality,
drop warning lamp flashes, central warning
sounds.
No. 22 Engine oil Caution When engine oil pressure OFF when normal.
pressure drop drops When there is any abnormality,
warning lamp flashes, central warning
sounds.
No. 23 Warning of Caution When there is abnormality OFF when normal.
abnormality in in charging circuit When there is any abnormality,
charging lamp flashes, central warning
circuit lamp lights up, and alarm buzzer
sounds.
No. 24
Transmission Caution When transmission filter is OFF when normal.
filter clogging clogged When there is any abnormality,
warning lamp flashes, central warning
sounds.
No. 25 Rear brake Caution When brake chamber OFF when normal.
warning stroke is too large When there is any abnormality,
sounds.
No. 26 Tilt warning Caution When dump body is raised OFF when normal.
and there is excessive tilt to When there is any abnormality,
left or right lamp flashes, central warning
sounds.
Maintenance Caution When there is a mainte- OFF when normal
warning nance related warning gen- ON when there is any abnormal-
erated ity
Steering oil Caution When steering oil tempera- OFF when normal
temperature ture rises When there is any abnormality,
rise warning lamp flashes, central warning
sounds.
Body actuated Caution When body dump lever is Lights up when lever is at posi-
at position other than tion other than FLOAT or body is
No. 29 FLOAT or when body is raised.
raised Goes OFF when lever is at FLOAT
and dump body is lowered.
When dump lever is at position
other than FLOAT and shift lever
is at position other than N, cen-
tral warning lamp lights up and
alarm buzzer sounds.
Parking brake Caution When parking brake is ON

No. 30 caution applied When parking brake is applied
and shift lever is at position other
than N, central warning lamp
lights up and alarm buzzer
sounds.
10-206 HD785-5
(15)
ENGINE COOLANT TEMPERATURE SENSOR

RETARDER OIL TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
1. Connector FUNCTION
2. Plug • These sensors are installed to the engine cyl-
3. Thermistor inder block, at a mid-point of the retarder oil
piping, and to the transmission case. Any
change in the temperature is taken as a
change in the resistance of the thermistor, and
a signal is sent to the shift controller. The
signal is then sent from the shift controller
through the network to the machine monitor
panel to display the temperature. When the
monitor panel display reaches the specified po-
sition, the lamp flashes and the buzzer sounds
to warn the operator of an abnormality.
AIR PRESSURE SENSOR
1. Connector
2. Tube
3. Frame
FUNCTION
• The air pressure sensor is installed to the air
piping behind the operator’s seat. It converts
any change in the air pressure inside the wet
tank to a change in the resistance, and sends
a signal to the shift controller.
The signal is sent from the shift controller
through the network to the machine monitor
panel, and the air pressure is displayed. If
the air pressure goes below the specified pres-
sure, the monitor panel lamp flashes and the
alarm buzzer sounds to warn the operator of
the abnormality.
HD785-5 10-211
(15)
TRANSMISSION OIL FILTER SENSOR
1. Body FUNCTION
2. Tube • This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A: Low pressure pickup port side and high-pressure side reaches the speci-
B: High pressure pickup port fied pressure, the switch goes OFF. The main-
tenance monitor display then flashes to warn
of abnormality.
Actuating pressure:
Transmission oil filter sensor:
275 ± 20 kPa {2.8 ± 0.2 kg/cm2}
Principle of switch: Pressure difference sliding

piston type
RADIATOR COOLANT LEVEL SENSOR
1. Float FUNCTION
2. Sensor • This sensor is installed to the top of the radia-
3. Connector tor, and when the coolant level goes below
the specified level, the float goes down and
the switch goes OFF. The caution lamp then
flashes and the buzzer sounds to warn of ab-
normality.
HD785-5 10-213
(15)
STRUCTURE AND FUNCTION PMC SYSTEM (OP)
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
• This is installed under the operator’s cab. The
accelerator pedal and accelerator sensor are
connected by a link. When the accelerator
pedal is depressed, the movement is passed
through the link and rotates the shaft of the
potentiometer inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 – 3
pins of the potentiometer. A voltage signal
corresponding to the angle of the accelerator
pedal is sent from the No. 2 pin to the PMC.
Idling validation signal

(only machines equipped with electronic
governor)
• This is installed under the operator’s cab.
When the accelerator pedal is released, sig-
nal 2 (No. 5 pin) is connected to the ground;
when the accelerator pedal is depressed, sig-
nal 3 (No. 6 pin) is connected to the ground.
The PMC then detects the condition.
HD785-5 10-223
(15)
STRUCTURE AND FUNCTION MAINTENANCE MONITOR SYSTEM
MAINTENANCE MONITOR SYSTEM

(In case the machine is equipped with a MAINTENANCE MONITOR
SYSTEM)
SYSTEM DIAGRAM
OUTLINE
• The maintenance monitor system uses sensors
installed to various parts of the machine to
observe the condition of the machine. This sys-
tem then processes the information swiftly, and
displays it on the maintenance monitor to give
the operator maintenance information about the
machine (timing for replacement of filters and oil
changes, etc.).
• The maintenance monitor system consists of the
maintenance monitor, various sensors, and the
power source.
• The items displayed can be broadly divided into
the monitor portion (CHECKS) that gives warn-
ing if there is any abnormality in the machine,
and the maintenance timer that shows the timing
for changing the oil and replacing filters.
HD785-5 10-228-1
(13)
MONITOR PANEL
1. Engine oil level 18. Hydraulic filter (clogging) OUTLINE

2. Transmission oil level 19. Retarder filter (clogging)
3. Hydraulic oil level 20. Maintenance time display • The maintenance monitor consists of the mainte-
nance module, monitor module, and other struc-
4. Retarder oil level 21. Replacement time
confirmation switch (oil) tural parts such as the plate.
5. Brake oil level
22. Replacement switch • There is one microcomputer in the maintenance
6. Retarder wear
module: this processes signals from the sen-
7. Battery electrolyte level 23. Misoperation cancel
switch sors, calculates the time that oil and filters have
8. Air cleaner been used, and displays this information. It uses
24. Replacement time confir-
9. Engine oil mation switch (filter) a liquid crystal display.
10. Transmission oil 25. Maintenance module • The monitor module is actuated by signals from
11. Hydraulic oil 26. Monitor module the maintenance module.
12. Retarder oil 27. Switch A
13. Final drive, differential oil 28. Switch II
14. Full-flow filter (clogging) 29. Switch B
15. Fuel filter 30. Switch C
16. Corrosion resistor 31. Switch I
17. Transmission filter 32. Switch D
(clogging)
10-228-2 HD785-5
(13)
MONITOR DISPLAY, FUNCTIONS
Display
Display item Display range Display method
category
Engine oil level Below low level
Transmission oil level Below low level
Displays when engine is stopped.

Hydraulic oil level Below low level Display is normally off.
Flashes when abnormal.
Retarder oil level Below low level
Brake oil level Below low level
Displays at neutral.
More than specified Display is normally off. Flashes when abnormal
Retarder wear
wear (the retarder wear has an abnormality recording
function)
Check
Below specified Displays when engine is stopped.

Battery electrolyte level
voltage Display is normally off, flashes when abnormal.
Displays when engine is running (has an

More than specified
Air filter clogging abnormality recording function).
pressure difference
Display is normally off, flashes when abnormal.
More than specified

Full-flow filter clogging
pressure difference Displays when engine is running and torque
converter oil temperature is above 50°C.
Transmission filter clog- More than specified Display is normally off, flashes when abnormal.
ging pressure difference
Displays when engine is running and brake oil

More than specified
Hydraulic filter clogging temperature is above 50°C.
pressure difference
Displays when engine is running and brake oil

More than specified
Retarder filter clogging temperature is above 50°C.
pressure difference
Time display: Out when 1 – 500 h.

Engine oil
Lights up when abnormal.

Maintenance
Transmission oil
Time display:
Less than 0 h
Hydraulic oil

Retarder oil
HD785-5 10-228-3
(13)
Display
Display item Display range Display method
category

Final drive, differential oil

Full-flow filter

Fuel filter
Maintenance
Time display: Time display: Out when 1 – 1000 h.

Corrosion resistor
Less than 0 h Lights up when abnormal.

Transmission filter

Hydraulic filter

Retarder filter
Maintenance timer
Time display
0 – 9999 h
(A negative Displays the time for the item indicated by an arrow
display is shown by the ( , ).
E
E
time display flashing.)
10-228-4 HD785-5
(13)
FUNCTIONS OF SWITCHES
Switch item Function
Each time the switch is pressed, the arrow ( ) changes in the following order, and the
E
time display changes accordingly.
Replacement time
Engine oil Transmission oil Hydraulic oil
confirmation (oil)
Final drive, differential oil Retarder oil
Each time the switch is pressed, the arrow ( ) changes in the following order, and the
E
time display changes accordingly.
Replacement time
Full-flow filter Fuel filter Corrosion resistor
confirmation (filter)
Retarder filter Hydraulic filter Transmission filter
When the oil is changed or the filter is replaced, use the above switches to select the
item that has been replaced, then press the switch for 2 seconds and the time display
will be set to the initial set time (see table on next page).
Replacement
Note: This function is only effective when the engine is stopped.
[The time setting is confirmed by starting the engine (generation of electricity by alter-
nator).]
If any mistake is made in the item for which the initial time is set when carrying out the
above operation, press this switch to return the time to its original setting.
Misoperation cancel
While this switch is being pressed, the maintenance timer is in the manual set mode,
and the time for the item selected by switch II can be manually set using the following
switches.
Each time either switch A, B, C, or D is pressed, the time display for that digit will
Switch I change 0 o 1 o 2 o ....... o 9.
Operate this switch only
when replacing the 4th digit 3rd digit 2nd digit 1st digit
maintenance module. Switch A Switch B Switch C Switch D
Each time all the digits become 0, the (+) or (–) will change.
[When the numeral is flashing it indicates (–).]
HD785-5 10-228-5
(13)
Switch item Function
This is the replacement time confirmation switch in the manual set mode.
Each time the switch is pressed, the arrow ( , ) changes in the following or order,
E
E
and the time display changes accordingly.
Engine oil Full-flow filter

O O
Transmission oil Fuel filter
O O
Switch II
Hydraulic oil Corrosion resistor
O O
Retarder oil Transmission filter
O O
Final drive, differential oil Hydraulic filter
O
Retarder filter
Initial set times for maintenance timer
Item Initial set time (H) Item Initial set time (H)
Engine oil 500 Full-flow filter 500
Transmission oil 1000 Fuel filter 500
Hydraulic oil 2000 Corrosion resistor 1000
Retarder oil 2000 Transmission filter 500
Final drive, differential oil 2000 Hydraulic filter 1000
Retarder filter 1000
10-228-6 HD785-5
(13)
SENSORS, SWITCHES
ENGINE OIL LEVEL SENSOR
1. Float Function
2. Sensor • This sensor is installed to the side face of the oil
3. Connector pan, and when the oil level goes below the spec-
ified level, the float goes down and the switch
goes OFF. The maintenance monitor display
then flashes to warn of abnormality.
RADIATOR COOLANT LEVEL SENSOR
1. Float Function
2. Sensor • This sensor is installed to the top of the radiator,
3. Connector and when the coolant level goes below the spec-
ified level, the float goes down and the switch
goes OFF. The caution lamp then flashes and
the buzzer sounds to warn of abnormality.
TRANSMISSION OIL LEVEL SENSOR
1. Float Function
2. Sensor • The sensor is installed to the side face of the
3. Connector transmission case, and when the oil level goes
below the specified level, the float goes down
and the switch goes OFF. The maintenance
monitor display then flashes to warn of abnor-
mality.
HD785-5 10-228-7
(15)
HYDRAULIC OIL LEVEL SENSOR

RETARDER OIL LEVEL SENSOR
1. Connector Function
2. Bracket • This sensor is installed to the side face of the
3. Float hydraulic oil and brake cooling oil tank, and
4. Switch when the oil level goes below the specified level,
the float goes down and the switch goes OFF.
The maintenance monitor display then flashes to
warn of abnormality.
AIR FILTER CLOGGING SENSOR

1. Hose
2. Connector
3. Case
4. Diaphragm
5. Guide
6. Spring
7. Terminal
8. Filter
9. Boss
Function
• This sensor is installed to the side face of the
outlet port of the air cleaner, and when the air
cleaner becomes clogged and the specified
pressure (negative pressure) is reached, a dia-
phragm turns the switch OFF. The maintenance
monitor display then flashes to warn of abnor-
mality.
10-228-8 HD785-5
(13)
RETARDER BRAKE WEAR SENSOR
1. Shaft Function
2. Cylinder • This sensor is installed to the rear brake, and the
3. Spring shaft is always pushed against the brake piston.
4. Bushing When the brake is actuated, if the shaft moves
5. Magnet beyond the actuation point because of wear of
6. Switch the brake disc, the switch goes OFF. The main-
7. Body tenance monitor display then flashes to warn of
8. Connector abnormality.
HYDRAULIC FILTER SENSOR

RETARDER OIL FILTER SENSOR
TRANSMISSION OIL FILTER SENSOR
1. Body Function
2. Tube • These sensors are installed to each filter, and
3. Connector when the filter becomes clogged, and the differ-
ence in pressure between the low-pressure side
A. Low pressure pickup port and high-pressure side reaches the specified
B. High pressure pickup port pressure, the switch goes OFF. The mainte-
nance monitor display then flashes to warn of
abnormality.
Actuating pressure
Hydraulic filter sensor: 0.10 ± 0.02 MPa
{1.0 ± 0.2 kg/cm²}
Retarder oil filter sensor: 0.10 ± 0.02 MPa
{1.0 ± 0.2 kg/cm²}
Transmission oil filter sensor: 0.27 ± 0.02 MPa
{2.8 ± 0.2 kg/cm²}
Principle of switch: Pressure difference sliding piston

type
HD785-5 10-228-9
(13)
BATTERY ELECTROLYTE LEVEL SENSOR
1. Body Function
2. Connector • This sensor is installed to the battery, and when
3. Filter the battery electrolyte goes below the specified
4. Packing level, the tip of the sensor comes out of the bat-
5. Pin tery electrolyte into the air, and a signal showing
a change in voltage is sent to the maintenance
monitor. The maintenance monitor display then
flashes to warn of abnormality.
TORQUE CONVERTER OIL TEMPERATURE SWITCH

RETARDER OIL TEMPERATURE SWITCH
1. Body Outline
2. Terminal • These switches are installed in the transmission
oil piping and retarder oil piping, and send the
inhibit signal to the maintenance monitor. (This
signal restricts actuation of the torque converter
filter sensor and retarder filter sensor at temper-
atures below 42°C.)
10-228-10 HD785-5
(13)
STRUCTURE AND FUNCTION ASR-II SYSTEM (OP)
ASR-II SYSTEM (IF EQUIPPED)

[Automatic Spin Regulator (ASR-II)]
SYSTEM DIAGRAM
1. ASR caution lamp Automatic Spin Regulator (ASR) is a system that

2. ASR working lamp is used to prevent spin of the drive wheels caused
3. ASR controller by excessive torque. The ASR system will aid the
4. Pressure control valve (R.H.) vehicle so that it can start and travel more easily
5. Pressure switching valve and safely on rough roads and frozen roads. If
6. Pressure control valve (L.H.) excessive torque is applied to the tires when the
7. Wheel speed sensor (L.H.) vehicle starts on a road covered with snow or a
8. Wheel speed sensor (R.H.) split road (a road having different conditions on
9. System switch its both sides, e.g. a road either side of which is
10. Steering angle sensor coverd with snow and the other side of with is
dry), both or either of the tires will spin and the
vehicle cannot move. If the vehicle is equipped
with ASR, the spinning tire (s) is (are) braked au-
tomatically in order to control the torque that is
applied to the tire (s) and the vehicle can start to
move.
Since the ASR-II controller has the automatic re-
tarder (ARSC) function, a combination system of
ASR and ARSC, which could not be made up in
the past, can be made up.
HD785-5 10-247
B
BASIC OPERATION 4) ASR working lamp

The ASR working lamp notifies that ASR is
1) Transmission control
working.
If the rear tires slip on soft ground and their
speeds are different from each other, then the
5) Wheel speed sensors
tire turning faster is braked and the drive force
Each wheel speed sensor generates pulse
of the tire turning is transmitted. The trans-
voltage with the gear installed on the periph-
mission control is turned on only while the
ery of each pulse wheel and sends it to the
travel speed is 0 – 30 km/h and the accelera-
sends it to the controller.
tor pedal is depressed.
If the accelerator pedal is released or the foot
6) Steering angle sensor
brake or retarder is operated while ASR is
The steering angle sensor is installed to the
working, the ASR system will shut down.
center steering arm lever. The sensor sends
the voltage signal of the center lever angle to
2) Turning correcting function
the controller.
A potentionmeter is installed to the center
steering arm lever. The condition for starting
7) Pressure supply valve
and finishing the transmission control is
The pressure supply valve supplies air to the
changed according to the center lever angle.
pressure control valve. If the system has a
The potentiometer is used in order to avoid
failure, the pressure supply valve will stop
mistaking the speed difference between the
supplying air to the pressure control valve
inner and outer tires for slip. of the tires. It
(upon receiving a command from the control-
also helps to secure normal turning when the
ler).
vehicle is steered while ASR is in operation.
8) Pressure control valve
3) Self-diagnosis function and saving of error
The pressure control valve controls the brake
code
according to the command from the control-
The controller monitors the system. If the sys-
ler.
tem has a failure, the controller alerts the op-
erator by turning on the trouble and buzzer.
An error code is displayed and saved accord-
ing to the contents of the failure. The con-
troller then turns off the system.
SYSTEM CONFIGURATION
The basic ASR system consists of electric parts
such as the controller, switches, relays, lamps,
wheel speed sensors, steering angle sensor, pres-
sure control valve, and pressure supply valve.
1) ASR controller
The ASR controller receives various signals
and calculates them. The ASR controller will
then output various signals for the above ba-
sic functions.
2) ASR system switch

The ASR system works only while the ASR
system switch is turned on.
3) ASR caution lamp

If a system failure is detected while the ASR
system switch is turned on, the ASR caution
lamp will flash. The ASR caution lamp will
also be utilized by the Automatic Retarder
Speed Control ARSC if the ARSC is installed.
10-248 HD785-5
8
When ASR does not operate When ASR operates (When vehicle starts)
While the vehicle is travelling normally and the If the speeds of both drive wheels become differ-
speeds of both rear wheels are not much different from each other while the accelerator pedal
ent from each other, ASR does not operate and is depressed as shown in the above graph, the
the brake is not applied to the drive wheels. slipping wheel is braked so that the speeds of both
When the vehicle turns, ASR still does not oper- wheels will be the same.
ate since the condition for starting the control
changes according to the steering angle. ASR will
operate if the vehicle turns on a slippery road and
the speeds of the drive wheels become greater
from each other than what they should at a given
steering angle.
HD785-5 10-249
(13)
10-250 HD785-5
(13)
STRUCTURE AND FUNCTION ASR • II SYSTEM (OP)
CONTROLLER OF AUTOMATIC SPIN REGULATOR
1. Self-diagnosis display window FUNCTION

2. Printed circuit board This controller senses the speeds of both rear
3. Connector wheels with the wheel speed sensors. If the speed
4. Connector difference between both wheels increases, this
5. Connector controller applies the brake to the slipping wheel
6. Case so that the speeds of both wheels will be the same.
HD785-5 10-251
8
HYDRAULIC TANK PRESSURIZING SYSTEM
STRUCTURE AND FUNCTION (HIGH ALTITUDE SPECIFICATION)

(HIGH ALTITUDE SPECIFICATION)
HD785-5
10-252 HD785-5
A
1. Air tank (wet) OUTLINE

2. Regulator valve • The machine with high altitude specification
3. Hand valve prevents cavitation in the hydraulic pumps
4. Quick release valve by pressurizing hydraulic tank (8).
5. Muffler • The pressure in the air tank (wet) (1) is re-
6. Pressure switch duced (78.4 kPa {0.8 kg/cm2}) by regulator
7. Pressure caution lamp valve (2) and applied through hand valve (3)
8. Hydraulic tank and quick release valve (4) to the hydraulic
tank.
A. To regulator valve • If the pressure in the tank lowers below 34.3
B. From air tank (wet) kPa {0.35 kg/cm2}, pressure caution lamp (7)
lights up.
HD785-5 10-253
A
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM
10-254 HD785-5
A
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine related parts ....... 20- 2
Standard value table for chassis ............................ 20- 3
Standard value table for electrical parts ................ 20- 8
Testing and adjusting ................................................. 20-101
Troubleshooting ......................................................... 20-201
fl Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
¤ When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is
removed when the coolant is still hot, the coolant will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt or other rotating parts.
HD785-5 20-1
(15)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

The figures in [ ] are for mechanical governor specification machine.
Model HD785-5, 985-5
Engine SA12V140-1
Standard value Permissible value

Item Measurement conditions Unit
HD785-5 HD985-5 HD785-5 HD985-5
Power mode 2,350±50 2,450±50 2,350±50 2,450±50

High idle rpm
Economy mode 2,300±50 2,300±50 2,300±50 2,300±50
Hi 1,000±30 1,000±30 1,000±30 1,000±30

Engine speed Low idle rpm
Lo 650±25 650±25 650±25 650±25
Power mode 2,000±50 2,100±50 2,000±50 2,100±50

Rated speed rpm
Economy mode 1,900±50 1,900±50 1,900±50 1,900±50
At sudden acceleration Bosch 7.0 8.0

index
Exhaust gas color
At high idle Bosch
index 1.5 2.5
Intake valve mm 0.43 —

Valve clearance
(Normal temperature)
Exhaust valve mm 0.80 —
MPa
Compression pressure Oil temperature: 40 – 60˚C {kg/cm2} Min. 2.84{29} 1.96{20}
(SAE30 oil) (Engine speed) (rpm) (200 – 250) (200 – 250)
Blowby pressure (Coolant temperature:

Operating range) kPa
(SAE30 oil) {mmH 2O}
Max. 1.471{150} 2.942{300}
(Reference value) At rated output
(Coolant temperature:
Operating range)
At high idle 0.294–0.392{3.0–4.0} 0.206{2.1}
(SAE30) MPa
Oil pressure (SEA10W) {kg/cm2} Min. 0.118{1.2} Min. 0.069{0.7}
At low idle
(SAE30) Min. 0.1{1.0} Min. 0.069{0.7}
(SEA10W)
Whole speed range °C

Oil temperature (Inside oil pan) 90 – 120 120
deg. 18±1 18±1

Fuel injection timing Before top dead center [24±1] [24±1]
Deflection when pressed with

Belt tension (Alternator) finger force of approx. 58.8 {6 kg} mm 21 21±1
★ Engine speed of economy mode is not applied for mechanical governor specification machine.
20-2 HD785-5
(15)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Compo- Standard Permissible

nent Item Measurement conditions Unit value value
F1 • Engine coolant temperature: 10.7 ± 5% 10.7 ± 5%

Within operating range
F2 • Transmission oil temperature: 15.0 ± 5% 15.0 ± 5%
70 – 90˚C
• When empty
F3 20.0 ± 5% 20.0 ± 5%
• Traveling resistance: 3.3%
Performance
F4 26.8 ± 5% 26.8 ± 5%
Travel speed km/h
F5 36.0 ± 5% 36.0 ± 5%
F6 49.0 ± 5% 49.0 ± 5%
F7 65.0 ± 5% 65.0 ± 5%
R 11.4 ± 5% 11.4 ± 5%
Shift up • Engine coolant temperature: 2,100 ± 50 2,100 ± 50

High Within operating range
power • Transmission oil temperature: 1,450 ± 50 1,450 ± 50
70 – 90˚C
Automatic shift control
mode Shift down

• Hydraulic oil temperature: 1,400 ± 50 1,400 ± 50
50 – 80˚C (F2→F1 only) (F2→F1 only)
• “Braking mode” refers to
Shift up when the accelerator is OFF
rpm 2,000 ± 50 2,000 ± 50
or the rear brake is ON.
Economy
mode 1,350 ± 50 1,350 ± 50
Shift down
1,300 ± 50 1,300 ± 50
(F2→F1 only) (F2→F1 only)
Engine speed
Shift up 2,450 ± 50 2,450 ± 50

Braking
mode
Shift down 1,550 ± 50 1,550 ± 50
F1 • F2 1,500 1,500
Auto lock-up
Set
F3 – F7 1,250 ± 50 1,250 ± 50
rpm
F1 • F2 1,200 1,200
Reset
F3 – F7 1,100 ± 50 1,100 ± 50
Overrun
preven-
Set 2,600 ± 10 2,600 ± 10

tion
rpm
Reset 2,350 ± 10 2,350 ± 10
Same as shift Same as shift
down for auto- down for auto-
Down-shift inhibitor rpm matic shift con- matic shift con-
trol given above trol given above
• Transmission oil temperature: Serial No. Serial No.

70 – 90˚C 4001 – 4188 4001 – 4188
• Hydraulic oil temperature: 4187 and up 4187 and up
Torque converter
50 – 80˚C
High power
High power
• Engine coolant temperature: 2,040 1,890

2,040 1,890
mode
mode
Within operating range ± ± ± ±

Engine speed at torque rpm
converter stall 100 100 100 100
Economy
Economy
1,950 1,830 1,950 1,830

±
mode
mode
± ± ±
100 100 100 100
HD785-5 20-3
(15)
HD985-5
Compo- Standard Permissible
nent Item Measurement conditions Unit value value
• Engine coolant temperature: Standard tire

Within operating range (30.00R51)
• Transmission oil temperature:
F1 12 ± 5% 12 ± 5%
70 – 90˚C
F2 • Engine speed: 2,300 rpm 16 ± 5% 16 ± 5%
• When empty
Performance
F3 22 ± 5% 22 ± 5%
Travel speed km/h
F4 29 ± 5% 29 ± 5%
F5 39 ± 5% 39 ± 5%
F6 53 ± 5% 53 ± 5%
F7 70 ± 5% 70 ± 5%
R 13 ± 5% 13 ± 5%
Shift up • Engine coolant temperature: 2,230 ± 50

High Within operating range
power • Transmission oil temperature: 1,500 ± 50
70 – 90˚C
Automatic shift control
mode Shift down

• Hydraulic oil temperature: 1,400 ± 50
50 – 80˚C (F2→F1 only)
• “Braking mode” refers to
when the accelerator is OFF 1,800 ± 50
Shift up or the rear brake is ON.
rpm 1,200 ± 50
Economy (F2→F1 only)
mode
1,250 ± 50
Shift down
1,200 ± 50
Engine speed
(F2→F1 only)
Braking Shift up 2,450 ± 50

mode
Shift down 1,550 ± 50
1,500.........(F1 • F2) 1,500.........(F1 • F2)
lock-up
Set 1,250 ± 50 (F3 – F7) 1,250 ± 50 (F3 – F7)

Auto
rpm
1,200.........(F1 • F2) 1,200.........(F1 • F2)
Reset 1,100 ± 50 (F3 – F7) 1,100 ± 50 (F3 – F7)
2,600 ± 10 2,600 ± 10
Overrun
preven-
Set
tion
rpm
Reset 2,350 ± 10 2,350 ± 10
Same as shift Same as shift
down for auto- down for auto-
Down-shift inhibitor rpm matic shift con- matic shift con-
trol given above trol given above
• Transmission oil temperature:

High power
High power
70 – 90˚C
mode
mode
• Hydraulic oil temperature:

2,040 ± 100 2,040 ± 100
Torque converter
50 – 80˚C
• Engine coolant temperature:
Engine speed at torque
converter stall rpm
Economy
Economy
mode
mode
1,950 ± 100 1,950 ± 100
20-3-1 HD785-5
(15)
Com- Item
ponent
Measurement conditions Unit Standard value Permissible value
(Electronic (Mechanical (Electronic (Mechanical

Starting to • Operating effort at a point 150 governor governor governor governor
Accelerator pedal
Operating depress mm from pedal fulcrum N specification specification specification specification

effort {kg) machine) machine) machine) machine)
Fully 17.7±4.9 17.7±4.9 17.7±4.9 17.7±4.9
depressed {1.8±0.5} {1.8±0.5} {1.8±0.5} {1.8±0.5}
Starting to • Travel at a point 150 mm from 42.1 +2.0

–4.9 34.3±4.9 42.1 +2.0
–4.9 34.3±4.9
+0.2
Travel depress pedal fulcrum mm {4.3 –0.5 } {3.5±0.5} {4.3 +0.2
–0.5 } {3.5±0.5}
↔ fully 44 ± 5 32 ± 5 44 ± 5 32 ± 5
Operating effort • At center of lever knob N{kg) 15.7 ± 3.9 Max. 19.6 {2}
{1.6 ± 0.4}
Gearshift lever
R–N
N–D
D–5 mm
Travel 18.5±1 18.5±2
5–4
4–3
3–L
Engine at • Oil temperature: 70 – 90°C
Oil pressure high idle 0.78±0.1 {8±1} 0.78±0.1 {8±1}
at inlet port Engine at
low idle 0.127±0.049 {1.3±0.5} 0.127±0.049 {1.3±0.5}
Torque converter
Engine at
high idle 50 – 80°C 0.39±0.1 {4±1} 0.39±0.1 {4±1}
Oil pressure
at outlet port Engine at
low idle MPa 0.1±0.05 {1.0±0.5} 0.1 ± 0.05 {1.0±0.5}
Engine at {kg/cm2}
Lock-up oil high idle 1.57±0.049 {16±0.5} 1.57±0.049 {16±0.5}
pressure Engine at
low idle 1.57±0.049 {16±0.5} 1.57±0.049 {16±0.5}
Engine at
Main relief high idle 3.82±0.2 {39±2} 3.82±0.2 {39±2}
pressure Engine at
low idle 3.383±0.2 {34.5±2} 3.383±0.2 {34.5±2}
Engine at • Oil temperature: 70 – 90°C
L, H, high idle 1.618±0.147 {16.5±1.5} 1.618±0.147 {16.5±1.5}
4th • Engine coolant temperature:
Engine at Within operating range
clutch low idle 1.618±0.147 {16.5±1.5} 1.618±0.147 {16.5±1.5}
On actual machine
Engine at 50 – 80°C
3rd high idle 2.01±0.147 {20.5±1.5} 2.01±0.147 {20.5±1.5}
clutch Engine at
low idle 2.01±0.147 {20.5±1.5} 2.01±0.147 {20.5±1.5}
Control valve set pressure
1st, Engine at
high idle 3.089±0.147 {31.5±1.5} 3.089±0.147 {31.5±1.5}
2nd
clutch Engine at
3.089±0.147 {31.5±1.5} 3.089±0.147 {31.5±1.5}
Transmission
low idle
Engine at MPa
R high idle {kg/cm2} 2.94±0.147 {30±1.5} 2.94±0.147 {30±1.5}
clutch Engine at
low idle 2.94±0.147 {30±1.5} 2.94±0.147 {30±1.5}
Engine at
When using modulation checker
L, 4th high idle 1.687±0.2 {17±2} 1.687±0.2 {17±2}

clutch Engine at
low idle 1.687±0.2 {17±2} 1.687±0.217±2}
Engine at
H, 3rd high idle 1.96±0.2 {20±2} 1.96±0.2 {20±2}
clutch Engine at
low idle 1.96±0.2 {20±2} 1.96±0.2 {20±2}
1st, Engine at
high idle 3.24±0.2 {33±2} 3.24±0.2 {33±2}
2nd, R
Engine at
clutch low idle 3.24±0.2 {33±2} 3.24±0.2 {33±2}
20-4 HD785-5
(15)
Com-
ponent
Item Measurement conditions Unit Standard value Permissible value

Tires (infla- Transmission

• Engine: Full throttle kPa 122.6±49.0 122.6±49.0
Lubricating oil pressure • Oil temperature: 60 – 80°C {kg/cm2} {1.25±0.5} {1.25±0.5}
(using EO10-CD) or
Oil temperature: 70 – 90°C
(using EO30-CD)
tion pressure)
Stan- HD785-5: 27.00 R49✩✩ • When empty 0.686 +0.03 0.686 +0.03
HD985-5: 30.00 R51✩✩ 0 0
dard {7.0 +0.3
tires (Front and rear wheels) MPa 0 } {7.0 +0.3
0 }
Op- HD785-5: {kg/cm2}

0.549 0.549
tional 27.00-49-48PR {5.60} {5.60}
tires (Front and rear wheels)
Operating force • Oil temperature: 50 – 80°C
(Turning speed for • When machine stopped
steering wheel: 30 rpm) (empty) (If it is impossible Max. 29.4 Max. 35.3
N{kg) {Max. 3.0} {Max. 3.6}
when the machine stopped,
travel at low speed with
engine at low idle)
Steering wheel
Play • Length at circumference of

steering wheel mm 130±30 130±30
• Engine stopped
No. of turns • Lock → lock Turns 3.5±0.4 3.5±0.6
Left • Oil temperature: 50 – 80°C

→ right Max. 4 Max. 5
Turning • Engine speed: Whole range
• Lock → lock sec.
time Right Max. 4 Max. 5
→ left
Brake pedal Steering valve
Engine at • Oil temperature: 50 – 80°C 20.59 +1.47

–0 20.59 +1.47
–0
high idle • Engine: Full throttle {210 +15 {210 +15
–0 }
–0 }
Relief • Demand valve relief valve MPa
pressure {kg/cm2}
Engine at 18.14 +0.98
–0 18.12 +0.98
–0
low idle {185 +10
–0 } {185 +10
–0 }
• Tip of pedal Max. 294 Max. 294

Operating force N{kg} Max. {30} Max. {30}
Travel mm 78±8 78±15

governor brake lever lever control lever
• At point 10 mm from tip of N{kg} 9.81–36.32 4.90–54.48

Retarder
Operating force lever {1.0–4.0} {0.5–6.0}
Travel deg. 0–90±3 0–90±3

Emer- Parking
brake
N{kg} Max. 19.6 29.4

Operating force • Tip of lever Max. {2.0} {3.0}
gency
Operating force N{kg} 0.098–0.196 Max. 0.49

• Tip of lever {0.01–0.02} Max. {0.05}
• Pressure at which air is
stored and circuit is unloaded
Set pressure MPa 0.814±0.029 0.814±0.029
Air
when air pressure is raised 2

2
from 0 MPa {0 kg/cm } with {kg/cm } {8.3±0.3} {8.3±0.3}
engine at full throttle.
HD785-5 20-5
(15)
Com-
ponent
Service 91 ton payload • Initial speed: 32 km/h Max. 29 Max. 29

brake • Distance from starting to lose
braking speed to stopping
distance Empty • Max. actuating air pressure: Max. 22.3 Max. 22.3
0.814 MPa {8.3 kg/cm2} m
Retarder 91 ton payload • Max. hydraulic pressure
Rear: 4.41 MPa {45 kg/cm2} Max. 29 38
brake
braking Front: 18.34 MPa {187 kg/cm2}
distance Empty • On flat, dry road surface Max. 22.3 30
Brakes
Front • Max. actuating air pressure:

chamber Min. 15.69 {160} Min. 15.69 {160}
0.814 MPa {8.3 kg/cm2}
Brake • Engine: Stopped
actuat- Rear chamber MPa
(service) • When first operated {kg/cm2} Min. 4.41 {45} Min. 4.41 {45}
ing
pressure Rear chamber
(retarder) Min. 4.41 {45} Min. 4.41 {45}
Stopping distance when • Carrying 91 ton payload

emergency brake is • Initial speed: 32 km/h m Max. 60.9 Max. 60.9
applied • On flat, dry road surface
• With 91 ton payload
Braking capacity • After adjusting clearance % Min. 15 Min. 15
Parking brake
between disc and pad

HD785-5 HD785-5
• F2 Serial No. 4001 – 4187 Serial No. 4001 – 4187
• Torque converter stall Min. 2,040 Min. 2,040
Starting test rpm Serial No. 4188 and up Serial No. 4188 and up
Min. 1,860 Min. 1,860
HD985-5 HD985-5
Min. 2,070 Min. 2,070
HOLD • Center of control lever knob Max. 98.1 Max. 98.1
→ RAISE Max. {10} Max. {10}
RAISE Automatically Automatically
→ HOLD reset reset
HOLD 49.0–98.1 49.0–98.1
Operating → FLOAT {5–10} {5–10}
force N{kg}
FLOAT 29.4–58.8 29.4–58.8
→ HOLD {3–6} {3–6}
LOWER Automatically Automatically
→ FLOAT
Hoist lever
reset reset
FLOAT Max. 127.5 Max. 127.5
→ LOWER Max. {13} Max. {13}
RAISE
↔ HOLD (A) 15±2 15±2
HOLD
↔ FLOAT (B) mm 11±2 11±2
Travel
FLOAT
↔ LOWER (C) 11±2 11±2
Engine at • Oil temperature: 50 – 80°C 19.61 +1.47

–0 19.61 +1.47
–0
high idle {200 +15 {200 +15
valve
Hoist
Relief • Measure at end of stroke MPa –0 } –0 }

pressure when raising body {kg/cm2} +0.98
18.14 +0.98
Engine at 18.14 – 0 –0
low idle {185 +10
–0 } {185 +10
–0 }
20-6 HD785-5
(15)
Com-
ponent
• Oil temperature: 50 – 80˚C

Lifting speed • Engine: Full throttle 13±1.5 13±1.5
• Use FLOAT when lowering sec.
Lowering speed 17±1.5 17±1.5
Body
• Oil temperature: 50 – 80˚C

• Set with No. 2 cylinder mm
Hydraulic drift extended 200 mm Max. 85 170
• Hydraulic drift after 5 minutes
262±10 262±20
A • On flat road surface
• When empty 246±10 (*1) 246±20 (*1)
Front
Suspension cylinder
484±10 484±20
B
Installed 484±10 (*1) 484±20 (*1)
mm
length 240±10 240±20
HD785-5 HD785-5
220±10(*1) 220±20(*1)
Rear A
250±10 250±20
HD985-5 HD985-5
230±10(*1) 230±20(*1)
Front 3.874±0.49 3.874±0.49

{39.5±5} (*2) {39.5±5} (*2)
MPa
Pressure {kg/cm2}
Rear 2.550±0.49 2.550±0.49
{26.0±5} (*2) {26.0±5} (*2)
• F2 HD785-5 Serial No. 4001 – 4187

• Torque converter stall Min. 2,000 Min. 2,000
Within operating range HD785-5 Serial No. 4188 and up
Service brake
• Air pressure: 8.3 ± 0.3 kg/cm2 Min. 1,750 Min. 1,750
• Transmission oil temperature: HD985-5
70 – 90°C
• Hydraulic oil temperature: Min. 2,000 Min. 2,000
50 – 80°C HD785-5 Serial No. 4001 – 4187
Min. 1,500 Min. 1,500
Checking brake performance
HD785-5 Serial No. 4188 and up

Retarder brake
Min. 1,300 Min. 1,300
HD985-5
rpm Min. 1,500 Min. 1,500
HD785-5 Serial No. 4001 – 4187
Min. 2,040 Min. 2,040
Emergency brake Min. 1,890 Min. 1,890
HD985-5
Min. 2,070 Min. 2,070
HD785-5 Serial No. 4001 – 4187
Min. 2,040 Min. 2,040
Parking brake
Min. 1,890 Min. 1,890
HD985-5
Min. 2,070 Min. 2,070
*1. For cylinder with buffer ring. *2. This is a reference value. The actual value
depends on the body specification.
HD785-5 20-7
(15)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Connector Inpsec- Measurement

Name of component tion Judgement table
tem No. method conditions
Measure voltage
E13 If the condition is as shown in the table 1) Start engine.
Right rack sensor below, it is normal 2) Insert T-
(male)
adapter.
Between (1) – (2) Approx. 4.6 – 5.4 V 3) There must be
no disconnec-
E9 tion or short
Left rack sensor circuit in
(male)
wiring harness.
Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance
Right governor If the condition is as shown in the table 1) Turn starting
E15 below, it is normal switch OFF.
solenoid (male) 2) Disconnect
Between (1) – (2) 10 – 21 Ω E15.
Left governor solenoid E11

(male)
If the condition is as shown in the table 1) Turn starting

Right governor cut R22E below, it is normal switch OFF.
relay (male) 2) Disconnect
Between (1) – (2) 100 – 500 Ω R22E.
Between (3) – (6) Min. 1 Ω
Left governor cut relay R23E
(male) Between (3) – (5) Min. 1 MΩ

Engine controller
Right pre-stroke E14 below, it is normal switch OFF.

solenoid (male) 2) Disconnect
Between (1) – (2) Approx. 10 – 21 Ω E14.
Left pre-stroke E10

solenoid (male)

Engine speed below, it is normal
sensor A E16 (male) switch OFF.
2) Disconnect E16
Between (1) – (2) 500 – 1,000 Ω and E12.
Engine speed E12 (male)

sensor B

below, it is normal switch ON.
2) Insert T-
Accelerator at Approx. adapter.
WAS1 3.55 – 3.75 V 3) Accelerator
Accelerator sensor (male) FULL position Between pedal Lo↔
(2) – (3) Approx. FULL.
Accelerator at
Lo position 0.35 – 0.55 V
If the condition is as shown in the table

below, it is normal 1) Turn starting
Engine coolant switch OFF.
26 (male) Coolant temperature 25˚C Approx. 2) Disconnect 26.
temperature sensor (normal temperature) Between 37 – 50 kΩ
Coolant tempera- (1) – (2) Approx.
ture 100 °C 3.5 – 4.0 kΩ
20-8 HD785-5
(15)

Measure resistance Measure resistance Measure voltage

If the condition is as shown in the table 1) Start engine.
below, it is normal 2) Insert
T-adapter.
Engine oil pressure 27 (male)
sensor Between (1) – (3) Approx. 0.45 – 4.5 V

Line controller
below, it is normal switch OFF.

2) Disconnect
Idle validation WAS1 Accelerator at No WAS1.
switch 2 (male) FULL position Between continuity
(5) – (6)
Accelerator at Continuity
Lo position

2) Disconnect
Idle validation WAS1 Accelerator at WAS1.
FULL position Continuity
switch 3 (male) Between
Accelerator at (4) – (6) No
Lo position continuity

2) Insert T-
Voltage value adapter.
When When not
selected selected
Measure voltage
Between (3)–(2) R Min.1.0V Max.15.0V

Between (4)–(2) N Min.1.0V Max.15.0V
Shifter lever SF (male) Between (5)–(2) D Min.1.0V Max.15.0V
Between (6)–(2) 5 Min.1.0V Max.15.0V
Transmission controller

Between (9)–(2) L Min.1.0V Max.15.0V
Between (1) – (2) 11.0 – 13.0V
Measure resistance Measure resistance
HPS (male) Between (1) – (2) 5 – 25 Ω 1) Turn starting

LPS (male) switch OFF.
RPS (male) ª 13.85Ω (20˚C) ± 5% 2) Disconnect PS
Pressure control valve connector.
solenoid 1PS (male)
2PS (male)
3PS (male)
4PS (male)
1) Turn starting
Between (1) – (2) 30 – 80 Ω switch OFF.
2) Disconnect
Lock-up solenoid L/CT(male) L/CT.
HD785-5 20-9
(15)

Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance
Between (1) – (2) 20 – 60 Ω 1) Turn starting
switch OFF.
Exhaust brake 2) Disconnect
solenoid SL5 (male) SL5.
Between (1) – (2) 20 – 60 Ω 1) Turn starting

switch OFF.
Rear brake 2) Disconnect
(Overrun prevention) SL4 (male) SL4.
solenoid
Oil Measure 1) Turn starting

temperature resistance switch OFF.
2) Disconnect
Transmission oil Normal tempera- C/VT.
ture (25˚C) Between 37 – 50 kΩ
temperature sensor C/VT (male)
(1) – (2)
100˚C 3.5 – 4.0 kΩ
Between (1) – (2) 100 – 500 Ω Check as

individual part
Relay Between (3) – (6) Max. 1 Ω
(Check as individual R01 – R29
(Except R09,11) Between (3) – (5) Min. 1 MΩ
part)
Between (5) – (6) 100 – 500 Ω Check as

individual part
Relay Between (3) – (4) Max. 1 MΩ
(Check as individual R09
R11 Between (1) – (2) Min. 1 MΩ
part)
Between (1) 1) Turn starting

HSW (male) Switch OFF Min. 1 MΩ switch OFF.
LSW (male) – chassis
2) Disconnect
RSW (male) switch
Fill switch 1SW (male) connector.
2SW (male)
3SW (male)
4SW(male)

below, it is normal 2) Insert T-
Engine oil pressure adapter.
sensor
 27 (male) Between (1) – (3) Approx. 0.45 – 4.5 V
mechanical 
governor specifica-
tion machine 
20-10 HD785-5
1

Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance
When engine is running 1) Start engine.
(1/2 throttle or above) → 27.5 – 29.5 V
Alternator ª If the battery is old, or after starting in
Alternator terminal cold areas, the voltage may not rise
R – chassis for some time.
If the condition is within the range shown 1) Turn starting

in the table below, it is normal switch OFF.
2) Disconnect
Approx.160 Ω
Air pressure sensor SR5 (male) Air pressure or less, or SR5.
0.81MPa {8.3kg/cm2} Between approx. 320 Ω
Air pressure
(1) – (2) Approx.640 Ω
or
0.51MPa {5.2kg/cm2} approx. 800 Ω
Engine coolant If the condition is within the range shown 1) Turn starting
temperature sensor in the table below, it is normal switch OFF.
(mechanical governor 2) Disconnect 26,
specification machine)26 (male) Normal tempera- Approx. TC.SE, and 64.
TC.SE(male) ture (25˚C) Between 37 – 50 kΩ
Torque converter oil 64 (male)
temperature sensor (1) – (2) Approx.
Retarder oil 100˚C
3.5 – 4.0 kΩ
temperature sensor

2) Disconnect 61.
Fuel level sensor 61 (male) Full (1) – Approx. 12 Ω or less
sensor
Empty flange Approx. 85 – 110 Ω

Transmission input in the table below, it is normal switch OFF.
shaft speed sensor N1 (male) 2) Disconnect
Transmission N1 – N3.
intermediate shaft Between (1) – (2) 500 – 1,000 Ω
N2 (male)
speed sensor
Transmission output N3 (male)
shaft speed sensor

2) Disconnect
Between (1) – (2) 500 – 1,000 Ω E12.
Engine speed sensor B E12 (male)

2) Disconnect 21.
Steering oil tempera- Oil temperature 25˚C No
21 (male) Between (normal temperature) continuity
ture sensor
(1) –
chassis Oil temperature No
above 123˚C continuity
HD785-5 20-11
(15)

Measure resistance
in the table below, it is normal switch ON.
2) Insert
Accelerator sensor WAS2 Accelerator at Approx. T-adapter.
(male) Max. position 1.0 – 1.4 V 3) Accelerator
Between
(1) – (2) pedal MIN
Accelerator at Approx. ↔ MAX
Min. position 3.6 – 4.0 V

Continuity
2) Disconnect
Differential DLB.
Differential lock switch DLB (male) pedal ON Continuity
Between
(3) – (4) Differential No
pedal OFF continuity

Continuity
2) Disconnect
Air pressure AS3.
Retarder switch AS3 (male) Min. 0.14 MPa Continuity
Between {1.4 kg/cm2}
(1) – (2) Air pressure No
Max. 0.06 MPa
{0.6 kg/cm2} continuity

Measure voltage

Air pressure 2) Disconnect
Service brake switch AS5 (male) Min. 0.06 MPa Continuity AS5.
Max. 0.02 MPa

Continuity

Emergency brake No AS4.
switch AS4 (male) Min. 0.48 MPa
Between {4.9 kg/cm2} continuity
(1) – (2) Air pressure
Max. 0.36 MPa Continuity
{3.7 kg/cm2}

Continuity
2) Disconnect
Air pressure
Parking brake switch AS2 (male) Min. 0.56 MPa AS2.
Continuity
Max. 0.36 MPa

Continuity
2) Disconnect
Body FLOAT switch RH2 (male) Dump lever at No RH2.
Between FLOAT continuity
(7) – (9) Dump lever at position
other than FLOAT Continuity
20-12 HD785-5
1

Continuity
2) Disconnect
Body seated switch DB1 (male) No DB1.
Body seated continuity
Between
(1) – (2) Body not
seated Continuity

Continuity
2) Disconnect
Tilt sensor SR3 (male) No SR3.
Between Tilt 17˚ or more continuity
(1) – (2)
Tilt 13˚ or less Continuity

Continuity
2) Disconnect
Body RAISE switch RH2 (male) Dump lever at No RH2.
Between RAISE continuity
(7) – (8) Dump lever at
position other than Continuity
RAISE

Continuity
2) Disconnect 52.
Transmission filter 52 (male) No
clogging sensor Between Filter normal continuity
(1) – (2)
Filter clogged Continuity

Continuity
2) Disconnect
BLSR(male) Stroke normal Continuity BLSR and
Brake stroke switch BLSL(male) Between BLSL.
(1) – (2) No
Large stroke continuity

Continuity

Exhaust brake switch AS1 (male) Min. 0.36 MPa Continuity AS1.
Max. 0.32 MPa
Engine running → Min. 20V 1) Start engine.

Continuity
Relay
Emergency steering terminal 78
timer relay – chassis
HD785-5 20-13
1

Continuity
2) Disconnect
Switch ON Continuity SH.
Shift limit switch SH (male) Between
(2) – (4) No
Switch OFF continuity

Continuity
2) Disconnect 03.
Radiator coolant
Radiator coolant level 03 (male) level normal Continuity
switch Between
(1) – (2) Radiator coolant No
level abnormal continuity

Continuity
2) Disconnect
Switch ON Continuity PW.
Power mode switch PW (male) Between
(2) – (4) No
1) Remove sensor
Measure voltage
FR suspension If the condition is within the range shown from suspen-

pressure sensor 63 (male) in the table below, it is normal sion cylinder.
2) Insert T-adapter.
Between each Approx. 3) Check that there is
connector (3) – chassis 0.45 – 1.50 V no disconnection
or short circuit in
FL suspension 62 (male) wiring harness.
pressure sensor 4) Turn starting
switch ON.
Measure resistance

2) Disconnect
Transmission output Between (1) – (2) 500 – 1,000 Ω N3.
Suspension controller
shaft speed sensor N3 (male)

Continuity
Air pressure
2) Disconnect
Emergency brake Min. 0.48 MPa No AS4.
AS4 (male) continuity
switch {4.9 kg/cm2} Between
Air pressure (1) – (2)
Max. 0.36 MPa Continuity
{3.7 kg/cm2}

Continuity
Air pressure
2) Disconnect
Min. 58.8 kPa Continuity AS5.
Service brake switch AS5 (male) {0.6 kg/cm2} Between
Air pressure (1) – (2) No
Max. 19.6 kPa
20-14 HD785-5
(15)

Measure resistance
SL1 (male) in the table below, it is normal switch OFF.
2) Disconnect SL1,
Suspension control Between (1) – (2) 20 – 60 Ω SL2, and SL3.
SL2 (male)
solenoid valve 3) Put black pole of

tester in contact
with (1); put red
SL3 (male) pole in contact
with (2).

Continuity
2) Disconnect
Body FLOAT switch No RH2.
RH2 (male) Lever at FLOAT continuity
Between
Lever at position (7) – (9)
other than FLOAT Continuity
FR suspension If the condition is within the range shown 1) Remove

39 (male) in the table below, it is normal sensor from
pressure sensor
suspension
Between each Approx. cylinder.
connector (3) – chassis 0.45 – 1.50 V 2) Insert
Measure voltage
FL suspension T-adapter.
pressure sensor 13 (male) 3) Check that
there is no dis-
connection or
short circuit in
Payload meter
RR suspension wiring harness.

pressure sensor 63 (male) 4) Turn starting
switch ON.
RL suspension 62 (male)
pressure sensor
If the condition is within the range shown 1) Stop chassis at

Measure voltage
in the table below, it is normal horizontal place.

2) Check that there
is no disconnec-
Clinometer Between (1) – (2) Approx. 2.1 – 3.1 V tion or short cir-
PM3
cuit in wiring har-
ness.
3) Insert T-adapter.
4) Turn starting
switch ON.
Measure voltage Measure resistance
If the condition is within the range shown 1) Disconnect

in the table below, it is normal terminal.
Engine oil pressure 2) Start engine.
sensor 27 (male) Min. 68.6 kPa
Between
{0.7 kg/cm2} Max. 1 Ω
sensor
Chassis monitor
terminal Max. 29.4 kPa

– chassis {0.3 kg/cm2} Min. 1 MΩ
When engine is running 1) Start engine.

(1/2 throttle or above) → 27.5 – 29.5 V
Alternator ª If the battery is old, or after starting in
Alternator terminal R cold areas, the voltage may not rise
– chassis for some time.
HD785-5 20-15
1

Measure voltage
2) Disconnect
Max. approx. SR5.
Air pressure sensor SR5 (male) Air pressure 3 Ω or
0.93MPa {9.5kg/cm2} Between approx. 160 Ω
Air pressure (1) – (2) Approx.640 Ω
or
0.51MPa {5.2kg/cm2} approx. 800 Ω
Measure resistance Measure resistance Measure resistance Measure resistance

Engine coolant in the table below, it is normal switch OFF.
temperature sensor 26 (male) 2) Disconnect 26,
Torque converter oil TC.SE(male) Normal tempera- Approx. TC.SE, and 64.
temperature sensor 64 (male) ture (25˚C) Between 37 – 50 kΩ
Retarder oil (1) – (2) Approx.
temperature sensor 100˚C
3.5 – 4.0 kΩ

2) Disconnect 61.
Fuel level sensor Full (1) – Approx. 12 Ω or less
61 (male) sensor
Empty flange Approx. 85 – 110 Ω

Chassis monitor

2) Disconnect
Transmission output Between (1) – (2) 500 – 1,000 Ω N3.
shaft speed sensor N3 (male)

2) Disconnect E6.
Engine speed sensor B Between (1) – (2) 500 – 1,000 Ω
E6 (male)
If the condition is within the range shown 1) Start engine.

in the table below, it is normal 2) Disconnect 52.
Continuity
Transmission filter Filter normal Continuity

clogging sensor 52 (male) Between
(1) – (2) No
Filter clogged continuity

Continuity
2) Disconnect
Caution pilot lamp Switch ON Continuity GK1.
bulb check switch GK1 (male) Between
(1) – (2) No
20-16 HD785-5
(15)

below, it is normal 2) Disconnect
Continuity
MM19 MM19 and
(male) No retarder MM20.
Retarder wear sensor Continuity 3) Actuate
MM20 wear Between
(male) (1) – (2) retarder brake.
No
Retarder wear continuity
Measure voltage
2) Insert T-
Accelerator sensor WAS1 Accelerator at Approx. 3.55 adapter.
(male) FULL position Between – 3.75 V 3) Accelerator
(1) – (2) pedal Lo ↔
Accelerator at Approx. 0.35 FULL.
Lo position – 0.55 V

Continuity
2) Disconnect
Idle validation switch 2 WAS1 Accelerator at No WAS1.
(male) FULL position Between continuity
(5) – (6)
Accelerator at
Lo position Continuity

PMC system
Continuity
2) Disconnect
Idle validation switch 3 WAS1 Accelerator at WAS1.
(male) FULL position Between Continuity
(4) – (6)
Accelerator at No
Lo position continuity

Continuity
2) Disconnect
Service brake switch AS5 (male) Air pressure 58.8 kPa No AS5.
{0.6 kg/cm2} or above Between continuity
Air pressure 19.6 kPa (1) – (2)
{0.2 kg/cm2} or above Continuity

Continuity
2) Disconnect
Emergency brake AS4 (male) Air pressure 0.481 MPa No AS4.
switch {4.9 kg/cm2} or above Between continuity
Air pressure 0.363 MPa (1) – (2)
{3.7 kg/cm2} or above Continuity
Measure resistance

Transmission input 2) Disconnect N1
shaft speed sensor N1 (male) Between (1) – (2) 500 – 1,000 Ω and N3.
Transmission output N3 (male)
shaft speed sensor
20-20 HD785-5
(15)
Tools for testing, adjusting and troubleshooting ................................................................................ 20-102
Adjusting valve clearance ...................................................................................................................... 20-104
Measuring compression pressure ........................................................................................................ 20-105
Measuring blowby pressure .................................................................................................................. 20-106
Measuring boost pressure ..................................................................................................................... 20-107
Measuring exhaust temperature ........................................................................................................... 20-108
Testing and adjusting fuel injection timing .......................................................................................... 20-109
Adjusting alternator belt tension .......................................................................................................... 20-112
Adjusting engine speed sensor ............................................................................................................. 20-113
Adjusting transmission speed sensor .................................................................................................. 20-113
Adjusting accelerator pedal ................................................................................................................... 20-114
Testing hydtaulic pressure of torque converter valve ......................................................................... 20-115
Testing ECMV hydraulic pressure ...................................................................................................... 20-115-2
Testing transmission lubrication pressure ........................................................................................... 20-118
Testing torque converter stall speed .................................................................................................... 20-119
Testing brake pressure ........................................................................................................................... 20-121
Bleeding air from brake circuit .............................................................................................................. 20-122
Testing wear of front brake pad ............................................................................................................ 20-122
Testing wear of rear brake disc ............................................................................................................. 20-123
Adjusting parking brake ......................................................................................................................... 20-124
Testing brake performance .................................................................................................................... 20-125
Testing and adjusting front suspension cylinder (with variable damping force selector valve) ..... 20-126
Testing and adjusting inverted type rear suspension cylinder ........................................................... 20-130
Testing and adjusting suspension air cylinder .................................................................................... 20-134
Testing and adjusting air pressure in air circuit ................................................................................... 20-135
Inspection of air drier (desiccant type) .............................................................................................. 20-135-1
Adjusting hoist lever linkage ................................................................................................................. 20-136
Adjusting body positioner ..................................................................................................................... 20-137
Testing and adjusting hydraulic pressure in steering, hoist circuit ................................................... 20-138
Air bleeding from steering cylinder ...................................................................................................... 20-140
Adjusting electronic monitor (speedometer, tachometer module) .................................................... 20-141
Adjusting Q [fuel injection amount] when replacing engine controller ............................................ 20-142
Setting rotary switch (model data, network data) when replacing transmission controller ........... 20-143
Method of deleting data from engine controller, transmission controller and PMC memory
(control from monitor panel) .............................................................................................................. 20-144
Method for emergency escape when there is failure in electrical system ........................................ 20-147
Procedure for operating modulation checker ...................................................................................... 20-153
Adjusting hydraulic tank pressure (High altitude specification) ........................................................ 20-158
Performing Pm clinic using manual snapshot (= quick PM) ............................................................... 20-159
Pm-clinic service ..................................................................................................................................... 20-163
HD785-5 20-101
(16)
TOOLS FOR TESTING, ADJUSTING AND
TESTING AND ADJUSTING TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Measurement item Symbol Part No. Part Name Remarks
799-205-1100 Tachometer KIT

Digital display: 6 – 99999.9 rpm
Engine speed A 6215-81-3500 Thermometer drive
6210-81-4111 Gear box —

Coolant, exhaust, and oil Digital temperature
temperatures B 799-101-1502 gauge –99.9 – 1,299˚C
Pressure gauge: 2.4,5.9,39.2,58,8 MPa
799-101-5002 Hydraulic tester {25,60,400,600kg/cm2}
1
Oil pressure C 790-261-1204 Digital hydraulic tester Pressure gauge: 58.8 MPa{600 kg/cm2}
2 799-401-2320 Hydraulic gauge 1.0 MPa{10 kg/cm2}
1 795-502-1590 Gauge assembly 0 – 0.69 MPa {0 – 70 kg/cm2}

Compression pressure D Kit Part No.: 795-502-1205
2 795-502-1500 Adapter assembly
1 799-201-1511 Nozzle
2 799-201-1450 Adapter Kit Part No.: 799-201-1504

Blow-by pressure E
3 799-201-1571 Tube
Measurement range:
5 799-201-1590 Gauge 0 – 9.80 kPa {0 – 1,000 mmH2O}
795-125-1210
Valve clearance F or Feeler gauge —
commercially
available
Air supply pressure –101.32 – 199.98 kPa
(boost pressure) V 799-201-2202 Boost gauge KIT {–760 – 1,500 mmHg}
Fuel injection timing Dial gauge as commercially
adjustment R 795-471-1200 Gauge assembly available
799-201-9001 Handy smoke checker
Exhaust color G Bosch index: 0 – 9
Commercially
available Smoke meter
79A-264-0091 Push-pull scale 0 – 490 N {0 – 50 kg}

Operating effort H
79A-264-0021 Push-pull scale 0 – 294 N {0 – 30 kg}
Commercially
Stroke, hydraulic drift I available Scale —
J Commercially Stopwatch
Work equipment speed available —
1 561-98-61120 Disc gauge For brake (ª1)

Disc wear K
2 561-98-61122 Disc gauge For brake (ª2)
Voltage, resistance L 79A-261-0211 Tester
This includes all the T-adapters

used on this machine. Depending
on the attachments and specifica-
tions, the following part numbers
Sensors, are also available.
wiring harnesses M 799-601-7400 T-adapter kit
• 799-601-2900
• 799-601-7300 799-601-7000

799-601-7200

For details of the above,
see Service Mate SMP-405.
ª1. HD785-5 Serial No.: 4001 – 4253, HD985-5 Serial No.: 1021 and up
ª2. HD785-5 Serial No.: 4254 and up
20-102 HD785-5
(16)
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE

Measuring conditions
1) Coolant temperature: Within operating range
2) Transmission oil temperature: 70 – 90°C
3) Hydraulic oil temperature: 50 – 80°C
fl If the temperatures are not as given above,
warm up the engine until the temperature
conditions are reached.
1. Install tool E1 to one end of the blowby hose, and

install tool E2 to the hose at the other end.
fl Block the gauge mounting hole of E2.
2. Start the engine, and measure the blowby pres-

sure when the engine is run at near the rated
speed.
fl For details, see the STANDARD VALUES
TABLE.
20-106 HD785-5
(15)
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
ADJUSTING ACCELERATOR PEDAL

1. Adjust dimension a of low idle stopper bolt (1),
and adjust clearance b at the low idle end.
Dimension a of stopper bolt: 19.3 mm
Clearance b: 8 ±␣ 0.1 mm
2. Adjust dimension c of high idle stopper bolt (2),

and adjust clearance d at high idle end.
Dimension c of stopper bolt: 25.5 mm
Clearance d: 2.5 ±␣ 0.1 mm
3. After adjusting, measure the output voltage of the

accelerator sensor.
Sensor output voltage: See Standard Value Table
20-114 HD785-5
(15)
TESTING HYDRAULIC PRESSURE OF
TESTING AND ADJUSTING TORQUE CONVERTER VALVE
TESTING HYDRAULIC PRESSURE

OF TORQUE CONVERTER VALVE
¤ Raise the dump body and lock it with the safety
pin.
¤ The oil is at high temperature, so be careful not
to get burned.
¤ Always remove and install the plugs and hydrau-
lic pressure gauge with the engine stopped.
fl Measure the oil pressure at the specified oil tem-

perature.
• For details, see the Standard Values Table.
• Using the following table for reference, install tool
C or tool S to the measurement plug.
Measurement location Gauge MPa {kg/cm2}

1 Main relief pressure 5.89 MPa {60 kg/cm2} (C)
Torque converter inlet port
2 pressure (IN) 0.98 MPa {10 kg/cm2} (S)
Torque converter outlet port
3 pressure (OUT) 2.45, 0.98 MPa {25, 10 kg/cm2} (C)(S)
Torque converter lock-up
4 pressure (LU) 5.89 MPa {60 kg/cm2} (C)
1. Measuring main relief pressure

Place the gearshift lever at N, and measure the
main relief pressure at low idling and high idling.
2. Measure the hydraulic pressure at the torque
converter inlet port (relief).
3. Measure the hydraulic pressure at the torque
converter outlet port (regulator).
Place the gearshift lever at N, and measure the
torue converter inlet port and outlet port pressure
at low idling and high idling.
4. Measuring torque converter lock-up pressure
1) Disconnect the connector from the transmis-
sion controller, and install tool N.
2) After pushing 4th button on the tool N, push
lock up buttom.
3) Measure the lock-up pressure at low idling
and high idling.
fl For details of the procedure for operating the
shift checker and modulation checker, see
PROCEDURE FOR OPERATING MODULATION
CHECKER.
HD785-5 20-115
(15)
TESTING AND ADJUSTING TESTING ECMV HYDRAULIC PRESSURE
TESTING ECMV HYDRAULIC PRESSURE

(Using modulation checker)
¤ Stop the machine on flat ground and block the
tires.
pin.
to get burned.
1. Transmission modulating pressure (clutch circuit

pressure)
fl Measure the hydraulic pressure at the speci-
fied oil temperature.
• For details, see the Standard Value Table.
1) Measure the main relief pressure and check
that it is normal.
2) Remove plugs (1) - (7) from the locations to
measure the hydraulic pressure, then install
tool C. [Oil pressure gauge for all places: 5.88
MPa {60 kg/cm2}].
Plug No. Hydraulic circuit measured

(1) H clutch
(2) L clutch
(3) 4th clutch
(4) 3rd clutch
(5) R clutch
(6) 2nd clutch
(7) 1st clutch
3) Install tool N.
fl For details, see PROCEDURE FOR MODU-
ECMV
LATION CHECKER.
4) Run the engine at low idle, operate checker ECMV
N, and press the clutch button of the clutch to Speed R 1st 2nd 3rd 4th L H
be measured. (One of R, 1st, 2nd, 3rd, 4th, L, range
or H). F1 c c
5) Measure the pressure of each clutch with the F2 c c
engine at low idle and high idle.
F3 c c
fl After completing the measurement, press
the clutch button of the clutch that was F4 c c
measured to stop the output. F5 c c
Note: To protect the clutch, always run the en-
F6 c c
gine at low idle when operating checker N.
F7 c c
N
R1 c c
HD785-5 20-115-2
(15)
TESTING AND ADJUSTING TESTING TRANSMISSION LUBRICATION PRESSURE
TESTING TRANSMISSION LU-

BRICATION PRESSURE
pin.
to get burned.
fl Measure the hydraulic pressure at the specified oil

temperature.
• For details, see the STANDARD VALUES TABLE.
1. Remove plug (1) and install tool S [0.98 MPa {10

kg/cm2}].
2. With the gearshift lever at N, measure the hydrau-

lic pressure at high idle.
20-118 HD785-5
(15)
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
TESTING TORQUE CONVERTER

STALL SPEED
¤ Stop the machine on flat ground and block the
tires.
1. Remove rotation pickup port cover (1), and install

tool A2.
2. Raise the engine water temperature to the oper-
ating range.
3. Measure the engine high idle and low idle speeds.
fl If the speed is too low, check the movement
of the linkage between the accelerator pedal
and fuel pump, and check that the accelera-
tor lever of the fuel pump contacts the FULL
stopper.
4. Raise the temperature of the hydraulic oil and
transmission oil.
fl Oil temperature when measuring:
Hydraulic oil 50 – 80˚C
Transmission 70 – 90˚C
5. Apply the parking brake and depress the brake
pedal fully, then place the gear shift lever at the D
position or use the checker and set to the F7 posi-
tion.
fl For details of the method of using the shift
checker, see "Procedure for operating shift
checker + modulation checker".
6. Depress the accelerator pedal gradually and stall
the torque converter with the engine at full
throttle. If the oil temperature exceeds 90°C (po-
sition A on the green range of the torque con-
verter oil temperature gauge lights up), lower the
engine speed to low idle and return the gear shift
lever to the "N" position.
With the gear shift lever at "N", run the engine at
a mid range speed and lower the oil temperature
until position B on the green range of the torque
converter oil temperature gauge lights up.
Lower the engine speed to low idling, carry out
the above Steps 4) to 6) again to make the oil tem-
perature of the torque converter and transmission
uniform, then measure the stall speed when the
oil temperature is approx. 80°C (position B on the
green range of the torque converter oil tempera-
ture gauge lights up).
fl Measure the stall speed two or three times.
¤ Do not operate the gear shift lever with the ac-

celerator pedal depressed.
This will cause a violent shock and will also re-
duce the life of the machine.
HD785-5 20-119
(15)
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR

BRAKE DISC
HD785-5 Serial No.: 4001 – 4253
¤ Stop the machine on level ground, apply the

parking brake, and put blocks under the tires.
¤ Install and remove plugs and gauges with the
brake cooling oil temperature below 60˚C and
with the retarder brake control lever at the OFF
position.
¤ If the disc is near the wear limit, check the wear
frequently, regardless of the maintenance inter-
val. In addition, check the performance of the
retarder carefully.
1. Remove air bleed plug (1) of the rear brake, then
install disc wear measurement gauge K.
When installing, tighten nipple [2] completely and
pull rod [1] of disc wear measurement gauge K
fully.
¤ Pull rod [1] of gauge K fully before operat-
ing the retarder brake.
2. Turn the starting switch ON, and check that the
air pressure gauge is in the green range.
3. If the air pressure is low, start the engine and run
it at 2000 rpm until the air pressure gauge enters
the green range. When it enters the green range,
turn the starting switch OFF.
4. Pull rod [1] of disc wear measurement gauge K
fully, then operate the retarder brake control le-
ver slowly (take approx. 10 sec.) to apply the
brake.
5. In this condition, push in rod [1] of disc wear mea-
surement gauge K until it contacts the piston.
6. If mark a on disc wear measurement gauge K goes
in beyond the end face (portion b) of the case,
the disc has reached the wear limit.
7. After checking the brake wear, pull back rod 1 of
wear measurement gauge K fully, then release the
retarder brake.
¤ After checking the wear, if the retarder brake
control lever is pulled suddenly, there is
seious danger that the rod of the disc wear
measurement gauge may fly out suddenly.
for this reason, when the rod is fully pulled,
release it, then pull the retarder control
lever slowly over a period of approx. 10 sec-
onds. (Release the retarder brake.)
8. After measuring the brake wear, install the air
bleed plug, and bleed the air.
For details, see Bleeding air from brake circuit.
HD785-5 20-123
(15)
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
¤ Stop the machine on level ground, apply the

parking brake, and put blocks under the tires.
¤ Install and remove plugs and gauges with the
brake cooling oil temperature below 60˚C and
with the retarder brake control lever at the OFF
position.
¤ If the disc is near the wear limit, check the wear
frequently, regardless of the maintenance inter-
val. In addition, check the performance of the
retarder carefully.
1. Remove plug (1) of the rear brake, then install disc
wear measurement gauge K.
When installing, tighten nipple [2] completely and
pull rod [1] of disc wear measurement gauge K
fully.
fl Pull rod [1] of gauge K fully before operating
the retarder brake.
2. Turn the starting switch ON, and check that the
air pressure gauge is in the green range.
3. If the air pressure is low, start the engine and run
it at 2000 rpm until the air pressure gauge enters
the green range. When it enters the green range,
turn the starting switch OFF.
4. Pull rod [1] of disc wear measurement gauge K
fully, then operate the retarder brake control le-
ver slowly (take approx. 10 sec.) to apply the
brake.
5. In this condition, push in rod [1] of disc wear mea-
surement gauge K until it contacts the piston.
6. If mark a on disc wear measurement gauge K goes
in beyond the end face (portion b) of the case,
the disc has reached the wear limit.
7. After checking the brake wear, pull back rod [1] of
wear measurement gauge K fully, then release the
retarder brake.
¤ After checking the wear, if the retarder brake
control lever is pulled suddenly, there is
seious danger that the rod of the disc wear
measurement gauge may fly out suddenly.
for this reason, when the rod is fully pulled,
release it, then pull the retarder control
lever slowly over a period of approx. 10 sec-
onds. (Release the retarder brake.)
8. After measuring the brake wear, install the plug,
and bleed the air.
For details, see Bleeding air from brake circuit.
20-123-1 HD785-5
(13)
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
TESTING BRAKE PERFORMANCE

Measurement conditions
• Air pressure: 0.814 MPa {8.3±0.3 kg/cm2}
• Hydraulic oil temperature: 50 – 80°C
• Transmission oil temperature: 70 – 90°C
¤ Stop the machine on a horizontal road sur-

face, and check that there is no one around
the machine before carrying out the check.
1. Measurement items
1) Parking brake
2) Service brake (front + rear brake)
3) Retarder brake (rear brake only)
4) Emergency brake (parking brake + service
brake)
2. Measurement procedure
1) Install the engine tachometer.
For details, see Measuring torque converter
stall speed.
2) Measure Items 1) – 4).
i) Raise the air pressure to the maximum,
operate each brake in Items 1) – 4) indi-
vidually, and set the gear shift lever at the
"D" position.
ii) Gradually depress the accelerator pedal
to raise the engine speed, and measure
the engine speed at the point where the
machine starts to move.
HD785-5 20-125
(15)
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
fl When the oil level valve is loosened, and

oil and gas spurt out together, tighten the
valve slightly, and allow time for the gas
to escape slowly.
iii) Operate the hydraulic jack so that dimen-
sion a of the cylinder is the specified di-
mension for the oil level.
Dimension a:
: 97±3 mm (HD785-5 Standard)
: 81±3 mm (HD785-5 With buffer ring)
Thickness of frange b:
: 49 mm (Standard)
: 65 mm (With buffer ring)
3. Adjusting of oil level

fl Release the nitrogen gas before adjusting the
oil level.
1) Remove supply vavle (3), and install joint P5.
2) Install fitting P4 to joint P3, then connect hose
P2 and volume pump P1.
3) Loosen air bleed valve (4), then operate vol-
ume pump P1 until no more bubbles come
out with the oil from air bleed side hole [a].
4) When no more bubbles come out with the oil,
tighten air bleed valve (4).
5) Remove oil level valve (1), then operate vol-
out with the oil from the oil level valve mount.
tighten the oil level valve.
7) After completion of supplying the oil, remove
the volume pump, then install supply valve
(3).
HD785-5 20-127
(13)
4. Filling suspension cylinder with gas

1) Remove cap (5) from supply valve cap (3).
2) Set tool P as shown in the diagram.
fl Before installing regulator P10, blow the
connector filter with nitrogen gas at 0.981
MPa {10 kg/cm2} or more to blow out all
dirt or dust. (Dirt or dust in the system
causes failures.)
3) Open valve [c] of the gas cylinder (6), and
check the pressure reading of gauge P10a (in-
ternal pressure of gas cylinder).
fl The pressure indicated must be at least
0.981 MPa {10 kg/cm2} higher than the
pressure inside the suspension cylinder
(max. pressure inside suspension cylin-
der: 4.02 MPa {41 kg/cm2}).
4) Turn handle [d] of regulator P10 slowly clock-
wise, set the pressure reading of gauge P10b
to 0.981 MPa {10 kg/cm2} above the internal
pressure of the suspension cylinder, then op-
erate valves P6 and P9 to fill the suspension
cylinder with nitrogen gas.
fl Fill the left and right cylinders in the same
way.
5) When dimension a of the left and right cylin-
ders reaches the standard value, turn handle
[d] of regulator P10 counterclockwise to stop
the flow of nitrogen gas.
fl Standard dimension a: See STANDARD
VALUE TABLE.
6) Turn handle [e] of P9 fully back counterclock-
wise, loosen air bleed plug [f], release the gas
inside the hose, then remove tool P.
fl Be careful not lose the O-ring of the sup-
ply valve.
5. Adjusting installed length of cylinder

fl Carry out adjustment of the installed length
of the cylinder with the machine-empty and
on level ground.
1) To remove the sliding resistance of the cylin-
der (catching of bushing or packing), drive the
machine forward approx. 15 m and stop sud-
denly, then drive in reverse to the original
position and stop again suddenly. Repeat this
cycle 3 – 4 times, and finally, allow the ma-
chine to stop slowly without depressing the
brake. Then measure the installed length.
fl Do not use the foot brake when braking
the machine. Use the retarder control le-
ver to brake the machine, and check that
the suspension is in the soft mode.
20-128 HD785-5
(13)
2) If the result of the check shows that the in-

stalled length is too long, release nitrogen gas
to adjust the length.
fl Loosen the oil level valve slightly to re-
lease the nitrogen gas. When doing this,
release only a small amount of gas; do
not make the cylinder move.
fl If too much nitrogen gas is released and
the cylinder moves, the installed length
may be below the specified length.
fl Do not press the tip of the valve core. If
the tip of the valve core is pressed, the
valve core may be damaged.
3) After releasing nitrogen gas and adjusting the
installed length, repeat Step 1) to check the
installed length again.
4) Repeat the above Steps 1) – 3) to adjust the
cylinder to the specified length.
5) Finally, check that there is no leakage of gas
from the valve core, oil level valve, and pis-
ton rod gland.
fl Use soapy water to check for leakage of
gas.
fl If there is any leakage of gas from the
valve core, use tool A6 and remove the
valve core.
Note: 1. Checking after changing oil and gas

After the oil and gas have been changed,
operation of the machine causes the gas to
dissolve in the new oil inside the cylinder
until it is saturated, so the volume of gas is
reduced and the installed length of the sus-
pension goes below the specified limit.
Therefore, 48 hours after changing the oil
and gas, check the installed length of the
suspension and adjust the gas if the length
is not within the specified value.
2. Checking for changes in installed length
caused by variation in ambient temperature.
Depending on the ambient temperature
when the machine is working, the gas in
the suspension may expand or contract, so
the installed length will also change. In ter-
ritories where there are big differences in
temperature throughout the year, inspect
daily and adjust to keep the installed length
within the specified range.
HD785-5 20-129
(13)
TESTING AND ADJUSTING INVERTED
TESTING AND ADJUSTING TYPE REAR SUSPENSION CYLINDER

INVERTED TYPE REAR
SUSPENSION CYLINDER
fl Stop the machine empty on flat ground.
1. Testing length of cylinder

Check that dimension a of the rear suspension
cylinder is within the specified value.
Specified value for dimension a:
Thickness if frange b : 50 mm (Standard)
: 70 mm (With buffer ring)
2. Releasing nitrogen gas

1) Rear suspension cylinder
i) Set block [2] between the stopper and axle
housing.
fl Thickness of block: 40 mm
Dimension a:
ii) Disconnect pressure sensor connector (2)

of oil level valve (1), then loosen the oil
level valve 2 – 3 turns.
fl When releasing the nitrogen gas,
there is danger that releasing the gas
from the valve core of supply valve (3)
will damage the valve core, so remove
the gas at the oil level valve.
fl When loosening the oil level valve,
loosen only the valve itself. Do not
loosen the pressure sensor or nipple.
¤ When loosening the oil level valve,
gradually loosen only valve (1) itself,
and do not remove the valve until all
the nitrogen gas has been released
from the slit.
¤ If the nitrogen gas has not all been
released, pressure sensor (5) are still
under high pressure, so do not
loosen them under any circum-
stances.
fl When the oil level valve is loosened,
and oil and gas spurt out together,
tighten the valve slightly, and allow
time for the gas to escape slowly.
20-130 HD785-5
(15)
3. Adjusting oil level

fl Release the nitrogen gas before adjusting the
oil level.
1) Remove supply valve (3), and install joint P5.
2) Install fitting P4 to joint P3, then connect hose
P2 and volume pump P1.
3) Loosen air bleed valve (1), then operate vol-
out with the oil from air bleed valve (1).
tighten air bleed valve (1).
5) After adding oil, remove the volume pump,
then install supply valve (3).
4. Filling suspension cylinder with gas

1) Remove cap (5) from supply valve cap (3).
2) Set tool P to the supply valve supply as shown
in the diagram.
fl Before installing regulator P10, blow the
filter in the connector with nitrogen gas
at 0.981 MPa {10 kg/cm2} or more to blow
out all dirt or dust. (Dirt or dust in the sys-
tem causes failures.)
3) Open valve [c] of the gas cylinder, and check

the pressure reading of gauge P10a (internal
pressure of gas cylinder).
fl The pressure indicated must be at least
0.981 MPa {10kg/cm2} higher than the
pressure inside the cylinder (max. pres-
sure inside cylinder: 2.45 MPa {25 kg/cm2}).
4) Turn handle [d] of regulator P10 slowly clock-
wise, set the pressure reading of gauge P10b
to 0.981␣ MPa {10kg/cm2} above the internal
pressure of the cylinder, then operate valves
P6 and P9 to fill the cylinder with nitrogen gas.
fl Fill the left and right cylinders in the same
way.
HD785-5 20-131
(13)
5) When dimension a of the left and right cylin-

ders reaches the standard value, turn handle
[d] of regulator P10 counterclockwise to stop
the flow of nitrogen gas.
fl Standard dimension a:
6) Turn handle [e] of P9 fully back counterclock-

wise, loosen air bleed plug [f], release the gas
inside the hose, then remove tool P.
fl Be careful not to lose the O-ring of the
intake valve.
5. Adjusting installed length of cylinder

fl Carry out adjustment of the installed length
of the cylinder with the machine empty and
on level ground.
1) To remove the sliding resistance of the cylin-
der (catching of bushing or packing), drive the
machine forward approx. 15 m and stop sud-
denly, then drive the machine forward approx.
15 m and stop suddenly, then drive in reverse
to the original position and stop again sud-
denly. Repeat this cycle 3 – 4 times, and fi-
nally, allow the machine to stop slowly with-
out depressing the brake. Then measure the
installed length.
fl Do not use the foot brake when braking
the machine. Use the retarder control le-
ver to brake, the machine, then check that
the suspension is in the soft mode.
2) If the result of the check shows that the in-
stalled length is too long, release nitrogen gas
to adjust the length.
fl Loosen the oil level valve slightly to re-
lease the nitrogen gas. When doing this,
release only a small amount of gas; do
not make the cylinder move.
fl If too much nitrogen gas is released and
the cylinder moves, the installed length
may be below the specified length.
fl Do not press the tip of the valve core. If
the tip of the valve core is pressed, the
valve core may be damaged.
3) After releasing nitrogen gas and adjusting the
installed length, repeat Step 1) to check the
installed length again.
4) Repeat the above Steps 1) – 3) to adjust the
cylinder to the specified length.
20-132 HD785-5
(13)
5) Finally, check that there is no leakage of gas

from the valve core (4), oil level valve, and
piston rod gland.
fl Use soapy water to check for leakage of
gas.
fl If there is any leakage of gas from valve
core (4), loosen cap (5) gradually and re-
move valve core (4).
¤ Cap (5) may fly out because of the inter-
nal pressure. Accordingly, do not loosen
cap (5) more than 1 turn until all the gas
is released.
3 Cap (5): 39 – 49 Nm {4 – 5 kgm}
6. Testing and adjusting dust cover

fl To protect the rear suspension from stones
and other objects thrown up by the tires when
the machine is traveling, carry out inspection
of the cover and repair or replace it as neces-
sary.
1) Check visually that there are no cracks or
breaks in cover (1).
fl If the cover (1) is damaged, replace it with
a new part.
2) Check that hooks (2) are not missing. (3 places)
fl If any hooks (2) are missing, remove all
mud and dirt, then install hooks.
3) Check that band (3) is not loose or missing.
fl If the band (3) is loose or missing, tighten
to the following torque.
3 Band: 669 ± 49 Ncm {69 ± 5 kgcm}
HD785-5 20-133
(16)
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION AIR CYLINDER

SUSPENSION AIR CYLINDER
fl Fill the air tank completely with air.
1. Testing
1) Check that installed dimension a of the air
cylinder is within the standard value.
fl Standard dimension a: 34.5 ± 1 mm
2) With the starting switch ON, check that lever
(1) of the air cylinder is offset b from horizon-
tal when the work equipment control lever is
operated to any position except FLOAT.
Air cylinder offset angle: 9° ± 30'
2. Adjusting
1) Loosen locknut (2) of the air cylinder, and ad-
just rod end (3) to set to installed standard
dimension a, then tighten locknut (2).
2) With the starting switch ON, check that lever
(1) of the air cylinder is offset b from horizon-
tal when the work equipment control lever is
operated to any position except FLOAT.
fl Air cylinder offset angle: 9° ± 30'
3) In the correctly installed condition, the slit of
lever (1) must face in the same direction as
the hole in the bracket, and the range limit
must be within 3 mm.
20-134 HD785-5
(16)
TESTING AND ADJUSTING AIR PRESSURE IN AIR CIRCUIT
TESTING AND ADJUSTING AIR

PRESSURE IN AIR CIRCUIT
Testing
Run the engine at full throttle and check that the
indicator of the panel gauge is in the green range.
Adjusting
If the air pressure is not within the standard value,
adjust as follows.
Remove the cap, then loosen the locknut and

turn adjustment screw (1) to adjust.
fl Set pressure:
0.814 ± 0.029 MPa {8.3 ± 0.3 kg/cm2}
fl Adjust with the screw (1) as follows.
To INCREASE pressure,
turn COUNTERCLOCKWISE
To DECREASE pressure,
turn CLOCKWISE
HD785-5 20-135
(16)
TESTING AND ADJUSTING INSPECTION OF AIR DRIER (DESICCANT TYPE)
INSPECTION OF AIR DRIER

(DESICCANT TYPE)
(IF EQUIPPED)
fl The air drier is installed at the rear of the operator's

cab.
1. Daily inspection
During the check before starting or after finishing
work, when draining water from the air tank, check
the quantity of the drained water and oil.
If the drained water or oil has increased, the ca-
pacity of the air drier may have lowered. In this
case, disassemble air drier (1) and see if the des-
iccant is attacked by oil or impurities, referring to
DISASSEMBLY AND ASSEMBLY, Removal and in-
stallation of air drier (desiccant type) (if equipped),
Disassembly and assembly of air drier (desiccant
type) (if equipped).
If 1/5 or more of the whole desiccant has been
attacked, replace it with new one.
When replacing the desiccant, replace all the oil
filters, too. (See *1. Repair kit.)
fl If the desiccant is attacked by oil, etc., its abil-
ity to absorb water lowers and that affects the
function of the drier largely. Accordingly, be
sure to replace the desiccant.
fl Carefully check the drain discharged from the
exhaust port of the air drier (1). If abnormally
much oil is drained, check the compressor for
oil consumption through piston cylinder.
fl Compressed air sent to the air drier (1) con-
tains oil (liquid oil and carbonized oil). This
oil is accumulated in the compressor and drier
piping, and may burn. Accordingly, clean
compressor and drier piping periodically.
2. 6 month or 1,000 operation hour inspection

• Disassemble the air drier (1) and replace the
desiccant, oil filter, filter, and all the rubber
parts.
(See *1. Repair kit.)
• Check the metallic parts for rust and repair or
replace them, if necessary.
• Check the piping and wiring for abnormality.
20-135-1 HD785-5
(16)
TESTING AND ADJUSTING INSPECTION OF AIR DRIER (DESICCANT TYPE)
(*1) Repair kit

When performing the periodic inspection of the
air drier or disassembling it, prepare the repair
kit to replace the used parts.
Repair kit
234-44-42150
No. Part name Q’ty

3 O-ring 1
4 O-ring 1
6 O-ring 1
7 Valve 1
11 O-ring 1
14 Oil filter 1
15 Gasket ring 1
16 Gasket ring 1
19 O-ring 1
21 Filter 2
22 Desiccant 1
24 O-ring 1
27 Check valve 1
30 O-ring 1
34 O-ring 1
HD785-5 20-135-2
(16)
TESTING AND ADJUSTING ADJUSTING HOIST LEVER LINKAGE
ADJUSTING HOIST LEVER LINKAGE

fl Lock the control levers inside the cab in the HOLD
position with the lock plate on the console box.
fl Install and connect the push-pull cable so that
there is no twisting or slack.
1. Set hoist valve lever (1) in the HOLD position.
2. Disconnect push-pull cable (2) and hoist valve le-

ver (1), and adjust the length of the cable at yoke
(4). Then connect push-pull cable (2) and hoist
valve lever (1), check standard dimension A, and
tighten the locknut.
fl Standard dimension A : 198.5 mm
3. Adjust intermediate rod (3) to standard dimen-

sion B.
fl Standard dimension B : 509 mm
4. Connect push-pull cable (2) to intermediate lever

(5), adjust to standard dimension C, then tighten
the locknut.
fl Standard dimension C : 203.5 mm
5. After adjusting, release the lock plate on the

consol box, and check that the travel from HOLD
to RAISE is the specified value D when the con-
trol lever is operated to RAISE.
fl Standard dimension D : 15 mm
20-136 HD785-5
(16)
ADJUSTING Q [FUEL INJECTION AMOUNT] WHEN
TESTING AND ADJUSTING REPLACING ENGINE CONTROLLER
ADJUSTING Q [FUEL INJECTION

AMOUNT] WHEN REPLACING
ENGINE CONTROLLER
fl When replacing the engine controller, adjust the
Q adjustment switch.
1. Check the number on seal (1) on the top of the

old controller and the engine name plate to con-
firm the Q adjustment No.
fl XXXXX is the Engine No. and X is the Q ad-
justment No.
2. Remove the rubber grommets from the L side and

R side at the top face of the replacement (new)
controller, use a screwdriver to turn built-in ro-
tary switch (3) to adjust the fuel injection amount,
and set the fuel injection amount adjustment num-
ber to the normal set value.
fl The white dot shows the fuel injection amount
adjustment number.
3. Return rubber grommets (2) at the top to their

original position.
4. Write the Q adjustment No. on seal (1) at the top

of the controller.
fl Use an oil-based ink pen or ball-point pen to
prevent the number from fading or disappear-
ing.
20-142 HD785-5
(15)
SETTING ROTARY SWITCH WHEN REPLACING
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
SETTING ROTARY SWITCH

(MODEL DATA, NETWORK
DATA) WHEN REPLACING
fl If the transmission controller is replaced with a
new controller or the controller is used on another
machine, set the model data and network con-
nection data to match the model and specifica-
tion of the machine.
1. Remove left and right grommets (1) on the top

face of the old controller (controller being re-
placed) and check the settings of built-in rotary
switch (2).
2. Remove left and right grommets (1) on the top

face of the new (replacement) controller and use
a screwdriver to turn built-in rotary switch (2) to
set the controller settings to the settings of the
old controller (settings before replacement).
3. Put left and right rubber grommets (1) back in their

original positions on the top face.
(Reference)
The model data are set with the right rotary switch
(switch 1) and the network connection data are set
with the left rotary switch (switch 2).
The relationship of the settings and the model data
and network connection data is as shown in the table
below.
Rotary switch combination table

Rotary switch (switch HD785-5 8–0 8–1 8–2 8–3 9–1 9–2 9–3 9–4 A–1 A–2 A–3 A–4 B–0 B–1 B–2 B–3
1, 2) combinations
(Switch 1 setting) –
(Switch 2 setting) HD985-5 8-8 8-9 8-A 8-B 9-8 9-9 9-A 9-B A-8 A-9 A-A A-B B-8 B-9 8-A B-B
ABS system No No No No Yes Yes Yes Yes No No No No Yes Yes Yes Yes
Engine controller
(Komatsu engine) No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes
PMC controller Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No
Suspension controller (SUS) Yes Yes No No Yes Yes No No Yes Yes No No Yes Yes No No
HD785-5 20-143
7
METHOD OF DELETING DATA FROM ENGINE
CONTROLLER, TRANSMISSION CONTROLLER AND
TESTING AND ADJUSTING PMC MEMORY (CONTROL FROM MONITOR PANEL)
METHOD OF DELETING DATA

FROM ENGINE CONTROLLER,
AND PMC MEMORY
(CONTROL FROM MONITOR
PANEL)
fl For details, see MONITOR PANEL USER CODE
AND SERVICE MODE FUNCTION in the Foreword
of the Troubleshooting Section.
1. Outline
fl If the transmission controller is going to be
used on another machine, delete the trouble
data and other data related to the current
machine from the memory of the engine con-
troller, transmission controller and PMC as
follows.
fl For the method of deleting the trouble data
after troubleshooting or for another common
reason, see MONITOR PANEL USER CODE
AND SERVICE MODE FUNCTION, 3.3 Method
of Operating Service Mode, (6) Method of
Deleting Trouble Data from Memory in the
Troubleshooting Section.
fl If this function is used, the machine informa-
tion saved in the controller is also deleted.
Take care, especially when the machine is
equipped with VHMS.
1) This function is used to delete data from the
memory of the engine controller, transmission
controller and PMC.
2) This function is effected by operating bulb
check switch (1) and mode change switches
(2) (the red switch at the front of the machine)
and (3) (the black switch at the rear of the
machine) {there are numbers on switch box
(4), so check the numbers}, and using the S-
NET to send the command from the monitor
panel to each controller to delete the data from
memory.
3) The monitor panel accepts the operation for
this function only when the starting switch is
ON and the engine is stopped.
In addition, each controller also accepts the
operation for this function only when the start-
ing switch is ON and the engine is stopped.
4) To prevent the data from being deleted from
the memory of the wrong controller,
mechatronics caution display (5) lights up to
make it possible to confirm the controller from
which the data is being deleted.
20-144 HD785-5
B
TESTING AND ADJUSTING PROCEDURE FOR OPERATING MODULATION CHECKER
5. Procedure for manual operation of lock-up

¤ Check that the indicator of the machine air
pressure gauge is in the green range.
1) Turn the parking brake ON.
2) Check that the surrounding area is safe, then
start the engine.
3) Turn the modulation checker power ON.
4) Press 4th switch F on the keyboard.
5) Press LOCK-UP switch C on the keyboard.
fl Do this with the engine running at a mid-
range speed and check that the lock-up
has been engaged by listening to the
change in the engine sound.
6) After this operation, press LOCK-UP switch
C to turn the lock-up OFF.
7) Press 4th switch F and check that the
clutch signal has changed to N.
8) After completing the measurement, stop the
engine.
6. Measuring torque converter stall speed

¤ Check that the indicator of the machine air
pressure gauge is in the green range.
1) Turn the parking brake ON.
2) Check that the surrounding area is safe, then
start the engine.
3) Turn the modulation checker power ON.
4) Depress the brake pedal and actuate the emer-
gency brake. 
5)  Press SHIFT UP switch 9 on the key-
 board three times to set the speed range


 to F3.
fl When pressing SHIFT UP switch 9 the
2nd and 3rd times, press within 1 – 3 sec-
onds each time.
6) Depress the brake pedal with your left foot,
then depress the accelerator pedal slowly with
your right foot as far as it will go.
7) Measure the engine speed.
8) After completing the measurement, run the
engine at low idle, then stop the engine.
HD785-5 20-157
(15)
ADJUSTING HYDRAULIC TANK PRESSURE
TESTING AND ADJUSTING (HIGH ALTITUDE SPECIFICATION)R
ADJUSTING HYDRAULIC TANK PRESSURE

(HIGH ALTITUDE SPECIFICATION)
HD785-5
Installation of pressure gauge
1. Before starting the engine, turn hand valve (1) to
the CLOSE position and turn regulator valve knob
(2) fully counterclockwise to close it (to prevent
application of high pressure to the hydraulic
tank).
2. Open the drain valve to discharge the all air from

the air tank.
3. After discharging the air, remove plug (3) of the

regulator valve and install a pressure gauge
which can measure pressure of 9.8 – 98 kPa {0.1
– 1.0 kg/cm2}.
Adjustment of pressure
1. Start the engine and accumulate air in the air tank.
2. Set regulator valve knob (2) to 49 kPa {0.5 kg/cm2}

(to prevent application of high pressure to the
hydraulic tank).
3. Turn hand valve (1) to the OPEN position to ap-

ply pressure to the hydraulic tank.
4. Raise the body slowly. At this time, the pressure

gauge pointer lowers.
5. Lower the body slowly in the "FLOAT" mode. At

this time, the pressure gauge pointer rises. When
the body lowers halfway, the air is discharged
through the quick release valve and the oil pres-
sure stops rising.
6. Repeat the above operation of the body 2 to 3

times and seat the body. At this time, the pres-
sure gauge pointer indicates the set pressure.
7. Set the pressure to the specified pressure by turn-

ing regulator valve knob (2).
fl Specified pressure: 78.4 kPa {0.8 kg/cm2}
8. Repeat above steps 4 to 7 to set the pressure pre-

cisely to the specified pressure.
Removal of pressure gauge

1. Stop the engine and release the air from the air
tank.
2. Remove the pressure gauge and install plug (3).
20-158 HD785-5
A
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT
TESTING AND ADJUSTING (= QUICK PM)

(= QUICK PM)
WHAT IS QUICK PM?
If a serious error occurs, the VHMS snapshot function saves all the data for a period of 5 minutes 30
seconds before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds).
This snapshot function can be started by pressing the manual switch. After the button is pressed, all
data is automatically saved for seven minutes 30 seconds. All data can be automatically collected in
cases such as torque converter stall, so it is possible to reduce the time taken for measurements in the
Pm clinic.
However, the data sampling frequency is one time every 10 seconds for the first 5 minutes and one time
every second for the next 2 minutes 30 seconds. To raise the precision of the data, it is necessary to
create the conditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.
NECESSARY TOOLS
• Personal computer
• VHMS technical analysis toolbox (software) 799-608-3211
• Download cable 799-608-3220
• Stopwatch
¤ To ensure safety, stop the machine on flat ground and put blocks under the tires to prevent the
machine from moving.
1. Start the engine.
2. Keep the manual snapshot switch (green push button) pressed for approx. 5 sec.
HD785-5 20-159
B
3. Run the engine at low idle for 2 minutes to stabilize it.

fl Check that the coolant temperature and torque converter oil temperature gauge are within the
green range.
4. After starting, operate the machine as shown in Table 1.
Table 1
Measurement conditions
Start Finish Time Engine speed Power Remarks
AISS mode Gear shift Parking Retarder Dump
SW selection lever brake lever
1 0:00 2:00 120 sec. Low idle(Low) Auto Economy N ON ON Hold
2 2:00 3:00 120 sec. Low idle(High) Auto Economy N OFF OFF Hold Note 1
Low idle
3 4:00 5:00 60 sec. (Economy mode) Auto Economy N ON ON Hold
High idle
4 5:00 5:30 30 sec. (Economy mode) Auto Economy N ON ON Hold
30 sec. Torque converter stall

5 5:30 6:00 (ª) (Economy mode) Auto Economy D OFF ON Hold Note 2, 3
High idle
6 6:00 6:30 30 sec. (Power mode) Auto Power N ON ON Hold
30 sec. Torque converter stall

7 6:30 7:00 (ª) (Power mode) Auto Power D OFF ON Hold Note 2, 3
High idle
8 7:00 7:30 30 sec. (Power mode) Auto Power N ON ON Hold
Note 1: Press the foot brake.

Note 2: When performing the torque converter stall {portion (ª)}, do not overheat the torque converter.
[The 30 seconds for torque converter stall is only a reference value. If the torque converter oil
temperature gauge enters the top level of the green range during the torque converter stall
operation, return the transmission (gearshift lever) immediately to the N position.]
Note 3: Reduce the speed to low idle before shifting to position D (to prevent the machine from starting
suddenly).
20-160 HD785-5
(15)
5. After completing the measurement, reduce the

engine speed to cool down the engine, then stop
the engine.
(End of snapshot)
6. Download the snapshot data to the personal com-

puter. For details, see Procedure for download-
ing VHMS data to personal computer.
NOTICE
The quick PM data is only recorded once. If the
operation is carried out again, the data is over-
written, so after performing the quick PM, always
download the data to the personal computer.
7. Use the technical analysis toolbox to read the

quick PM data.
fl For details of the method of using the techni-
cal analysis toolbox, see the instruction
manual.
• Open the quick PM data and make a graph
For the X-axis, select Time and for the Y-axis
select the following:
1) Engine Speed
2) Blowby Press (Blow-by pressure)
3) Exhaust Temp RB (Right bank)
4) Exhaust Temp LB (Left bank)
5) Engine Oil Press (Engine oil pressure) and
put a check mark against Graph value display
at the click position (marked by ).
HD785-5 20-161
B
• If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph.
(Example of graph display)
• Enter these values on the Pm Clinic check sheet.

The relationship between the measurement conditions and the necessary data in the Pm Clinic is as
shown below.
Conditions Measurement items
Lublicating oil Exhaust
Engine speed Mode Engine speed Blow-By pressure pressure temperature
1 Low idle Low
2 Low idle High
3 Low idle Economy mode
4 High idle Economy mode
5 Torque converter stall Economy mode
6 High idle Power mode
7 Torque converter stall Power mode
8 High idle Power mode
20-162 HD785-5
(15)
TESTING AND ADJUSTING Pm-CLINIC SERVICE
Pm-CLINIC SERVICE
HD785-5 20-163
(15)
TESTING AND ADJUSTING Pm-CLINIC SERVICE
20-164 HD785-5
(15)
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 20-202

Sequence of events in troubleshooting ................................................................................................ 20-203
Points to remember when carrying out maintenance ......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Type of connector and position of installation ..................................................................................... 20-214
Connector pin arrocation chart .............................................................................................................. 20-220
Connection table for connector pin numbers ....................................................................................... 20-226
Explanations of functions (Control mechanism) of electrical system ................................................ 20-236
Monitor panel user codes and service mode function ......................................................................... 20-244
Self-diagnostic display method for monitor panel and controllers .................................................... 20-259
Table of service codes and user codes .................................................................................................. 20-266
Method of using judgement tables ........................................................................................................ 20-276
Method of using troubleshooting charts ............................................................................................... 20-277
Troubleshooting of engine controller system electronic govenor specification (G mode) ............... 20-301
Troubleshooting of engine system (S mode)........................................................................................ 20-401
Troubleshooting of transmission controller system (A mode) ............................................................ 20-501
Troubleshooting of suspension controller system (SP mode) ............................................................ 20-601
Troubleshooting of payload meter (Printer type) system (LP mode).................................................. 20-701
Troubleshooting of payload meter II (Card type) system (LC mode) ................................................. 20-801
Troubleshooting of ARSC [Automatic retarder speed controller] system (R mode) ......................... 20-901
Troubleshooting of hydraulic and mechanical system (H mode) ..................................................... 20-1001
Troubleshooting of monitor panel system (P mode) ......................................................................... 20-1101
Troubleshooting of PMC system (M mode) ........................................................................................ 20-1201
Troubleshooting of ABS/ASR system (OP) .......................................................................................... 20-1251
Troubleshooting of maintenance monitor system ............................................................................. 20-1301
VHMS machine health diagnosis system (OP) ................................................................................... 20-1501
This troubleshooting manual gives flowcharts for troubleshooting, including the electrical display
system, for the monitor system (abnormal display) and each controller system (self-diagnostic dis-
play) according to the nature of the problem.
Therefore, before starting troubleshooting, it is necessary to read and fully understand the testing,
adjusting, and troubleshooting procedures given in this manual.
HD785-5 20-201
(13)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. ﬂ When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from ﬂ The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-202 HD785-5
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
fl If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole heavy duty type
connectors have 2 latches respectively, push
them in until they click 2 times.
1. Male connector, 2. Female conector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
HD785-5 20-207
A
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
er to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 HD785-5
A
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

fl The Address column in this table shows the address in the connector pin allocation drawing
(3-dimensional drawing).
Con- No. Con- No.
nector Connec-
tor type of Mounting location Add- nector Connec- Mounting location Add-
No. pins ress tor type of ress
No. pins
01 SWP 14 Intermediate connector A6 34 1-pin
connector 1 Clearance lamp A5
02 SWP 8 Intermediate connector A6 35 1-pin

connector 1 Clearance lamp A5
03 X 2 Radiator coolant level sensor A4 36 1-pin

connector 1 Turn signal lamp A5
04 X 2 Air conditioner pressure switch A3 37 1-pin

connector 1 Fog lamp A5
06L — 3 Head lamp (Lo) D1 39 X 3 Suspension pressure sensor A6
07H — 3 Head lamp (Hi) D1 40 SWP 6 Payload meter display lamp (right) B7
1-pin
08 connector 1 Clearance lamp E1 41 M 1 Right side lamp C7
1-pin
09 connector 1 Clearance lamp F1 51 X 2 Flow switch F9
1.PS X 2 Transmission solenoid valve Q1 52 X 2 Transmission oil filter sensor L4
1.SW X 1 Fill switch Q1 53 X 2 Retarder filter sensor L6
2.PS X 2 Transmission solenoid valve Q1 54 X 2 Hydraulic oil filter sensor L6
2.SW X 1 Fill switch P1 55 X 2 BCV solenoid L8
3.PS X 2 Transmission solenoid valve P4 59 SWP 6 Tail lamp J8
3.SW X 1 Fill switch P4 60 SWP 6 Tail lamp K8
4.PS X 2 Transmission solenoid valve P4 61 X 1 Fuel gauge sensor G9
4.SW X 1 Fill switch P4 62 X 3 Suspension pressure sensor K8

1-pin
10 connector 1 Turn signal lamp E1 63 X 3 Suspension pressure sensor J9
1-pin
11 connector 1 Fog lamp E1 64 X 2 Retarder oil temperature sensor K8
12 — 2 Washer motor A6 1-pin

76 connector 1 Auto drain valve heater B7
Emergency stop solenoid (me-
13 X 3 Suspension pressure sensor A4 84 — 2 chanical governor specification) A4
AISS motor (mechanical governor
14 SWP 6 Payload meter external display lamp (left) L4 86 — 8 specification) —
Engine stop motor (mechanical
15 M 1 Left side lamp L3 87 — 8 governor specification) —
17 — 1 Air conditioner compressor A4 90 — 2 Diode L8
18 — 2 Diode A4 99 — 2 Intermediate connector —
20 SWP 14 Intermediate connector A5 A1 KES1 1 Emergency escape switch T1
21 X 1 Steering oil temperature sensor L5 A2 KES 1 Emergency escape switch T1
24 X 2 Starting motor A3 AC1 M 4 Intermediate connector N7
26 X 2 Coolant temperature sensor A3 AI — 7 AISS switch M4
27 Socket 1 Engine oil pressure sensor A4 AS1 X 2 Exhaust brake switch S9

Emergency stop solenoid (me-
28 — 2 chanical governor specification) A3 AS2 X 2 Parking brake switch T9
30 SWP 14 Intermediate connector B7 AS3 X 2 Retarder brake switch T9
31 SWP 8 Intermediate connector A6 AS4 X 2 Emergency brake switch S9
32H — 3 Head lamp (Hi) A5 AS5 X 2 Service brake switch T9
33L — 3 Head lamp (Lo) A5 ATC1 MIC 17 Transmission controller U1
20-214 HD785-5
(15)
Con- No. Con- No.

nector Connec-
tor type of Mounting location Add- nector Connec-
tor type of Mounting location Add-
No. pins ress No. pins ress
ATC2 MIC 21 Transmission controller U4 DB1 X 4 Body seated switch J9
ATC3A AMP040 20 Transmission controller U4 DB4 — 2 Diode —
ATC3B AMP040 16 Transmission controller U4 DLB X 2 Differential lock switch S8
ATC4 AMP040 12 Transmission controller V3 DP01 MIC 5 Monitor panel O6
ATC5A AMP040 20 Transmission controller V3 DP02 AMP040 8 Monitor panel P9
ATC5B AMP040 16 Transmission controller U3 DP03 Socket 2 Monitor panel O6
ATC6 X 4 Transmission controller T2 DP04 APM040 8 Monitor panel P9
BLSL X 2 Brake stroke sensor K8 DP05 AMP040 12 Monitor panel P6
BLSR X 2 Brake stroke sensor I9 DP06 Socket 2 Monitor panel P9
BT1 — — Fuse box U5 DP07 Socket 2 Monitor panel Q9
BT2 — — Fuse box T6 DP08 AMP040 16 Monitor panel Q9
BT3 — — Fuse box T6 DP09 Socket 2 Monitor panel R8
BZ M 2 Alarm buzzer O6 DP10 AMP040 8 Monitor panel R8
C1 — 1 Intermediate connector U4 DP11 AMP040 16 Monitor panel R8
C2 — 1 Intermediate connector T4 DP12 M 4 Monitor panel R7

1-pin DP13 Socket 2 Monitor panel R8
CA+ connector 1 AM/FM cassette O9
1-pin E7 SWP 14 Intermediate connector F9
CA– connector 1 AM/FM cassette N9
1-pin E8 SWP 14 Intermediate connector F9
CAB connector 1 AM/FM cassette N9
1-pin E9 X 4 Rack sensor E9
CG1 connector 1 Cigar lighter M6
1-pin E10 X 3 Pre-stroke solenoid E9
CG2 connector 1 Cigar lighter M6
CK1 KES1 2 Bulb check switch M5 E11 X 2 Governor solenoid E8
CM S 8 Combination switch Q8 E12 X 2 Engine speed sensor B E9
CNS S 12 Intermediate connector V2 E13 X 4 Rack sensor C8
C/V.T X 2 Transmission oil temperature sensor P1 E14 X 3 Pre-stroke solenoid C7
D04 — 2 Diode S7 E15 X 2 Governor solenoid A6
D05 — 2 Diode X6 E16 X 2 Engine speed sensor A D8
D06 — 2 Diode X5 EC1 MIC 17 Engine controller S4
D08 — 2 Diode N4 EC2 MIC 21 Engine controller S2
D1 — 2 Diode B2 EC3A AMP040 20 Engine controller S4
D1 — 10 Message display X1 EC3B AMP040 16 Engine controller S3

1-pin EC4 AMP040 12 Engine controller —
D5-1 connector 1 Horn valve C2
1-pin EC5A AMP040 20 Engine controller S4
D5-2 connector 1 Horn valve B2
D12 — 2 Diode M5 ECA S 16 Intermediate connector V5
D14 — 2 Diode S7 EXH Socket 7 Exhaust brake switch O5
HD785-5 20-215
7
Con- Connec- No. Con- Connec- No.

nector tor type of Mounting location Add- nector tor type of Mounting location Add-
No. pins ress No. pins ress
FB PA 7 Front brake cut switch O5 MM16 X 2 Transmission oil level sensor L6
FCM — 7 Intermediate connector R6 MM17 X 3 Intermediate connector K8
FCS — 7 Intermediate connector R6 MM19 X 2 Rear brake (left) wear sensor L6
FL PA 7 Fog lamp switch O6 MM20 X 2 Rear brake (right) wear sensor J9
FU — 2 Fuse unit B7 MM21 S 12 Intermediate connector H9
HAZ Socket 7 Hazard switch O5 MS11 M 1 Model selection switch T1
HEAT M 1 Heater N6 MS12 M 1 Model selection switch S2

1-pin
HN connector 1 Horn Q9 N1 X 2 Input shaft speed sensor O1
H.PS X 2 Transmission solenoid valve O3 N2 X 2 Intermediate shaft speed sensor O1
H.SW X 1 Fill switch O3 N3 X 2 Output shaft speed sensor Q4
HT PA 7 Preheat switch M5 P15 M 2 MPH selection connector P6

Intermediate connector inside,
J01 S 16 outside cab S7 PL1 S 10 Monitor lamp M5
Intermediate connector inside, Suspension pressure sensor GND
J02 S 16 outside cab S8 PL1 — 2 selection connector H1
J03 S 16 outside cab S8 PL2 S 10 Monitor lamp N6
Intermediate connector inside, Suspension pressure sensor GND
J04 S 12 outside cab T9 PL2 — 2 selection connector H1
J06 Terminal 1 outside cab S7 PLS M 4 Monitor lamp M4
J07 Terminal 1 outside cab S7 PM1 MIC 21 Payload meter M9
J09 S 12 Intermediate connector — PM2 M 4 Payload meter I1

Intermediate connector
J09E S 12 (for electronic governor) W5 PM3 X 3 Clinometer L4
Intermediate connector
J09M S 16 (for mechanical governor) W4 PM4 M 6 Intermediate connector M9
J10 S 16 Intermediate connector — PM5 MIC 13 Payload meter (card type) M8
J11 S 12 Intermediate connector — PM6 AMP040 12 Payload meter (card type) M8

Suspension pressure sensor FR
L/C.T X 2 Torque converter lock-up solenoid N3 PM6 KES1 2 selection connector S2
LPS X 2 Transmission solenoid valve O3 PM7 MIC 9 Payload meter (card type) M7
LS M 3 Rheostat R7 PM7B MIC 9 Payload meter (card type) N7
LSW X 1 Fill switch sensor O3 PM8 MIC 5 For connecting PC G1
MM8 S 16 Intermediate connector X6 PMC1 MIC 17 PMC L7
MM9 X 2 Engine oil level sensor A3 PMC2A AMP040 20 PMC I1
MM10 Terminal 1 Engine oil filter sensor A4 PMC2B AMP040 16 PMC L6
MM11 X 1 Battery electrolyte level sensor B6 PMC3 AMP040 12 PMC H9
MM12 X 2 Front brake fluid level sensor C7 PMC4A AMP040 20 PMC L7
MM13 1 1 Air cleaner clogging sensor E8 PMC4B AMP040 16 PMC L7
MM14 X 1 Hydraulic oil level sensor L5 PMC5 MIC 21 PMC H1

G1,
MM15 X 1 Retarder oil level sensor L6 PMC6 M 3 For S-NET monitor U5
20-216 HD785-5
(15)
TROUBLESHOOTING FOR ARSC
FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL)
Con- No. Con- No.

nector Connec- of Place of use Add- nector Connec- of Place of use Add-
No. tor type pins ress tor type ress
No. pins
1-8 X 1 Selection connector d4 RH1-EL1 S 10 Intermediate connector d6
1-pin
78/98 connector 1 Model selection connector — RH1-EL2 S 10 Intermediate connector d6
8S X 1 Selection connector d4 RM4-1 M 6 Payload meter Y5
250 — 2 Resistor a3 RM4-2 M 6 Payload meter Y5
1020 — 2 Resistor Z3 RW For relay 6 RW relay Y6
A1 1-pin 1 ARSC caution lamp Z3 RZ For relay 5 RZ relay Y6

connector
A2 1-pin 1 ARSC caution lamp Z3 SHIFT X 1 Selection connector c4
connector
A6 1-pin 1 ARSC stand-by lamp Y4 SHUT — 2 Air shut-off valve D8
connector
ARC1 MIC 21 ARSC controller Y6 SOSW X 2 Air switch (air shut-off valve) D8
ARC2 AMP040 20 ARSC controller Y6 SP2 M 2 Suspension pressure selection Z7

connector
ARC3 AMP040 16 ARSC controller a7 SP4 M 2 Power source for suspension pres- c8
sure sensor/sensor GND connection
BRJ M 8 Intermediate controller a8 SP5 M 2 Power source for suspension pres- c8
sure sensor/sensor GND connection
BRR X 2 Air switch (brake solenoid) D8 SPR M 2 Suspension pressure selection Z7
connector
BSOR — 2 Brake solenoid valve (right) D8 SPSW M 3 ARSC set switch b3
BT3 — — Fuse box d4 SW — 7 ARSC system switch c3
BZ-EL1 M 2 Buzzer b3 TIRE1 X 1 Tire large diameter/small diameter c4

selection
BZ-EL2 M 2 Buzzer b3 TIRE2 X 1 Tire large diameter/small diameter c4
selection
CR1 M 1 For clearing error code a8 TMA1 X 16 Intermediate connector d7
CR2 M 1 For clearing error code b8 TMA2 X 16 Intermediate connector d5
D01 — 2 Diode d6 TMB1 X 16 Intermediate connector d7
D02 — 2 Diode d5 TMB2 X 16 Intermediate connector d5
D03 — 2 Diode d6 TMC1 X 12 Intermediate connector d7

1-pin
FS1 connector 1 Spare terminal d5 TMC2 X 12 Intermediate connector d5
J02-EL1 S 16 Intermediate connector b8 TMD1 X 16 Intermediate connector d7
J02-EL2 S 16 ntermediate connector c8 TMD2 X 16 Intermediate connector d6
J04-EL1 S 12 Intermediate connector c8 WL-EL1 M 2 Warning lamp c3
J04-EL2 S 12 Intermediate connector d7 WL-EL2 M 2 Warning lamp b3

1-pin
K0 connector 1 ARSC stand-by lamp Y4
R2 Terminal 1 Travel speed display —
RB For relay 5 RB relay Y7
HD785-5 20-219
7
TROUBLESHOOTING CONNECTOR PIN ALLOCATION CHART
CONNECTOR PIN ALLOCATION CHART
20-220 HD785-5
(13)
HD785-5 20-221
(13)
20-222 HD785-5
(13)
*1. R23: for mechanical governor spec. *3. J09M: for mechanical governor spec.
*2. R22: for mechanical governor spec.
HD785-5 20-223
(13)
ARSC SYSTEM
fl For connector BOSR, BRR, SHUT SOSW see page, 20-220.
20-224 HD785-5
(13)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
No. X-type connector

of T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part no.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part no.: 79A-222-3370 Terminal part no.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: black • Grommet: black
• Quantity: 20 • Quantity: 20
Terminal part no.: 79A-222-3380 Terminal part no.: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-226 HD785-5
(15)
No. SWP-type connector

of T-adapter
Part No.
6 799-601-7050
Part No.: 08055- 10681 Part No.: Part No.: 08055- 10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055- 10891
12 799-601-7310
Part No.: 08055- 11281 Part No.: 08055- 11291
14 799-601-7070
Part No.: 08055- 11481 Part No.: 08055-11491
HD785-5 20-227
(15)
No. SWP-type connector

of T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part no.: Terminal part no.:
— —
• Grommet: black • Grommet: black
Terminal part no.: Terminal part no.:
— —
• Grommet: red • Grommet: red
20-228 HD785-5
(15)
No. M-type connector

of T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
HD785-5 20-229
(15)
S-type connector
No.
of pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(white)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(white)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(white)
Part No.: 08056-11671 Part No.: 08056-11681
20-230 HD785-5
(15)
S-type connector
No.
of pins T-adapter
Part No.
10
—
(blue)
— —
12
799-601-7160
(blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(blue)
Part No.: 08056-11672 Part No.: 08056-11682
HD785-5 20-231
(15)
MIC type connector

No.
of pins T-adapter
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7 —
Qty.: 5 Qty.: 5
11 —
Qty.: 5 Qty.: 5
5 799-601-2710

Qty.: 5 Qty.: 5
9 799-601-2950

Qty.: 5 Qty.: 5
13 799-601-2720

Qty.: 2 Qty.: 2
20-232 HD785-5
(15)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730

Qty.: 2 Qty.: 2
21 799-601-2740

Qty.: 2 Qty.: 2
—
Qty.: 50 Qty.: 50
HD785-5 20-232-1
(15)
AMP040-type connector
No. of
pins T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

—
Qty.: 5
12 799-601-7190

—
Qty.: 5
16 799-601-7210

—
Qty.: 5
20 799-601-7220

—
Qty.: 5
aTerminal part No.: 79A-222-3470 (no relation with number of pins)
20-232-2 HD785-5
(15)
AMP070-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
HD785-5 20-232-3
(15)
L type connector
No. of
pins T-adapter
Part No.
—
2
— — —
PA type connector
No. of
pins T-adapter
Part No.
— —
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
— —
20-232-4 HD785-5
(15)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
2 —
Part No.: 08027-10210 (natural color) Part No.: 08027-10260 (natural color)
08027-10220 (black) 08027-10270 (black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (black) 08027-10470 (black)
6 —
08027-10620 (black) 08027-10670 (black)
HD785-5 20-232-5
(15)
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
8 —
08027-10820 (black) 08027-10870 (black)
20-232-6 HD785-5
(15)
Connector for relay (socket type)

No. of
pins T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
HD785-5 20-232-7
(15)
F-type connector
No. of
pins T-adapter
Part No.
4 —
— —
20-232-8 HD785-5
(15)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
799-601-9210
(1) Pin (female terminal) Pin (male terminal)
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
HD785-5 20-232-9
(15)

Part No.
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-232-10 HD785-5
(15)

Part No.
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

Part No.: 08191-61201, 08191-62202 Part No.: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
HD785-5 20-232-11
(15)

Part No.
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Part No.: 08191-81201, 08191-81202, Part No.: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-81205, 08191-84103, 08191-84104, 08191-84105,
24-22 08191-81206 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202, Part No.: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-82205, 08191-83103, 08191-83104, 08191-83105,
08191-82206 08191-83106
20-232-12 HD785-5
(15)

Part No.
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
HD785-5 20-232-13
(15)
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-232-14 HD785-5
(15)
DT series connector
No. of
pins T-adapter
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9090
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
HD785-5 20-232-15
(15)
DTM series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD series connector

No. of
pins T-adapter
Part No.
Part No.: 08192 - 31200 (contact size #12) Part No.: 08192 - 31100 (contact size #12)
08192 - 41200 (contact size #8) 08192 - 41100 (contact size #8)
08192 - 51200 (contact size #4) 08192 - 51100 (contact size #4)
20-232-16 HD785-5
(15)
TROUBLESHOOTING EXPLANATIONS OF FUNCTIONS OF ELECTRICAL SYSTEM
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF

ELECTRICAL SYSTEM
This section gives the necessary knowledge for
troubleshooting of the electrical system, and ex-
plains the functions and nature of checks for the
engine controller (machine with electronic gov-
ernor specification), the transmission controller,
suspension controller, and monitor panel.
1. EXPLANATION OF FUNCTIONS
The control mechanism of the electrical sys- The monitor panel informs the operator of the
tem consists of the engine controller (machine abnormality when there is a failure in the
with electronic governor specification), the mechatronics equipment of each system. At
transmission controller, suspension control- the same time, it uses the service mode to
ler, and the monitor panel. It carries out vari- monitor the input and output, such as the in-
ous controls such as changing the output of put voltage from the switch sensors of each
the engine (power mode), providing the most controller and the output current to the sole-
suitable transmission clutch oil pressure (full noids, and a monitor function for the failure
electronic modulation), and changing the data stored in the memory of each controller.
damping of the suspension (auto suspension).
Input/output signal system for monitor and controller

1) Mechanical governor specification machine
20-236 HD785-5
(15)
2) Electronic governor specification machine
HD785-5 20-237
(15)
Network data (fl1)

(Display items) (Control data)
1 Troubleshooting data (user code, trans- 1 Travel speed compensation data
mission mechatronics caution display) 2 Model selection data
2 Suspension mode display
Network data (fl2)

(Display items)
1 Troubleshooting data (user code, trans- 9 Air pressure level display
mission mechatronics caution display) 0 Retarder oil pressure level display
2 Engine speed display A Engine coolant temperature level display
3 Speed display (mechanical governor specification ma-
4 Shift position display chine)
5 Mode selector display B Fuel level display
6 Speed range display C Torque converter oil temperature
7 Shift limit display level display
8 Lock-up display D Caution/pilot lamp output
Network data (fl3) (machine with electronic governor specification)

(Display items) (Control data)
1 Troubleshooting data (user code, trans- 1 AISS signal
mission mechatronics caution display) 2 Brake signal
2 Engine speed display 3 Retarder signal
3 Engine coolant temperature level display (Movement information)
1 Engine real time motor data
(Engine speed, rack voltage, engine oil
pressure, engine coolant temperature,
etc.)
Sensor signals (ª)
1 Air pressure 5 Radiator coolant temperature
2 Engine coolant temperature 6 Engine oil pressure
(mechanical governor specification ma- 7 Fuel level
chine) 8 Steering oil temperature
3 Torque converter oil temperature 9 Transmission filter clogging
4 Retarder oil temperature 0 Brake chamber stroke
2. EXPLANATION OF SELF-DIAGNOSTIC
DISPLAY FUNCTIONS causes of these problems can be seen by
Each controller is equipped with a self-diag- pushing the bulb check switch.
nostic troubleshooting display function, so if In addition, the controllers share some of the
any electrical abnormality (disconnection, sensor signals, such as the transmission out-
short circuit, internal short, or short circuit put shaft speed signal, so if any abnormality
between wires, etc.) occurs in output signal occurs in these sensor signals, the same type
systems from No. (1) to (12) and Nos. *1 to of failure display may be given at the same
*14, and input signal systems from A to J, or time.
there is input or output that does not match With the input signal systems from A to J,
the operation of the machine, the nature of even if there is an abnormality, the self-diag-
the abnormality is displayed. nostic display is not given, so in cases where
When the self-diagnostic display function is there is no abnormality display but the move-
actuated, the abnormality occurrence data is ment of the machine is abnormal, to check if
transmitted from each controller to the net- the cause is in the electrical system or in the
work, and the monitor panel displays the user hydraulic, air, or mechanical system, go to
code. The mechatronics abnormality display, Section 3 Method of checking actuation of
warning lamp, and buzzer may also be actu- electrical system, and check if the signals are
ated. The service codes which display the being input.
20-238 HD785-5
(15)
3. CHECKING OPERATION OF ELECTRICAL SYSTEM

When a sequence of operations is carried out using the procedure below, if the monitor panel, en-
gine controller (mechanical governor specification machine), transmission controller, suspension
controller, and payload meter controller carry out the actions given below, the input and output
signals, and the monitor panel and controllers are normal.
Carry out the actuation check with the machine unloaded. (The actuation of the suspension control-
ler differs when the machine is loaded or unloaded, but it is possible to check all of the mode selec-
tions with the machine unloaded.)
Check items (when normal)
Sequence of operations and Engine controller, Suspension
condition of machine Monitor panel Engine controller transmission controller
controller
(1) Turn starting switch OFF All OFF All OFF All OFF All OFF
(2) Turn starting switch to ACC Monitor panel liquid 8.8 is displayed for 3 8.8 is displayed for 3 2-digit LED displays
crystal display lights seconds seconds 0.0 (normal)
up After self-diagnostic Self-diagnostic dis-
display is shown for play lights up for 4.2
• Parking only with parking brake Suspension mode 4.2 seconds, it goes seconds, then goes
soft portion lights up out, and past trouble out, and details of
data are displayed past failures are dis-
• Bulb check switch ON Caution, pilot lamps for 3 seconds each. played for 3 seconds
all light up After that, if condi- each. After that, if
tion is normal, 0.0 is the condition is nor-
• Power mode selection switch • Power mode displayed. mal, 0.0 or 0.C (in
Economy ON/OFF display cold weather) is dis-
Economy/high played.
power lights up
• Shift limiter switch ON/OFF Shift limiter liquid
crystal display lights
up/goes out
• Shift lever set to N Shift indicator N
• Shift position dis-
play N
(3) Start engine • Engine speed is Engine speed: When transmission
• If coolant temperature is below displayed 1,000 rpm oil temperature is
40˚C, automatic warming-up op- • On cooling water below 10˚, 0.0 is dis-
eration is actuated temperature displayed
play, only lowest
segment lights up
• If coolant temperature is above When coolant tem- Engine speed: When oil tempera-
70˚C after completion of warm- perature display is in 650 rpm ture is below 10˚, 0.0
ing-up operation green range is displayed
(4) Release parking brake and stop Engine speed rises Engine speed: Suspension mode
machine with service brake only Parking lamp goes 1,000 rpm switched
out Soft → medium
Rear brake lamp
lights up
Suspension mode
display
Soft → medium
Release service brake and pull re- • Rear brake lamp Engine speed: Suspension mode
tarder lever lights up 650 rpm stays at soft
• Suspension mode
soft portion lights
up
(5) Apply parking brake and raise body Suspension mode 2-digit LED displays Suspension mode
display 0.0 (normal) selection
Soft → hard Soft → hard
(6) In condition (5), set shift lever to R Shift indicator N Body FLOAT
• Shift position REVERSE safety
display R actuated
• Body caution lamp • When body is at
lights up FLOAT, machine
Warning lamp, travels in reverse
buzzer are actuated
Shift indicator 1
• Shift position dis-
play L
20-240 HD785-5
(15)
TROUBLESHOOTING MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
3.5 Monitoring items in machine data monitoring mode

Monitoring item values are useful when-cheking or troubleshooting the machine.
fl For details of the method for going on to the next monitor item (or going back to the previous monitor item)
in the machine data monitoring mode, see 3.3 Method of operating service mode.
Control- Monitor Item Display unit Remarks
ler code item code
Monitor panel
1 Standard service meter 10h After 10000h, shows units of 100h, and left turn signal lamp lights up
2 Switch check ª1 The 1), 2), etc. in the item corresponds to the bit number. When ON,
applicable bit number lights up, See Table 1-a (ª1-a)
1) KPH/MPH selector signal ON/OFF ON: MPH displayed
A 2) Exhaust brake switch ON/OFF Only when exhaust brake is installed
3) AISS switch ON/OFF
4) Mode selector switch 1 ON/OFF
5) Mode selector switch 2 ON/OFF
3 Rotary switch setting 0–F Applicable item in Table 1-b lights up (ª1-b)
1 Model recognition ª2 See Table 2 (ª2)
2 Service meter 10h For details, see Item 3) Service meter for each controller (ª5)
After 10000h, shows units of 100h, and left turn signal lamp lights up
applicable bit number lights up. See Table 1-a (ª1-a)
1) Body seated switch ON/OFF ON: When not seated
2) Spare —
3) Spare —
4) Spare —
5) Spare —
6) Spare —
7) AISS relay signal ON/OFF HD785 mechanical governor specification machine only
8) Spare —
9) BCV solenoid ON/OFF HD465 – HD785 ON: When retarder lever or brake pedal is ON
10) Model selection signal 1 ON/OFF OFF : OPEN (HD785), ON : GND (HD985)
11) Model selection signal 2 ON/OFF OFF : OPEN (HD785, HD985)
12) Model selection signal 3 ON/OFF ON : GND (HD785, HD985)
13) Model selection signal 4 ON/OFF ON : GND (HD785, HD985)
14) Connector check 1 ON/OFF OFF : OPEN
15) Connector check 2 ON/OFF ON : GND
16) Emergency escape switch ON/OFF
17) Starting switch ON/OFF ON: When cranking (START position)
4 Fill signal switch ª1 The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number
lights up. See Table 1-a (ª1-a) For details of the relationship between the speed range and the
clutches, see ECMV Clutch Actuation Table in the section on the transmission valve.
1) L clutch ON/OFF
2) Spare —
3) H clutch ON/OFF
4) 1st clutch ON/OFF
5) 2nd clutch ON/OFF
6) 3rd clutch ON/OFF
7) 4th clutch ON/OFF
b 8) R clutch ON/OFF
5 Engine speed 10rpm
6 Transmission input shaft speed 10rpm
7 Transmission intermediate shaft speed 10rpm
8 Transmission output shaft speed 10rpm
9 Accelerator sensor 0.02 V When at Li : 180–200, when at Hi : 50–70
10 Brake air pressure ª3 See Table 3 (ª3)
11 Spare —
12 Spare —
13 Rear brake cooling oil temperature 1˚C Lo display when less than 60˚C, see Table 4 (ª4)
14 Engine coolant temperature 1˚C Lo display when less than 60˚C (mechanical governor specification machine only), see Table 4 (ª4)
15 Torque converter outlet port oil temperature1˚C Lo display when less than 60˚C, see Table 4 (ª4)
16 Fuel level 1Ω 4 – 100 (FULL: Less than 13; EMPTY: More than 75)
17 Spare —
18 ECMV oil temperature 1˚C Lo display when less than 60˚C, see Table 4 (ª4)
19 Spare —
20 Spare —
21 Spare —
22 Engine oil pressure 9.81kPa Mechanical governor specification machine only.
{0.1kg/cm2} For details, see “Pressure display value” in Item 4) (ª6)
23 Max. speed range 4–7 4 – 7: F4 – F7 (no limit)
24 Max. speed range (when body is raised) 0–3 1 – 3: F1 – F3, 0: default (F2 only when lever is at D, F1 only when lever is at position other than D)
25 Caution setting (when body is raised) 1 or 2 1: OFF, 2: ON,
26 Spare —
27 Solenoid H output 4 mmA When actuated : 133–138
28 Solenoid L output 4 mmA When actuated : 150–156
29 Solenoid 1 output 4 mmA When actuated : 211–220
33 Spare —
34 Spare —
HD785-5 20-255
(15)
Control- Monitor Item Display unit Remarks

ler code item code
Engine controller
1 Service meter 10h See item 3). After 10000h, shows units of 100h, and left turn signal
lamp lights up
2 Switch check 1ª The 1), 2), etc. in the item corresponds to the bit number, When ON,
applicable bit ummber lights up. See Table 1-a (ª1-a)
1) Governor cut relay signal (Left) ON/OFF HD785 (V engine only)

2) Governor cut relay signal (Right) ON/OFF
3) Connector check 1 ON/OFF OFF: OPEN
4) Connector check 2 ON/OFF ON : GND
5) Idle varidation signal 2 ON/OFF ON : GND (at accelater pedal OFF)
6) Idle varidation signal 3 ON/OFF ON : GND (at accelater pedal ON)
7) Start switch ON/OFF ON : When cranking (START position)
3 Set value rotary switch1 0-F Applicable item in Table 1-b lights up (ª1-b)
4 Set value rotary switch2 0-F Applicable item in Table 1-b lights up (ª1-b)
5 Axcel sensor 0.02 V When at Li : 15–27, when at Hi : 175–225
6 Rack sensor (Left) 0.1 mm HD785 (V engine only) When at Li : 60–80
7 Rack sensor (Right) 0.1 mm When at Li : 60–80
8 Pre-stroke solenoid (Left) 10 mmA HD785 (V engine only) When at Li : 55–60, when at Hi : 63–80
9 Pre-stroke solenoid (Right) 10 mmA When at Li : 55–60, when at Hi : 63–80
10 Governor solenoid (Left) 10 mmA HD785 (V engine only) When at Li : 49–52, when at Hi : 47–53
c
11 Governor solenoid (Right) 10 mmA When at Li : 49–52, when at Hi : 47–53
12 Engine oil pressure 9.81kPa When at Li : 10–20, when at Hi : 30–40
{0.1kg/cm2} For details, see “Pressure display value” in Item 4) (ª6)
13 Engine coolant temperature 1°C Lo display wheb less than 60°C, ª4: See Table 4
14 Spare —
15 Spare —
16 Spare —
17 Spare —
18 Spare —
19 Spare —
20 Spare —
21 Spare —
22 Spare —
23 Spare —
24 Spare —
25 Spare —
26 Spare —
27 Spare —
28 Engine 10rpm
29 Spare —
1 Service meter 10h For details, see Item 3) Service meter for each controller (ª5)
After 10000h, shows units of 100h, and left turn signal lamp lights up
applicable bit number lights up, See Table 1-a (ª1-a)
1) Auto suspension solenoid 1 output ON/OFF ON : When at M mode or H mode
2) Auto suspension solenoid 2 output ON/OFF ON : When at M mode
3) Auto suspension solenoid 3 output ON/OFF ON : When at S mode or H mode
4) Rear brake ON/OFF
5) Body FLOAT switch ON/OFF ON : GND (when not at FLOAT position)
d 6) Body selection switch ON/OFF ON : GND (HD465) OFF : OPEN (other than HD465)
3 Suspension pressure (left) 0.098MPa{1kg/cm2} For details, see “Pressure display value” in Item 4) (ª6)
4 Suspension pressure (right) 0.098MPa{1kg/cm2} For details, see “Pressure display value” in Item 4) (ª6)
5 Steering angle speed 1 rpm
6 Spare —
7 Spare —
8 Spare —
9 Spare —
10 Spare —
11 Transmission output shaft speed 10 rpm
20-256 HD785-5
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Table 1-a Bit number (ª1-a)

Of the machine data monitoring mode items, with the displays for the switch checks (monitor
panel item code 2, transmission controller 3, 4, engine controller 2, suspension controller 2),
the values 1), 2), 3)... with each signal in the item corrspond to the number of each pin in the
chart below.
Table 1-b Rotary switch set (ª1-b)
HD785-5 20-257
7
fl When it is difficult to judge which bit number is lighted up (in particular, numbers 3 and 8 or 5 and
14), it is possible to press the burned-out bulb check switch (1) to light up all the segments and
check the bit position.
Table 2 Controller model recognition (ª2)

Model display value Model display value
for machine data Machine specification for machine data Machine specification
monitoring mode monitoring mode
325 HD325/405 mechanical governor 785 HD785 mechanical governor
32b HD325/405 electronic governor 78b HD785 electronic governor
465 HD465/605 electronic governor 985 HD985 mechanical governor
98b HD985 electronic governor
Table 3 Pressure display of brake air pressure sensor (ª3)

The brake air pressure sensor is not an analog output but a level output, so the value for the
pressure display corresponding to the air pressure level display is the fixed value in the table
below.
Pressure display value in machine data monitoring mode MPa {kg/cm2}
Caution level Gauge level When pressure is rising and at When pressure is rising and at
present level present level
Red 7 0.932 {9.5}
Green 6 0.814 {8.3} 0.912 {9.3}
Green 5 0.716 {7.3} 0.794 {8.1}
Green 4 0.618 {6.3} 0.696 {7.1}
Green 3 0.510 {5.2} 0.598 {6.1}
Red 2 0.245 {2.5} 0.510 {5.2}
Red 1 0 {0} 0.226 {2.3}
20-258 HD785-5
B
SELF-DIAGNOSTIC DISPLAY METHOD FOR
TROUBLESHOOTING MONITOR PANEL AND CONTROLLERS
Warning display table
Abnormal system Display code Re-enaction Actuation of

controller
Pilot lamp warning

Transmission filter clogging d.1 — ( )
Tilt warning d.5 — ( )
Drop in radiator coolant level d.6 — ( )
Battery charge d.7 — ( )
Steering oil level (overheating) E.5 — ( )
Drop in engine oil pressure F.5
(Mechanical governor specification machine)
Drop in rear brake oil pressure F.6 — ( )
Actuation warning
Engine overrun actuated d.8 —
Engine overrun short circuit actuated d.9 —
Overheat warning
Torque converter oil temperature d.2 —
Retarder oil temperature F.3 —
Engine coolant temperature d.3 —
(Mechanical governor specification machine)
Pressure drop warning

Drop in air pressure E.9 —
Explanation of symbols: ← 1 – 8: indicates that there are display patterns from 1 to 8 that appear in
the portion.
1 : Lock-up clutch related parts
2 : H clutch related parts
3 : L clutch related parts
4 : 1st clutch related parts
5 : 2nd clutch related parts
6 : 3rd clutch related parts
7 : 4th clutch related
8 : R clutch related parts
: Blank (no display)
fl See the next page for explanation of the symbols used in the controller actuation column.
20-260 HD785-5
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SELF-DIAGNOSTIC DISPLAY METHOD FOR
TROUBLESHOOTING MONITOR PANEL AND CONTROLLERS
• Method of re-enacting failure display

Using the following procedure, it is possible to re-enact the abnormality display and carry out in-
spection.
 System: Turn the starting switch OFF → ON.

 System: Turn the starting switch OFF → ON, and operate the lever slowly in turn to N, R, N, D,
 5, 4, 3, L. (Stop for at least 3 seconds at each position, then go to the next position.)

 System: Set the lever to N and start the engine.
 System: Use the clutch specified in the failure display (set to the speed range using that
 clutch) and carry out a travel test.


 Display Applicable clutch Speed range

 Either 7 or 9 .1 Lock-up clutch L/U
 (inside [ ])
 .2 H clutch F3, F5, F7
 
  .3 L clutch F1, F2, F4, F6
  .4 1st clutch F1
 
 One of 2, 3, 4, 5,
 .5 2nd clutch F2, F3
 7, 9 (inside [ ])

 
.6 3rd clutch F4, F5
  .7 4th clutch F6, F7
 
  .8 R clutch R
 — (intermediate shaft
 1.2 sensor) F2

 System: Apply exhaust brake during travel test. (When traveling in lock-up, operate the brake
 with the accelerator released)

) System: If there is a failure in the sensor system, turn the starting switch OFF → ON.
 (
• Operation of controller when abnormality is detected

If an abnormality is detected, the transmission controller displays the failure and carries out the
following action.
 System: Transmission neutral — there is a failure in the power source or controller, so the
 transmission is set to neutral.
 System: Transmission neutral — the electrical system on the machine and the controller may
 be broken, so the controller automatically turns the output
 OFF.

 System: Transmission neutral — there is probably a failure in the hydraulic or mechanical
 system, so to avoid fatal damage to the transmission, the
 controller automatically turns the output OFF.

 System: Speed range held, ------ because of the abnormal condition, the controller judges
 but when lever is that it is impossible to shift gear, so it holds the speed range.
 at N, N is held
 System: Travel possible,----------- the controller automatically stops the functions in the ab-
 but some functions normal system.
 stopped

 System: Travel possible ----------- the controller works normally.
HD785-5 20-261
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TROUBLESHOOTING TABLE OF SERVICE CODES AND USER CODES
Monitor panel display Controller LED display
Automatic Transmission oil

gearshifting Central temperature
Service code User
No. Details of failure code mechatronics warning
caution lamp
lamp
15˚ or Below
above 15˚
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Existing) (Reset)
27 Abnormality 1 in pressure control valve system for 1st clutch b034 02 ON FLASHES E. ↔ 3.4 E.C ↔ 3.4 3.4
28 Abnormality 1 in pressure control valve system for 2nd clutch b035 02 ON FLASHES E. ↔ 3.5 E.C ↔ 3.5 3.5
29 Abnormality 1 in pressure control valve system for 3rd clutch b036 02 ON FLASHES E. ↔ 3.6 E.C ↔ 3.6 3.6
30 Abnormality 1 in pressure control valve system for 4th clutch b037 02 ON FLASHES E. ↔ 3.7 E.C ↔ 3.7 3.7
31 Abnormality 1 in pressure control valve system for R clutch b038 02 ON FLASHES E. ↔ 3.8 E.C ↔ 3.8 3.8
32 Abnormality 2 in pressure control valve system for H clutch b042 02 ON FLASHES E. ↔ 4.2 E.C ↔ 4.2 4.2
33 Abnormality 2 in pressure control valve system for L clutch b043 02 ON FLASHES E. ↔ 4.3 E.C ↔ 4.3 4.3
34 Abnormality 2 in pressure control valve system for 1st clutch b044 02 ON FLASHES E. ↔ 4.4 E.C ↔ 4.4 4.4
35 Abnormality 2 in pressure control valve system for 2nd clutch b045 02 ON FLASHES E. ↔ 4.5 E.C ↔ 4.5 4.5
36 Abnormality 2 in pressure control valve system for 3rd clutch b046 02 ON FLASHES E. ↔ 4.6 E.C ↔ 4.6 4.6
37 Abnormality 2 in pressure control valve system for 4th clutch b047 02 ON FLASHES E. ↔ 4.7 E.C ↔ 4.7 4.7
38 Abnormality 2 in pressure control valve system for R clutch b048 02 ON FLASHES E. ↔ 4.8 E.C ↔ 4.8 4.8
39 Abnormality in oil flow detection valve system for H clutch b052 02 ON FLASHES E. ↔ 5.2 E.C ↔ 5.2 5.2
40 Abnormality in oil flow detection valve system for L clutch b053 02 ON FLASHES E. ↔ 5.3 E.C ↔ 5.3 5.3
41 Abnormality in oil flow detection valve system for 1st clutch b054 02 ON FLASHES E. ↔ 5.4 E.C ↔ 5.4 5.4
42 Abnormality in oil flow detection valve system for 2nd clutch b055 02 ON FLASHES E. ↔ 5.5 E.C ↔ 5.5 5.5
43 Abnormality in oil flow detection valve system for 3rd clutch b056 02 ON FLASHES E. ↔ 5.6 E.C ↔ 5.6 5.6
44 Abnormality in oil flow detection valve system for 4th clutch b057 02 ON FLASHES E. ↔ 5.7 E.C ↔ 5.7 5.7
45 Abnormality in oil flow detection valve system for R clutch b058 02 ON FLASHES E. ↔ 5.8 E.C ↔ 5.8 5.8
46 Abnormality in engine speed sensor system b060 02 ON FLASHES E. ↔ 6.0 E.C ↔ 6.0 6.0
47 Abnormality in transmission input shaft speed sensor system b061 02 ON FLASHES E. ↔ 6.1 E.C ↔ 6.1 6.1
48 Abnormality in transmission intermediate shaft speed sensor system b062 02 ON FLASHES E. ↔ 6.2 E.C ↔ 6.2 6.2
49 Abnormality in transmission output shaft speed sensor system b063 02 ON FLASHES E. ↔ 6.3 E.C ↔ 6.3 6.3
50 Short circuit in lock-up clutch solenoid system b071 02 ON FLASHES E. ↔ 7.1 E.C ↔ 7.1 7.1
51 Short circuit in H clutch solenoid b072 02 ON FLASHES E. ↔ 7.2 E.C ↔ 7.2 7.2
52 Short circuit in L clutch solenoid b073 02 ON FLASHES E. ↔ 7.3 E.C ↔ 7.3 7.3
53 Short circuit in 1st clutch solenoid b074 02 ON FLASHES E. ↔ 7.4 E.C ↔ 7.4 7.4
54 Short circuit in 2nd clutch solenoid b075 02 ON FLASHES E. ↔ 7.5 E.C ↔ 7.5 7.5
55 Short circuit in 3rd clutch solenoid b076 02 ON FLASHES E. ↔ 7.6 E.C ↔ 7.6 7.6
56 Short circuit in 4th clutch solenoid b077 02 ON FLASHES E. ↔ 7.7 E.C ↔ 7.7 7.7
57 Short circuit in R clutch solenoid b078 02 ON FLASHES E. ↔ 7.8 E.C ↔ 7.8 7.8
58 Disconnection in lock-up clutch solenoid system b091 02 ON FLASHES E. ↔ 9.1 E.C ↔ 9.1 9.1
59 Disconnection in H clutch solenoid b092 02 ON FLASHES E. ↔ 9.2 E.C ↔ 9.2 9.2
60 Disconnection in L clutch solenoid b093 02 ON FLASHES E. ↔ 9.3 E.C ↔ 9.3 9.3
61 Disconnection in 1st clutch solenoid b094 02 ON FLASHES E. ↔ 9.4 E.C ↔ 9.4 9.4
62 Disconnection in 2nd clutch solenoid b095 02 ON FLASHES E. ↔ 9.5 E.C ↔ 9.5 9.5
63 Disconnection in 3rd clutch solenoid b096 02 ON FLASHES E. ↔ 9.6 E.C ↔ 9.6 9.6
64 Disconnection in 4th clutch solenoid b097 02 ON FLASHES E. ↔ 9.7 E.C ↔ 9.7 9.7
65 Disconnection in R clutch solenoid b098 02 ON FLASHES E. ↔ 9.8 E.C ↔ 9.8 9.8
66 Abnormality in model selection system rotary switch b0A1 04 ON FLASHES E. ↔ A.1 E.C ↔ A.1 A.1
67 Abnormality in torque converter oil temperature sensor system b0A2 02 ON FLASHES E. ↔ A.2 E.C ↔ A.2 A.2
68 Abnormality in fuel sensor system b0A3 02 ON FLASHES E. ↔ A.3 E.C ↔ A.3 A.3
69 Abnormality in coolant temperature sensor system (✩) b0b2 02 ON FLASHES E. ↔ b.2 E.C ↔ b.2 b.2
70 Abnormality in air pressure sensor system b0b3 02 ON FLASHES E. ↔ b.3 E.C ↔ b.3 b.3
71 Abnormality in retarder brake oil level sensor (right) system b0b4 02 ON FLASHES E. ↔ b.4 E.C ↔ b.4 b.4
72 Abnormality in engine oil pressure sensor system (✩) b0b7 04 ON FLASHES E. ↔ b.7 E.C ↔ b.7 b.7
73 Abnormality in connector connection b0C1 04 ON FLASHES E. ↔ C.1 E.C ↔ C.1 C.1
74 Short circuit with ground in BCV solenoid system b0C4 02 ON FLASHES E. ↔ C.4 E.C ↔ C.4 C.4
75 Disconnection in BCV solenoid system b0C6 02 ON FLASHES E. ↔ C.6 E.C ↔ C.6 C.6
76 Short circuit in BCV solenoid system b0C8 02 ON FLASHES E. ↔ C.8 E.C ↔ C.8 C.8
77 Transmission filter clogging warning b0d1 01 OFF FLASHES(ª) E. ↔ d.1 E.C ↔ d.1 d.1
HD785-5 20-267
(15)
Monitor panel display Controller LED display
Automatic Transmission oil

gearshifting Central temperature
Service code User
No. Details of failure code mechatronics warning
caution lamp
lamp
15˚ or Below
above 15˚
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Existing) (Reset)
78 Torque converter oil temperature overheat warning b0d2 05 OFF FLASHES E. ↔ d.2 E.C ↔ d.2 d.2
79 Engine coolant temperature overheat warning (✩) b0d3 05 OFF FLASHES E. ↔ d.3 E.C ↔ d.3 d.3
80 Tilt warning b0d5 07 OFF FLASHES E. ↔ d.5 E.C ↔ d.5 d.5
81 Radiator coolant level drop warning b0d6 01 OFF FLASHES E. ↔ d.6 E.C ↔ d.6 d.6
82 Abnormality in charging circuit system b0d7 01 ON FLASHES(ª) E. ↔ d.7 E.C ↔ d.7 d.7
83 Engine overrun prevention brake actuated b0d8 03 OFF FLASHES E. ↔ d.8 E.C ↔ d.8 d.8
84 Engine overshoot b0d9 02 ON FLASHES E. ↔ d.9 E.C ↔ d.9 d.9
85 Drop in battery direct power source voltage b0dA 04 ON FLASHES E. ↔ d.A E.C ↔ d.A d.A
86 Drop in main power source voltage b0db 04 ON FLASHES E. ↔ d.b E.C ↔ d.b d.b
87 Steering oil temperature overheat warning b0E5 05 OFF FLASHES E. ↔ E.5 E.C ↔ E.5 E.5
88 Drop in air pressure b0E9 05 OFF FLASHES E. ↔ E.9 E.C ↔ E.9 E.9
89 Retarder overheat warning b0F3 05 OFF FLASHES E. ↔ F.3 E.C ↔ F.3 F.3
90 Drop in engine oil pressure b0F5 04 OFF OFF E. ↔ F.5 E.C ↔ F.5 F.5
91 Abnormality in brake circuit system b0F6 04 OFF FLASHES E. ↔ F.6 E.C ↔ F.6 F.6
Note 1: “Existing” means that the problem is still occurring; “Reset” means that the problem occurred in the past.
Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is FLASHES.)
For items marked ª, the alarm buzzer does not sound.
Note 3: Reset failures are kept as existing failures for 5 minutes by the transmission controller only; after that, they are saved
as a service code for past failures.
Note 4: For details of the method of display of the service code for reset failures on the monitor panel, see MONITOR PANEL
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in
the Foreword to the Troubleshooting Section. For the method of displaying with the transmission controller LED
display, see SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS, Section 2.4 SAVING
SERVICE CODE TO MEMORY in the Foreword to the Troubleshooting Section.
✩: Applicable only for mechanical governor specification machine.
3. TABLE OF SERVICE CODES AND USER CODES RELATED TO ENGINE CONTROLLER

Monitor panel display
Engine Central
mecha- Controller LED display
No. Details of failure Service code User code tronics warning
lamp
caution lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Reset)
1 Abnormality in power source system C010 04 ON FLASHES E. ↔ 1.0 1.0
2 Abnormality in controller C011 04 ON FLASHES E. ↔ 1.1 1.1
3 Abnormality in pressure sensor right bank system C012 02 ON FLASHES E. ↔ 1.2 1.2
4 Abnormality in pressure sensor left bank system C013 02 ON FLASHES E. ↔ 1.3 1.3
5 Abnormality in governor (right) solenoid system C014 04 ON FLASHES E. ↔ 1.4 1.4
6 Abnormality in governor (left) solenoid system C015 04 ON FLASHES E. ↔ 1.5 1.5
7 Abnormality in governor cut relay (right) system C016 02 ON FLASHES E. ↔ 1.6 1.6
8 Abnormality in governor cut relay (left) system C017 02 ON FLASHES E. ↔ 1.7 1.7
9 Abnormality in rack sensor power source system C018 02 ON FLASHES E. ↔ 1.8 1.8
10 Abnormality in governor servo (right) system C019 04 ON FLASHES E. ↔ 1.9 1.9
11 Abnormality in governor servo (left) system C01A 04 ON FLASHES E. ↔ 1.A 1.A
12 Abnormality in engine speed sensor A system C01b 02 ON FLASHES E. ↔ 1.b 1.b
13 Abnormality in engine speed sensor B system C01C 02 ON FLASHES E. ↔ 1.C 1.C
14 Abnormality in pre-stroke solenoid right bank system C01d 02 ON FLASHES E. ↔ 1.d 1.d
15 Abnormality in pre-stroke solenoid left bank system C01E 02 ON FLASHES E. ↔ 1.E 1.E
16 Abnormality in connection of connector C021 04 ON FLASHES E. ↔ 2.1 2.1
17 Engine overrun actuated C022 03 OFF OFF E. ↔ 2.2 2.2
18 Engine coolant temperature overheat warning C023 05 OFF OFF E. ↔ 2.3 2.3
20-268 HD785-5
(15)

Engine
mech- Central
No. Details of failure Service code User code atronics warning Controller LED display
caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing) (Reset)
19 Drop in engine oil pressure C024 04 FLASHES FLASHES E. ↔ 2.4 2.4
20 Abnormality in oil cooler system C02F 02 OFF OFF E. ↔ 2.F 2.F
21 Abnormality in accelerator signal C031 02 ON FLASHES E. ↔ 3.1 3.1
22 Abnormality in engine coolant temperature sensor system C034 02 ON FLASHES E. ↔ 3.4 3.4
23 Abnormality in engine oil pressure sensor system C036 02 ON FLASHES E. ↔ 3.6 3.6
24 Abnormality in network system C055 02 ON FLASHES E. ↔ 5.5 5.5
25 Abnormality in solenoid power source system right C056 02 ON FLASHES E. ↔ 5.6 5.6
26 Abnormality in solenoid power source system left C057 02 ON FLASHES E. ↔ 5.7 5.7
27 Abnormality in backup power source system C058 02 ON FLASHES E. ↔ 5.8 5.8
28 Abnormality in switch power source system C059 02 ON FLASHES E. ↔ 5.9 5.9
29 Abnormality in model selection data system C0C2 04 ON FLASHES E. ↔ C.2 C.2
30 Abnormality in travel speed compensation data system C0C2 04 ON FLASHES E. ↔ C.2 C.2
31 Defective machine speed data C0C3 04 ON FLASHES E. ↔ C.3 C.3
32 Lack of throttle signal C0C4 02 ON FLASHES E. ↔ C.4 C.4
33 Abnormality in idle validation system C0C5 02 ON FLASHES E. ↔ C.5 C.5
Note 3: Reset failures are kept as existing failures for 5 minutes by the transmission controller only; after that, they are saved
as a service code for past failures.
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in the
Foreword to the Troubleshooting Section. For the method of displaying with the transmission controller LED display,
see SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS, Section 2.4 SAVING SERVICE
CODE TO MEMORY in the Foreword to the Troubleshooting Section.
4. TABLE OF SERVICE CODES AND USER CODES RELATED TO SUSPENSION CONTROLLER

Other
mechatro- Central Controller
No. Details of failure Service code User code nics warning LED display
caution lamp
lamp
(Existing, reset) (Existing) (Existing) (Existing) (Existing)

1 Abnormality in power source system d001 — OFF OFF E. ↔ 0.1
2 Abnormality in controller d002 — OFF OFF E. ↔ 0.2
3 Abnormality in pressure sensor (right) system d011 02 ON FLASHES E. ↔ 1.1
4 Abnormality in pressure sensor (left) system d012 02 ON FLASHES E. ↔ 1.2
5 Abnormality in travel speed sensor system d015 02 ON FLASHES E. ↔ 1.2
6 Abnormality in steering sensor system d016 02 ON FLASHES E. ↔ 1.6
7 Abnormality in solenoid 1 system d021 02 ON FLASHES E. ↔ 2.1
10 Abnormality in network system d0C1 — OFF OFF E. ↔ C.1
11 Defective model selection data d0C2 — OFF OFF E. ↔ C.2
12 Defective travel speed compensation data d0C3 — OFF OFF E. ↔ C.3
USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in the
Foreword to the Troubleshooting Section.
Note 4: Reset failures are not displayed on the suspension controller LED display.
HD785-5 20-269
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5. TABLE OF SERVICE CODES AND USER CODES RELATED TO PMC (POWER TRAIN MANAGEMENT
CONTROLLER)
Other Central Controller

Service LED
No. Details of failure code
User code mechatronics warning display
caution lamp lamp
(Existing) (Existing) (Existing) (Existing) (Existing)

1 NV RAM data failure E001 02 ON FLASHES 0.1(flashes)
2 Drop in voltage of battery direct power source E002 02 ON FLASHES 0.2(flahses)
3 Abnormality in connection of connector E003 04 ON FLASHES 0.3(flashes)
4 Disconnection in GSP communications E011 02 ON FLASHES 1.1(flashes)
5 Abnormality in GSP communications E012 02 ON FLASHES 1.2(flashes)
6 Disconnection in MOM communications E013 02 ON FLASHES 1.3(flashes)
7 Abnormality in MOM communications E014 02 ON FLASHES 1.4(flashes)
8 Disconnection in TMS communications E015 15 ON FLASHES 1.5(flashes)
9 Abnormality in TMS communications E016 16 ON FLASHES 1.6(flashes)
10 Disconnection in CENSE communications E017 02 ON FLASHES 1.7(flahses)
11 Abnormality in CENSE communications E018 02 ON FLASHES 1.8(flashes)
12 PLM communication abnormality 1 E026 02 ON FLASHES 2.6(flashes)
16 PLM communication abnormality 5 E02A 02 ON FLASHES 2.A(flashes)
17 Idle validation abnormality E035 02 ON FLASHES 3.5(flashes)
18 Disconnection, short circuit with ground in suspension pressure sensor (right) system E041 02 ON FLASHES 4.1(flashes)
19 Disconnection, short circuit with ground in suspension pressure sensor (left) system E042 02 ON FLASHES 4.2(flashes)
20 Short circuit in suspension pressure sensor (right) system E043 02 ON FLASHES 4.3(flashes)
21 Short circuit in suspension pressure sensor (left) system E044 02 ON FLASHES 4.4(flashes)
22 Disconnection in accelerator signal system E054 02 ON FLASHES 5.4(flashes)
23 Short circuit in accelerator signal system E055 02 ON FLASHES 5.5(flashes)
24 Abnormality in engine speed sensor system E056 02 ON FLASHES 5.6(flashes)
25 Abnormality in transmission input shaft speed sensor system E057 02 ON FLASHES 5.7(flashes)
26 Abnormality in travel speed sensor (transmission output shaft speed sensor) system E058 02 ON FLASHES 5.8(flashes)
27 Drop in brake oil level E0A1 01 OFF OFF A.1(flashes)
28 Drop in retarder oil level E0A2 01 OFF OFF A.2(flashes)
29 Drop in hydraulic oil level E0A3 01 OFF OFF A.3(flashes)
30 Retarder filter clogged E0A5 01 OFF OFF A.5(flashes)
31 Full-flow filter clogged E0A7 01 OFF OFF A.7(flashes)
32 Hydraulic filter clogged E0A8 01 OFF OFF A.8(flashes)
33 Wear of retarder brake disc right E0b2 01 OFF OFF b.2(flashes)
34 Wear of retarder brake disc left E0b3 01 OFF OFF b.3(flashes)
35 Drop in battery electrolyte level E0b4 01 OFF OFF b.4(flashes)
36 Drop in engine oil level E0b5 01 OFF OFF b.5(flashes)
37 Air cleaner clogged E0b6 01 OFF OFF b.6(flashes)
38 Abnormality in network system E0C1 02 OFF OFF C.1(flashes)
39 Abnormality in model selection data E0C2 04 OFF OFF C.2(flashes)
40 Abnormality in travel speed compensation data E0C3 04 OFF OFF C.3(flashes)
Note 1: “Existing” means that the problem is still occurring.

Note 2: Reset failures are not saved as trouble data.
Note 3: For the items where the central warning lamp lights up, the alarm buzzer also sounds.
20-270 HD785-5
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6. PAYLOAD METER (Printer type)

This is shown on the payload meter display. (It is not shown on the monitor panel display.)
fl When the condition is normal, the display shows the weight display or the time display.
Order of
priority Display Content
1 –––8 Internal CPU stopped (CPU is reset) (Controller power source etc. normal)
E – 31 Abnormal sensor power source (18V)
2 E – 32 Short circuit in relay
E – 33 Drop in back-up battery voltage
E – 01 Rear right wheel • Disconnection in pressure sensor signal wire

E – 02 Rear left wheel • Signal wire in contact with chassis
3
E – 03 Front right wheel • Defect inside sensor
E – 04 Front left wheel
E – 11 Rear right wheel
E – 12 Rear left wheel

4 • Pressure sensor signal wire in contact with power source line
E – 13 Front right wheel
E – 41 Disconnection in clinometer signal wire or signal wire in contact with chassis

5
E – 42 Clinometer signal wire in contact with electric line
6 PAPE Printer REDY signal not given (paper jam)
7 FULL Data saved in memory has reached 200 cycles (overflow)
8 CAL – Calibration needed
E – 21 Rear right wheel
E – 22 Rear left wheel • When sensor check is carried out, abnormality in sensor
9
E – 23 Front right wheel system is detected.
Note 1: Once an error is displayed, the error continues to

be displayed until CAL switch (1) is pressed.
Continues to display service code in display por-
tion (2).
Note 2: If the controller detects the abnormalities in the
above table, all the display lamps light up.
HD785-5 20-271
1
7. PAYLOAD METER II (Card type)

This is shown on the payload meter II (card type) display. (It is not shown on the monitor panel
display.)
fl When the condition is normal, the display shows the weight display or the time display.
Order of Service code
priority Content Monitor Controller LED External display lamps
for panel
display display
display
Dump lever at position other than FLOAT — b-FL lights up All light up
1
(other than dumping soil) — b-FL lights up
2 Memory card missing — Cd flashes —
3 Drop in backup battery voltage F009 F-09 flashes —
Cycle data memory FULL
Engine ON/OFF data FULL See next page —
4 —
Abnormality warning data memory FULL (*1)
Aggregate payload total cycle number data memory FULL
5 Disconnection in terminal R F018 F-18 flashes All flash
6 Abnormality in sensor power source (18V) F020 F-20 flashes All flash
Short circuit with ground, disconnection in front left sus-
7 pension pressure sensor system F021 F-21 flashes All flash
Short circuit with ground, disconnection in front right sus-

Short circuit with ground, disconnection in rear left suspen-

9 sion pressure sensor system F023 F-23 flashes All flash
Short circuit with ground, disconnection in rear right sus-

Short circuit with power source of front left suspension pres-

11 sure sensor system F025 F-25 flashes All flash
Short circuit with power source of front right suspension

12 pressure sensor system F026 F-26 flashes All flash
Short circuit with power source of rear left suspension pres-

Short circuit with power source of rear right suspension pres-

15 Short circuit with ground, disconnection in clinometer system F031 F-31 flashes All flash
16 Short circuit with power source in clinometer system F032 F-32 flashes All flash
17 Calibration not carried out or abnormality in RAM F019 F • CAL flashes All flash
18 Short circuit in external display lamp No. 1 relay F041 F-41 flashes Applicable lamp
Machine stopped: Always ON
19 Short circuit in external display lamp No. 2 relay F042 F-42 flashes Traveling: OFF
Other lamps
20 Short circuit in external display lamp No. 3 relay F043 F-43 flashes When loading: Specified actuation
21 Short circuit in external display lamp No. 4 relay F044 F-44 flashes When stopped but not loading:
Flashes
22 Short circuit in external display lamp No. 5 relay F045 F-45 flashes Traveling: OFF
23 Defective cycle data payload [see (*2) on page after next] — L.bad flashes —
24 Over limit speed — SP : SP flashes —
F071 F-71 flashes
F073 F-73 flashes
F080 F-80 flashes
F081 F-81 flashes
F091 F-91 flashes
F092 F-92 flashes
25 Defective communications or defective option code setting —
F093 F-93 flashes
F094 F-94 flashes
F095 F-95 flashes
F096 F-96 flashes
F097 F-97 flashes
F098 F-98 flashes
fl The above is displayed on the monitor panel only when the PMC is installed.
PMC: Power train Management Controller
20-272 HD785-5
(15)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
G-cc Troubleshooting of engine controller system
S-cc Troubleshooting of engine
A-cc Troubleshooting of transmission controller system
SP-cc Troubleshooting of suspension controller input signal system
LP-cc Troubleshooting of payload meter (printer type) system
LC-cc Troubleshooting of payload meter (card type) system
R-cc Troubleshooting of auto retarder controller system
H-cc Troubleshooting of hydraulic, mechanical system
P-cc Troubleshooting of monitor panel system
M-cc Troubleshooting of machine monitor system
2. Method of using troubleshooting table for each troubleshooting mode

(1) Troubleshooting code number and problem (for (1) - (4), see the examples on the next page.)
The title at the top of the troubleshooting chart gives the troubleshooting code and failure mode
(problem with the machine).
(2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according
to the model, component, or problem. In such cases, the failure mode (problem) is further di-
vided into sections marked with small letters (for example, a)), so go to the appropriate section to
carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item in the failure mode.
(3) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when carrying
out the check inside the .
(4) Method of following troubleshooting chart
YES
• Check or measure the item inside NO
, and according to the answer follow either the YES
line or the NO line to go to the next . (Note: The number written at the top right corner
of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy col-
umn on the right.
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the answer
to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
(5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
(6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin num-
ber. When carrying out troubleshooting, see this chart for details of the location for inspection
and measurement of the wiring connector and the pin number appearing in the troubleshooting
flow chart for each failure mode (problem).
HD785-5 20-277
(15)
<Example>
(1) A-1 Abnormality in power source system
(3) fl When fuse BT1 (No. 10) is normal.

If it is blown, check for a short circuit with the ground between the fuse and controller.
fl When the battery is normal.
fl Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
fl Always connect any disconnected connectors before going on to the next step.
(2) a) [OFF] Controller self-diagnostic display LED does not light up
(4)
Cause Remedy
2 YES
Defective controller Replace
Is voltage be-
YES tween ACT1 (9),
1 (17) - (8), (16) Defective contact or
normal? disconnection in wiring Repair or
harness between fuse BT1 replace wiring
Does horn • 20 – 30 V NO (No. 10) - TMB (11) - ACT1 harness
sound? • Turn starting (female) (9),(17)
switch ON. Defective contact or
disconnection in wiring Repair or
• Turn starting harness between battery replace wiring
switch ON. NO relay M - circuit breaker harness
J07 - BT1 (19)
A-1 a) Related electrical circuit diagram
20-278 HD785-5
1
TROUBLESHOOTING OF ENGINE CONTROLLER
SYSTEM (ELECTRONIC GOVERNOR
SPECIFICATION G MODE)
Action taken by self-diagnostic device and problems on machine .................................................... 20-302

Judgment table for transmission controller, transmission related parts ........................................... 20-310
Electeical circuit diagram for engine controller system ....................................................................... 20-314
Monitor
panel Controller
display display
G-1 C010 [E.↔1.0] Abnormality in power source ........................................................................ 20-315
G-2 C011 [E.↔1.1] Abnormality in controller .............................................................................. 20-315
G-3 C012 [E.↔1.2] Abnormality in rack sensor system .............................................................. 20-316
G-4 C013 [E.↔1.3] Abnormality in rack sensor system left bank ............................................... 20-317
G-5 C014 [E.↔1.4] Abnormality in governor solenoid system right bank ................................ 20-318
G-6 C015 [E.↔1.5] Abnormality in governor solenoid system left bank ................................... 20-319
G-7 C016 [E.↔1.6] Abnormality in governor cut relay system right bank ................................ 20-320
G-8 C017 [E.↔1.7] Abnormality in governor cut relay system left bank ................................... 20-321
G-9 C018 [E.↔1.8] Abnormality in rack sensor power source system ...................................... 20-322
G-10 C019 [E.↔1.9] Abnormality in governor servo system right bank ..................................... 20-323
G-11 C01A [E.↔1.A] Abnormality in governor servo system left bank ........................................ 20-323
G-12 C01b [E.↔1.b] Abnormality in engine speed sensor system A ........................................... 20-324
G-13 C01c [E.↔1.c] Abnormality in engine speed sensor system B ........................................... 20-325
G-14 C01d [E.↔1.d] Abnormality in pre-stroke solenoid system right bank ............................... 20-326
G-15 C01E [E.↔1.E] Abnormality in pre-stroke solenoid system left bank ................................. 20-327
G-16 C021 [E.↔2.1] Mistaken connection of connector ................................................................ 20-328
G-17 C022 [E.↔2.2] Engine overrun ............................................................................................... 20-329
G-18 C023 [E.↔2.3] Engine overheating ........................................................................................ 20-329
G-19 C024 [E.↔2.4] Drop in engine oil pressure ........................................................................... 20-329
G-20 C031 [E.↔3.1] Abnormality in acceleration sensor system ................................................. 20-330
G-21 C034 [E.↔3.4] Abnormality in engine coolant temperature system .................................. 20-333
G-22 C036 [E.↔3.6] Abnormality in engine oil pressure sensor .................................................. 20-334
G-23 C055 [E.↔5.5] Abnormality in network ................................................................................. 20-335
G-24 C056 [E.↔5.6] Abnormality in solenoid power source system right .................................. 20-336
G-25 C057 [E.↔5.7] Abnormality in solenoid power source system left .................................... 20-336
G-26 C058 [E.↔5.8] Abnormality in backup power source system ............................................. 20-336
G-27 C059 [E.↔5.9] Abnormality in backup power source system ............................................. 20-338
G-28 C0C2 [E.↔C.2] Defective model selection data ..................................................................... 20-339
G-29 C0C4 [E.↔C.4] Abnormality in acceleration sensor system ................................................. 20-340
G-30 C0C5 [E.↔C.5] Abnormality in idle validation ....................................................................... 20-343
G-31 Engine does not start .................................................................................................................. 20-348
fl Re-enacting failures in electrical system

With failures in the electrical system, there are cases where failures, such as defective contact of
wiring harnesses and connectors, occur only under special conditions particularly at the initial stage
of the occurrence of the failure.
(For example, when the engine is running at high speed or the truck is traveling at high speed on
rough road surfaces)
Therefore, investigate the values for the resistance and voltage at the locations indicated by the
abnormal display, Even if no abnormality is found, it is necessary to investigate the conditions under
which the failure occurred, and to try to re-enact the failure condition to carry out troubleshooting.
HD785-5 20-301
(15)
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE
TROUBLESHOOTING AND PROBLEMS ON MACHINE
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROB-

LEMS ON MACHINE
Details of abnormality Check the wiring harnesses and equipment
Display Abnormal system given below : Disconnection, short circuit in wiring harness
code fl Judgment conditions
(+): Positive, (–): Negative
OFF or Power source system Drop in voltage at same time in power source voltage system correspond-
C010 fl (Voltage between EC1 ing to service codes 59 and 58 [E ↔ 5.9], [E ↔ 5.8]
[E.↔1.0] (9) – (8) and (17) – (16): 1. Between (+) battery (+) – FU (2)
(OFF) less than 17V) and (Volt-
age between EC1 (7) – 2. Between (+) FU (1) – FUA (1)
 or  3. Between (+) FUA (1) – J03 (13)
E.↔1.0 (16): more than 17 V)
generated at same time 4. Between (+) J03 (13) – BT2 (13),(14)
5. Between (+) BT2B (13) – (14) – starting switch terminal B
6. Between (+) starting switch ACC – BT2 (1),(2)
7. Between (+) BT2 (1),(2) – ECA (15)
8. Between (+) ECA (15) – EC1 (9) or (17)
9. Between (–) EC (18),(19) – ECA (13) – J06 – battery relay E
10. Between (+) battery (+) – FUA (1) – J03 (13) – BT2 (15),(16) – ECA (12) – EC1 (7)
11. Between (–) EC1 (16) – EC2 (21), EC3A (14) – ECA (13) – J06 – battery relay E
fl Content of abnormality is same as 59 and 58
C011 Controller Defective controller

[E.↔1.1] fl Inside controller
• Watch dog timer actu-
ated
• Data abnormal
C012 Disconnection, short circuit 1. Between EC3A (7) – E8 (3) – F13 (3) (signal (+))
[E.↔1.2] with ground in rack sensor
right bank 2. Between EC3A (17) – E8 (1) – F13 (4) (signal (–))
fl Between EC3A (7) and 3. Between (+) EC2 (16) – E8 (1) – F13 (1)
(17) 4. Between (–) EC1 (8),(16) and EC3A (14) – E8 (2) – E13 (2)
• Min. 4.4 ± 0.1 V
• Max. 0.1 ± 0.05 V 5. Defective rack sensor
C013 Disconnection, short circuit 1. Between EC3A (8) – E7 (3) – E9 (3) (signal (+))
[E.↔1.3] with ground in rack sensor
left bank 2. Between EC3A (18) – E7 (7) – E9 (4) (signal (–))
fl Between EC3A (8) and 3. Between (+) EC2 (16) – E8 (1) – E13 (1)
(18) 4. Between (–) EC1 (8),(16) and EC3A (14) – E7 (2) – E9 (2)
• Min. 4.4 ± 0.1 V
• Max. 0.1 ± 0.05 V 5. Defective rack sensor
C014 Disconnection, short circuit 1. Between (+) EC2 (7) and E15 (2)
[E.↔1.4] with ground in governor 2. Between (–) EC2 (17) and E15 (1)
solenoid right bank
fl Between EC2 (female) 3. Defective governor solenoid
(7) and (17) 1) Defective resistance between E15 (2) and (1)
• 10 – 21 Ω 2) Defective short circuit between E15 (2) and chassis
4. Between (+) EC2 (1) – ECA (14) – R22E (6) – (governor cut relay) (3) –
BT2 fuse (1)(2)
C015 Disconnection, short circuit 1. Between (+) EC2 (8) and E11 (2)
[E.↔1.5] with ground in governor
solenoid left bank 2. Between (–) EC2 (18) and E11 (1)
fl Between EC2 (female) 3. Defective governor solenoid
(8) and (18) 1) Defective resistance between E11 (2) and (1)
• 10 – 21 Ω
2) Defective short circuit between E11 (2) and chassis
4. Between (+) EC2 (12) – ECA (16), (6) – (governor cut relay) (3) – BT2 fuse
(1)(2)
C016 Disconnection, short circuit, 1. Defective governor cut relay
[E.↔1.6] short circuit with ground in
governor cut relay right 2. Between EC1 (5) – ECA (1) – R22E (2), (1) (governor cut relay) – fuse II
bank (BT1)-(1)
3. Between EC2 (1) – ECA (14) – R22E (6), (3) (governor cut relay) – fuse II
(BT1)-(1)
20-302 HD785-5
7
Action of controller Symptoms that appear in ma-

Condition when normal : Check with tester chine when there is abnormality
when abnormality is
Voltage (V), current (A), resistance value Ω detected
Mechatronics abnormality dis-
play given, warning actuated
Controller display [0.0] Stops engine 1. The engine stalls

during operation.
2. The engine cannot
be started.
Controller display normal Stops engine 1. The engine stalls

Normal [0.0] during operation.
2. The engine cannot
be started.
EC3A EC13 E8 (V) Ω Open control 1. There is a feeling of

loss of power during
Between (7) – (17) Between (3) – (4) Between (3) – (7) 0.2 –␣ 3.8 — operation.
Between (1) – (2) Between (1) – (2) 4.6 – 5.4 — 2. Engine pick-up be-
comes poor.
Between each pin – chassis — — Min. 1 MΩ 3. It becomes difficult to
start the engine again.
EC3A EC13 E8 (V) Ω Open control 1. There is a feeling of

loss of power during
Between (8) – (18) Between (3) – (4) Between (3) – (7) 0.2 –␣ 3.8 — operation.
Between (1) – (2) Between (1) – (2) 4.6 – 5.4 — 2. Engine pick-up be-
comes poor.
Between each pin – chassis — Min. 1 MΩ 3. It becomes difficult to
start the engine again.
EC2 E15 E8 (V) Ω Right bank: 1. There is a feeling of

stops engine loss of power during
Between Left bank: operation.
Between (7) – (17) Between (1) – (2) Between (13) – (14) — 10 – 21 Ω normal control 2. Engine pick-up be-
Between (7) and Between (2) – Between (14) – comes poor.
EC1 (4) – chassis chassis chassis — Min. 1 MΩ 3. It becomes difficult to
Between (1) – chassis — — 20 –␣ 30 — start the engine again.
Between each pin – chassis — — Min. 1 MΩ
EC2 E11 E7 (V) Ω Right bank: 1. There is a feeling of

normal control loss of power during
Between (8) – (18) Between (1) – (2) Between (13) – (14) — Between Left bank: operation.
10 – 21 Ω stops engine 2. Engine pick-up be-
Between (8) and Between (2) – Between (14) – comes poor.
EC1 (5) – chassis chassis chassis — Min. 1 MΩ 3. It becomes difficult to
Between (12) – chassis — — 20 –␣ 30 — start the engine again.
Between each pin – chassis — — Min. 1 MΩ
EC1 EC2 ECA R22E (V) Ω Normal control —

Between (4) Between (1) Between (1), Between (1),
– chassis – chassis (14) – chassis (3) – chassis 20 – 30 —
Between
— — — (1) – (2) — 200 – 900
HD785-5 20-303
(15)

when abnormality is
Voltage between EC5A (1) – chassis ground: Max. 1 V Stops engine 1. Engine does not
start.
Controller display [0.0] Cuts fuel spray 1. Engine does not re-
spond to accelerator.
2. No mechatronics ab-
normality is displayed.
Controller display [0.0] Restricts output to 1. There is loss of power

80% for operation during operation.
2. Engine acceleration
becomes poor.
Controller display [0.0] Restricts output to 1. There is loss of power

50% for operation during operation.
2. Engine acceleration
becomes poor.
Voltage between EC3A (6) – (16): 4.6 – 5.4 V Idle validation op- 1. Engine speed does
eration not rise to high idle.
Voltage between EC3B (11) – EC3A (16): 0.3 – 4.5 V 2. Defective engine ac-
Controller display [0.0] celeration.
Voltage between EC3B (10) – EC3A (16): 0.3 – 4.7 V Normal control —
Voltage between EC3A (6) – EC3A (16): 4.6 – 5.4 V Normal control —
Voltage between EC3B (12) – EC3A (16): 0.3 – 4.7 V
Controller display When it occurs at 1. Engine speed stays at

same time as C2 low idle, or does not
1. EC4 (12) – ATC4 (12): Max. 1 Ω  and C4, idle rise to high idle.
2. EC4 (6) – ATC4 (6): Max. 1 Ω  validation opera-
3. EC4 (10) – ATC4 (10): Max. 1 Ω  tion.
 Resistance: Max. 1 Ω
4. EC4 (12) – DP05 (4): Max. 1 Ω  In other cases: —
5. EC4 (6) – DP05 (3): Max. 1 Ω  normal control
6. EC4 (10) – DP05 (5): Max. 1 Ω 
HD785-5 20-307
(15)

C056 Disconnection, short circuit 1. Defective governor cut relay
[E.↔5.6] in solenoid power source
system right bank 2. Between EC2 (1) – ECA (14) – R22E (6), (3) (governor cut relay) – BT2
fl Voltage between EC2 (1) fuse (1),(2)
and chassis less than 5
V
C057 Disconnection, short circuit 1. Defective governor cut relay

[E.↔5.7] in solenoid power source
system left bank 2. Between EC2 (12) – ECA (16) – R23E (6), (3) (governor cut relay) – BT2
fl Voltage between EC2 fuse (1),(2)
(12) and chassis less
than 5 V
C058 Backup power source sys- 1. Between (+) battery (+) – FU (2),(1) – FUA (1) – J03 (13) – fuse II (BT-2)
[E.↔5.8] tem
fl Voltage between EC1 (7) (16), (18) – ECA (12) – EC1 (7)
and (16) becomes less 2. Between (–) EC1 (16), EC2 (21), EC3A (14) – ECA (13) – J06 – FUA (4) –
than 17 V chassis ground
Switch power source sys- 1. Between (+) battery (+) – FU (2)

C059 tem
[E.↔5.9] fl Voltage between EC1 (9) 2. Between (+) FU (1) – FUA (1)
– (18), (17) – (16) be- 3. Between (+) FUA (1) – J03 (13)
comes less than 17 V 4. Between (+) J03 (13) and fuse II (BT2) (11)
5. Between (+) fuse II (BT2) (11) and starting switch terminal B
6. Between (+) starting switch ACC and BT2 (1),(2)
7. Between (+) BT2 (1),(2) – ECA (15)
8. Between (+) ECA (15) – EC1 (9) or (17)
9. Between (–) EC1 (8),(16) – ECA (13) – J06 – FUA (4) – chassis ground
C0C2 Model selection data Disconnection in network {see display C055 [E ↔ 5.5]
[E.↔C.2] fl C055 [E ↔ 5.5] is dis- or
played Mistake in selection of model selection data for rotary switch of transmis-
Abnormality in rotary sion controller
switch of transmission
controller
C0C4 Disconnection, short circuit 1. EC3A (12) – ECA (6) – PMS (7) – PMC3 (6)
[E.↔C.4] in acceleration sensor sys- 2. Defective acceleration sensor
tem
fl Input frequency be- 3. Defective model selection data “C0C2 [E.↔C2]” error display given
tween EC3A (12) and (sometimes given)
chassis: 109 Hz or below 4. Disconnection in network wiring “C055 [E.↔55]” error display given
(sometimes given)
C0C5 Disconnection in wiring har- 1. EC5A (3) – J09E (8) – WAS1 (4)
[E.↔C.5] ness, short circuit in idling 2. EC5A (4) – J09E (9) – WAS1 (5)
validation system
fl When accelerator is at 3. EC3A (14) – ECA (13) – WAS1 (6)
low idling 4. Defective model selection data “C0C2 [E.↔C2]” error display given
(Voltage between EC5A (sometimes given)
(3) and EC3A (14): 15 V
or below, or voltage be- 5. Disconnection in network wiring “C055 [E.↔55]” error display given
tween EC5A (4) and (sometimes given)
EC3A (14): 1 V or below)
or when accelerator is at
full
(Voltage between EC5A
(3) and EC3A (14):
1 V or above, or
voltage between EC5A
(4) and EC3A (14):
15 V or below)
20-308 HD785-5
1

when abnormality is
Operates bank on 1. There is a feeling of loss

EC2 ECA R22E (V) one side of power during operation.
Left bank: nor-

Between Between Between (3), 2. Engine pick-up becomes
mal operation 
20 – 30 
(1) – chassis (14) – chassis (6) – chassis poor.
3. The engine is difficult to
start.
Operates bank on 1. There is a feeling of loss

EC2 ECA R22E (V) one side of power during operation.
Right bank: nor-

Between Between Between (3), 2. Engine pick-up becomes
mal operation 
20 – 30 
(12) – chassis (16) – chassis (6) – chassis poor.
3. The engine is difficult to
start.
1. Voltage between EC1 (7) and (16): 20 – 30 V Normal control —

2. Voltage between EC1 (7) and chassis: 20 – 30 V
3. Resistance between EC1 (16) and chassis: Max. 1 Ω
1. Voltage between EC1 (9),(10 and (8),(16): 20 – 30 V Normal control —

2. Voltage between EC1 (9),(17) and chassis: 20 – 30 V
3. Resistance between EC1 (8),(16) and chassis: Max. 1 Ω
Controller display [0.0] Low idling or idle 1. Engine speed stays at

validation opera- low idle, or does not
tion rise to high idle.
Transmission controller Switch 1 A or B
rotary switch
Switch 2 One of the following: 0,1,2,3,8,9,A,B
Input frequency between EC3A (12) and chassis: 109 – 394 Hz Idle validation op- 1. Engine speed does
eration not rise to high idle.
Controller display [0.0] 2. Defective engine ac-
celeration.
Controller normal display [0.0] Normal control —

Resistance between EC5A (3) and WAS1 (4): Max. 1 Ω
HD785-5 20-309
(15)
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,
TROUBLESHOOTING TRANSMISSION RELATED PARTS

TRANSMISSION RELATED PARTS
Self-diagnostic display (abnormal display)
Abnor- Abnor-
Con- mality mality Abnor- Abnor- Abnor- Abnor- Abnor- Abnor-
troller in in mality mality mality mality mality mality
power in in in rack in in rack in rack
Check item
sole- sole-
source noid noid backup switch sensor con- sensor sensor
sys- power power power power power troller right left
tem source source source source source BOX bank bank
system system sys- sys- sys- sys- sys- sys-
(right) (left) tem tem tem tem tem tem
OFF
or 56 57 58 59 18 11 12 13
10
No. Category Failure mode C010 C056 C057 C058 C059 C018 C011 C012 C013
b←→b
1 Engine does not start b Occurs simultaneosly b b b
Difficulty in star- Exhaust smoke comes out but engine does not b . . . . . .b
ting engine, no (1) start, or is difficult to start b . . . . . .b One of these
2 One of these
exhaust smoke
comes out (2) No exhaust smoke comes out
Engine (1) Engine stalls when machine is stopped b b
3 stopped during
b . . . . . .b
operation (2) Engine stalls when turning or braking suddenly One of these
Engine lacks (1) Machine is driven with balance on one side b . . . . . .b b . . . . . .b
One of these One of these
4 power, acceleration
b . . . . . .b
is poor (2) Machine is driven with balance on both sides One of these
Engine speed
stays at low idle, (1) Exhaust gas is normal (operator’s judgment)
5 does not change
when accelerator (2) Exhaust smoke is abnormally black
pedal is depressed
Engine acceler- (1) Accelerated at same time as abnormality display

6 ates to high idle (2) Accelerated while abnormality display was showing
Low idle speed is (1) Does not change to high speed Hi
not actuated
7 according to
operation (2) Does not change to low speed Lo
High fuel (1) Exhaust gas is normal (operator’s judgment)
8
consumption (2) Exhaust smoke is abnormally black
Engine speed (1) Does not reach high idle
9 does not change
to high idle (2) Reaches high idle but returns to low idle
10 Defective automatic warming-up operation
(1) Engine continues to run at high speed
Engine does
11 not stop Engine continues to run at low idling even when
(2) starting switch is turned OFF
There is (1) Engine rotation is unstable at low idle

12 hunting (2) Engine rotation is unstable at high idle
13 High oil consumption, or exhaust smoke is blue
14 Oil becomes dirty quickly
15 Oil in coolant
16 Oil pressure lamp lights up
17 Oil level rises
18 Coolant temperature rises too high
19 Abnormal noise is generated
20 Excessive vibration
Troubleshooting code when abnormality display is given G-1 G-24 G-25 G-26 G-27 G-9 G-2 G-3 G-4
20-310 HD785-5
(15)
Self-diagnostic display (abnormal display)

Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Abnor- Over-
mality mality mality mality mality mality mality mality mality mality mality mality mality mality mality mality run
in in in in in in in pre- in pre- in in in oil in in in in in
gover- gover- gover- gover- speed speed stroke stroke wiring coolant pres- net- model idling throttle throttle
nor nor nor cut nor cut sensor sensor sole- sole- har- tem- sure work selec- valida- signal signal
sole- sole- relay relay sys- sys- noid noid ness pera- sensor tion tion Troubleshooting
noid noid sys- sys- tem A tem B sys- sys- sys- ture sys- code when no
data sys-
system system tem tem tem tem tem sensor tem tem abnormality
(right) (left) (right) (left) (right) (left) system
display is given
14 15 16 17 1b 1C 1d 1E 21 34 36 55 C2 C5 31 C4 22
C014 C015 C016 C017 C01b C01C C01d C01E C021 C034 C036 C055 C0C2 C0C5 C031 C0C4 C022
b←→b
Occurs simultaneosly b b b S Mode
b . . . . . .b b . . . . . .b
One of these One of these
S Mode
b b S Mode
b . . . . . .b
One of these b b S Mode
b . . . . . .b
One of these b b G-20
b b —
b←→b b . . . . . .b
Occurs simultaneosly One of these b b b b —
—
G-20
G-20
b . . . . . .b
One of these b b b b S Mode
b b b b S Mode
G-20
b . . . . . .b —
One of these
b b b b —
b b —
b b b —
—
S Mode
S Mode
S Mode
S Mode
S Mode
S Mode
S Mode
S Mode
S Mode
G-5 G-6 G-7 G-8 G-12 G-13 G-14 G-15 G-16 G-21 G-22 G-23 G-28 G-30 G-20 G-29 G-17
HD785-5 20-311
(15)
Self-diagnostic display Machine signal

(abnormal display)
Over- Drop Abnor- Abnor- When Ex- AISS Park- Rear
heat in mality mality start- haust switch ing brake
in in
Check item
en- gover- gover- ing brake brake
gine nor nor mo-
oil servo servo tor
pres- right left does
sure system system not
turn
23 24 19 1R
No. Category Failure mode C023 C024 C019 C01R

b . . . . . .b
1 Engine does not start One of these b
Difficulty in star- Exhaust smoke comes out but engine does not
ting engine, no (1) start, or is difficult to start
2 exhaust smoke
comes out (2) No exhaust smoke comes out
Engine (1) Engine stalls when machine is stopped b . . . . . .b
One of these
3 stopped during
b . . . . . .b
operation (2) Engine stalls when turning or braking suddenly b b One of these
Engine lacks (1) Machine is driven with balance on one side b . . . . . .b
One of these
4 power, acceleration
is poor (2) Machine is driven with balance on both sides b b c
Engine speed
stays at low idle, (1) Exhaust gas is normal (operator’s judgment)
5 does not change
when accelerator (2) Exhaust smoke is abnormally black
pedal is depressed
b . . . . . .b
Engine acceler- (1) Accelerated at same time as abnormality display One of these
6 ates to high idle (2) Accelerated while abnormality display was showing
Low idle speed is (1) Does not change to high speed Hi
not actuated c c c
7 according to
operation (2) Does not change to low speed Lo c c c
High fuel (1) Exhaust gas is normal (operator’s judgment)
8
consumption (2) Exhaust smoke is abnormally black
Engine speed (1) Does not reach high idle c
9 does not change
to high idle (2) Reaches high idle but returns to low idle
10 Defective automatic warming-up operation b . . . . . .b
One of these
(1) Engine continues to run at high speed b . . . . . .b
Engine does One of these
11 Engine continues to run at low idling even when b . . . . . .b
not stop (2) starting switch is turned OFF One of these
There is (1) Engine rotation is unstable at low idle

12 hunting (2) Engine rotation is unstable at high idle
13 High oil consumption, or exhaust smoke is blue
14 Oil becomes dirty quickly
15 Oil in coolant
16 Oil pressure lamp lights up b
17 Oil level rises
18 Coolant temperature rises too high b
19 Abnormal noise is generated
20 Excessive vibration
P-38 P-36
Troubleshooting code when abnormality display is given G-18 G-19 G-10 G-11 G-31 P-51 P50 P-39 P-37
20-312 HD785-5
(15)
TROUBLESHOOTING G-5
G-5 Abnormality in governor solenoid system

right bank
fl Before carrying out troubleshooting, check that all the related Cause Remedy
connectors are properly inserted.
fl Always connect any disconnected connectors before going on
to the next step.
YES
3
Is resistance be-
YES tween EC2 (female)
and chassis as 4 YES Short circuit in wiring Repair or
shown in Table 1? harness between EC2 (7)
Is resistance be- (female) – E15 (2) or EC2 replace
2 • Turn starting tween E15 (male) (17) (female) – E15 (1)
Is resistance be- switch OFF. NO and chassis as
YES tween EC2 (fe- • Disconnect EC2. shown in Table 2?
male) (7) and (17) Defective governor Replace
NO solenoid
normal?
• 10 – 21 Ω Short circuit,
1 • Turn starting 5 YES disconnection in wiring Repair or
switch OFF. harness between EC2 (7) replace
Is voltage between Is resistance – E15 (2) or EC2 (17) – E15
EC1 (4) – chassis, • Disconnect EC2. between E15 (1)
and between EC2 (1) NO (male) (1) and (2)
– chassis normal? normal?
Defective governor Replace
• 20 – 30 V • 10 – 21 Ω NO solenoid
• Turn starting • Turn starting
switch ON. switch OFF.
• Disconnect E15.
Go to G-7 —
NO
Table 1
Between EC2 (female) (7) – chassis Min. 1 MΩ
Table 2
Between E15 (male) (1) – chassis
Min. 1 MΩ
Between E15 (male) (2) – chassis
G-5 Related electrical circuit diagram
20-318 HD785-5
(15)
TROUBLESHOOTING G-20
G-20 Abnormality in acceleration sensor system
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl This abnormality is reported as an abnormality in the acceleration sensor system if the PMC is not
installed.
Cause Remedy
YES Model selection data not

Carry out trou-
clear because of
disconnection in network bleshooting X-6
1
3 YES
Is service code Defective transmission Replace
Is position of ro- controller
C055 [E ↔ 5.5]
being displayed?
YES tary switch for
transmission con- Adjust rotary
troller correct? Defective model selection switch of
• Turn starting 2 data in transmission
switch ON. • Check rotary NO transmission
controller
switch. controller
Is error [C2] being
NO displayed?
YES Replace
4 Defective engine
• Turn starting controller
switch ON.
Is error [C4] being
NO displayed? 5 YES
Go to A —
Is voltage between
• Turn starting EC3A (6) (male) and
switch ON. NO EC3A (16) (male)
abnormal?
Defective engine Replace
• Normal: 4.6 – 5.4 V NO controller
• Disconnect EC3A.
• Turn starting
YES switch ON.
7 controller
Is resistance
YES between EC3B Short circuit,
(female) (11) and disconnection in wiring
EC3A (female) (16) 8 YES Repair or
harness between WAS1
in Fig. 1? Is resistance (female) (1) – J09E (7) – replace
6 • See Table 1 for between WAS1 (1) EC3A (16) or WAS1 (2) –
normal resistance NO and WAS1 (2) in ECA (5) – EC3B (11)
Is resistance be- value.
tween EC3A (fe- Fig. 1?
From A male) (6) and EC3A • Disconnect EC3A Defective accelerator
and B. • Disconnect WAS1. NO sensor
(female) (16) in Fig. • Turn starting
1? • Turn starting switch OFF.
switch OFF.
Short circuit,
• Disconnect EC3A. disconnection in wiring
• Turn starting 9 YES Repair or
harness between WAS1
switch OFF. Is resistance be- replace
(female) (1) – J09E (7) –
tween WAS1 EC3A (16) or WAS1 (3) –
(male) (3) and J09E (6) – EC3A (6)
WAS1 (male) (1) in
Defective accessory Replace
• Disconnect WAS1. NO
• Turn starting
switch OFF.
20-330 HD785-5
(15)
HD785-5 20-331
(15)
Fig. 1
Fig. 2
20-332 HD785-5
(15)
G-21 Abnormality in engine coolant temperature

system
Cause Remedy
YES Defective engine

Replace
1 controller
Is resistance
between EC3B Short circuit or disconnec-
(female) (10) and tion between EC3B (female)
EC3A (female) (16) 2 YES (1) – J09E (10) – J02 (1) – 20 Repair or
normal? Is resistance (5) – 26 (1) or EC3A (16) – replace
• Resistance of between 26 (male) J09E (7) – J02 (3) – 20 (9) –
less than 1 Ω or NO (1) and (male) (2) 26 (2)
infinity is abnormal. normal? Defective coolant
• Turn starting Replace
• Resistance of NO temperature sensor
switch OFF. less than 1 Ω or
• Disconnect EC3A infinity is abnormal.
and EC3B. • Turn starting
switch OFF.
• Disconnect 26.
HD785-5 20-333
(15)
G-22 Abnormality in engine oil pressure sensor
Cause Remedy
4 YES Defective engine

controller
Is voltage
YES between EC3B Short circuit, disconnec-
3 (12) and EC3A tion in wiring harness
Is voltage (16) normal? between EC3B (female)
YES between 27 (3) (12) – J09E (5) – J02 (2) –
• 0.3 – 4.7 V NO 27 (female) (3) or EC3A
and 27 (1) • Turn starting (female) (16) – J09E (7) –
2 normal? switch ON.
• Connect T-adapter J02 (3) – 27 (female) (1)
Is voltage
• 0.3 – 4.7 V to EC3B and EC3A. Defective hydraulic
YES between 27
(female) (2) – 27 • Turn starting NO sensor
Replace
(female) (1) switch ON.
1 • Connect T-a Short circuit, disconnec-
normal?
dapter to 27. tion in wiring harness
Is voltage • 4.6 – 5.4 V
between EC3A between EC3A (female) Repair or
• Turn starting (16) – J09E (7) – J02 (3) –
(male) (6) and switch ON. NO replace
EC3A (male) (16) 27 (female) (1) or EC3A
• Disconnect 27. (6) – J09E (6) – J01 (11) –
normal?
27 (female) (2)
• 4.6 – 5.4 V
• Turn starting Defective engine
switch ON. Replace
NO controller
• Disconnect EC3A.
20-334 HD785-5
1
G-23 Abnormality in network
Cause Remedy
3 YES
Is there continuity controller
YES between EC4 and
DP05 of network
2 wiring shown in
diagram? Disconnection between
Is monitor panel Repair or
EC4 and DP05 of network
YES also detecting NO wiring which has no replace
other abnormali- continuity
ties in network?
1
Go to Troubleshooting
NO for monitor panel
Is monitor panel
detecting A015?
4 YES Replace
Defective engine
When starting controller
switch is turned ON
again, is C055 [E ↔
NO 5.5] detected, but
A015 not detected?
System has been reset
NO
HD785-5 20-335
(15)
HD785-5 20-341
(15)
Fig. 1
Fig. 2
20-342 HD785-5
(15)
G-30 Abnormality in idle validation
1) When PMC is not installed
Cause Remedy
YES Model selection data not Carry out trou-

clear because of bleshooting G-
disconnection in network 23
1
3 YES Defective transmission
controller Replace
Is C055 [E ↔ 5.5] Is position of ro-
YES tary switch for
being displayed?
• Turn starting 2 data in transmission transmission
switch ON. ª Check rotary NO controller controller
switch.
Is C0C2 [E ↔ C.2]
NO being displayed? YES
4 controller
• Turn starting
switch ON.
Is C0C4 [E ↔ C.4]
NO being displayed? 5 YES Carry out troubleshooting
G-20 for service code
Is accelerator sen- C031 [E ↔ 3.1], then
• Turn starting sor system abnor- return to Step 5
mality C031 [E ↔
switch ON. NO 3.1] being dis-
played? Go to A
• Turn starting NO
switch ON.
6 Defective engine
Depress accelerator YES controller Replace
pedal to change ac-
celerator signal vol- Disconnection, short
tage between EC3B 7 circuit between WAS1 (4)
From A (11) and EC3A (16).
Depress accelerator – J09E (8) – EC5A (3) or
Do idle validation pedal to change ac- YES Repair or
between WAS1 (5) – J09E
signals 3 and 2 celerator signal vol- (9) – EC5A (4) or between replace
change as shown in tage between WAS1 WAS1 (5) – ECA (13) –
Fig. 1? (2) and WAS1 (1).
EC3A (14)
• Turn starting NO Do idle validation
signals 3 and 2
switch ON. change as shown in
Defective accelerator Replace
• Connect T-adapter NO sensor
Fig. 1?
to EC3A, EC3B, EC5A.
• Turn starting
• Idle validation
switch ON.
signal voltage
• Connect T-adapter
3 : EC5A (3)
to WAS1.
– EC3A (14)
• Idle validation
2 : EC5A (4)
signal voltage
– EC3A (14)
3 : WAS1 (4)
– WAS1 (6)
2 : WAS1 (5)
– WAS1 (6)
HD785-5 20-343
(15)
G-30 1) Related electrical circuit diagram
Fig. 1
20-344 HD785-5
(15)
2) When PMC is installed
Cause Remedy
YES Model selection data not Carry out trou-

clear because of bleshooting G-
disconnection in network 23
1
3 YES Defective transmission
controller Replace
Is C055 [E ↔ 5.5] Is position of ro-
YES tary switch for
being displayed?
• Turn starting 2 data in transmission transmission
switch ON. ª Check rotary NO controller controller
switch.
Is C0C2 [E ↔ C.2]
NO being displayed? YES
4 controller
• Turn starting
switch ON.
Is C0C2 [E ↔ C.2]
NO being displayed? 5 YES Carry out troubleshooting
G-20 for service code
Is accelerator sen- C031 [E ↔ 3.1], then
• Turn starting sor system abnor- return to Step 5
mality C0C4 [E ↔
switch ON. NO C.4] being dis-
played? Go to A
switch ON.
6 Defective engine
Depress accelerator YES controller Replace
pedal to change ac-
celerator signal vol- Disconnection, short
tage between EC3B 7 circuit between WAS1 (4)
From A (11) and EC3A (16).
Depress accelerator – J09E (8) – EC5A (3) or
Do idle validation pedal to change ac- YES Repair or
between WAS1 (5) – J09E
signals 3 and 2 celerator signal vol- (9) – EC5A (4) or between replace
change as shown in tage between WAS1 WAS1 (6) – ECA (13) –
Fig. 1? (2) and WAS1 (1).
EC3A (14)
• Turn starting NO Do idle validation
signals 3 and 2
switch ON. change as shown in
• Connect T-adapter NO sensor
Fig. 1?
to EC3A, EC3B, EC5A.
• Turn starting
• Idle validation
switch ON.
signal voltage
3 : EC5A (3)
to WAS1.
– EC3A (14)
• Idle validation
2 : EC5A (4)
signal voltage
– EC3A (14)
3 : WAS1 (4)
– WAS1 (6)
2 : WAS1 (5)
– WAS1 (6)
HD785-5 20-345
(15)
G-30 2) Related electrical circuit diagram
20-346 HD785-5
(15)
Fig. 1
Fig. 2
HD785-5 20-347
(15)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts ............................................................................................... 20-402

S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-406
S- 2 Engine does not start ................................................................................................................... 20-408
a) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-408
b) Exhaust smoke comes out but engine does not start (fuel is being injected) .................. 20-409
S- 3 Engine does not pick up smoothly (Follow-up is poor) ............................................................ 20-410
S- 4 Engine stops during operations .................................................................................................. 20-412
S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-414
S- 6 Engine lacks output (or lacks power) ......................................................................................... 20-415
S- 7 Exhaust smoke is black (Incomplete combustion) .................................................................... 20-416
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................ 20-417
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-418
S-10 Fuel consumption is excessive .................................................................................................... 20-419
S-11 Oil is in coolant, or water spurts back, or coolant level goes down ........................................ 20-420
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ....................................................... 20-421
S-13 Oil level rises ................................................................................................................................. 20-422
S-14 Coolant temperature becomes too high (Overheating) ............................................................ 20-423
S-15 Abnormal noise is made .............................................................................................................. 20-424
S-16 Vibration is excessive ................................................................................................................... 20-426
HD785-5 20-401
(15)
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the Causes
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and (1) (2) (3)
[Check items].
(a) w
Questions
A (b) w
(c) w
(d) c
(e) c
B
Check items
i b
shooting
Trouble-
ii b
iii b
20-402 HD785-5
(15)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system Causes
• Insufficient supply of fuel
• Insufficient supply of air
• Improper selection of fuel
iner
(At ambient temperature of 10ºC or below, use ASTM D975 No. 1)
stra
t
elem alve sea
fl Battery charging rate
ump
Ambient Charging rate
100 % 90 % 80 % 75 % 70 %
p
temperature
ce
ve, v
ent
g
r
devi
20°C 1.28 1.26 1.24 1.23 1.22
imin
inde
f val
0°C 1.29 1.27 1.25 1.24 1.23
g aid
r, pr
, cyl
–10°C 1.30 1.28 1.26 1.25 1.24
ner
r
act o
lato
filte
ring
• The specific gravity should exceed the value for the charging rate of 70%
n
clea
i
regu
t
cont
star
in the above table.
fuel
ston
i r
• In cold areas the specific gravity must exceed the value for the charging
ctive
ctive
ctive
ged
ged
n pi
rate of 75% in the above table.
Defe
Defe
Defe
Clog
Clog
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Starting again takes time after warming-up

Preheating indicator lamp is light up
Engine oil must be added more frequently
Replacement of filters has not been carried out according to Operation Manual
Dust indicator is red
Non-specified fuel has being used
Battery charge caution lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items
Blow-by gas is excessive

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E Yes
with engine at low idle?
Troubleshooting
No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return (when rack stopper
bolt at rear of pump is removed, and rack piston is pushed with a
screwdriver during cleaning, rack does not move)
When fuel tank cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff or open
Legend
c : Possible causes (judging from Questions and check items)
Replace
Replace
Replace
Correct
w : Most probable causes (judging from Questions and check items)

Clean
Clean
Remedy
t : Possible causes due to length of use (used for a long period)
b : Items to confirm the cause.
20-406 HD785-5
(15)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
fl Check that there is no abnormality display for the gov- Causes
ernor control system on the monitor panel.
General causes why engine does not pick up smoothly
ap
y
seat
spra
nk c
lve
el ta
ive
d va
renc
fect
ner
er
in fu
• Improper condition of fuel injction
ung
e an
ent
ng
, de
erfe
er
er li
er
rain
pipi
e
• Improper fuel used
ole
lem
p pl
rain
valv
zzle
ranc
, int
n d
h
p st
i
er e
fuel
pum
, cyl
r, st
n no
her
rger
clea
t of
pum
lean
reat
filte
ing
ring
ntac
ctio
cha
tion
lve
Legend
leak
air b
feed
air c
urbo
uel
inje
r va
ston
e co
njec
,
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Rust and water are found when fuel tank is drained
Dust indicator caution is red
Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
There is leakage from fuel piping

High idle speed under no load is normal, but speed
suddenly drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When air cleaner element is inspected directly, it is found to

be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-410 HD785-5
(15)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting) Causes
General causes why engine does not rotate smoothly
ump
zle
l)
e
poo
, pip
z
ing p
n o
id, s
and
ilter
• Air in fuel system
prim
ilter
leno
• Defective governor mechanism
ort f
mp
nk
and
pum creen f
d pu
r (so
el ta
let p
ck
tank
a
r
iner
n fee
o
erno
p in
vern
trol
fuel
f
s
le in
mp
stra
wee
er
gov
con
een
f go
rain
u
o lo
r ho
mp
p
t bet
betw
n of
f
nt o
o
l
r oil
r, st
i
s to
o
g pu
athe
ion
i
circu
ratio
tme
cuit
r
erno
erno
filte
ed i
erat
min
e
in cir
djus
r
ope
air in
air b
Legend
spe
gov
gov
fuel
e op
l
i
e
r
, air
a
p
of fu
tive
ctive
idle
ged
ged
ged
ged
ged
ged,
ctiv
ging
Lack
Defe
Clog
Clog
Clog
Clog
Defe
Clog
Low
Defe
Clog
Clog
Occurs at a certain speed range
Questions
Condition of hunting Occurs at low idle

Occurs even when speed is raised
Occurs on slopes
When fuel tank is inspected, it is found to be empty
Replacement of filters has not been carried out according
to Operation Manual
Rust is found when fuel is drained
When priming pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Movement of governor lever (solenoid plunger) is stiff

Movement of spool valve is stiff
When control rack is pushed, it is found to be heavy, or
Troubleshooting
does not return

When fuel cap is inspected directly, it is found to be clogged
When priming pump strainer is inspected directly, it is found
to be clogged
When fuel filter, strainer are inspected directly, they are found
to be clogged
When governor oil screen filter is inspected directly, it is found
to be clogged
When governor oil inlet port filter, supply pipe are inspected
directly, they are found to be clogged
Replace
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
20-414 HD785-5
(15)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power) Causes
General causes why engine lacks output
noid
seat
spra
sole
tank
lve
• Improper condition of fuel injection
ool
tive
e
d va
fuel
renc
• Improper fuel used
e sp
efec
er
e an
(if non-specified fuel is used, output drops)
ung
le in
ing
ent
er
erfe
trok
le, d
pum ainer
r
rain
e
inde
• Lack of output due to overtaking
l pip
lem
p pl
valv
ranc
, int
o
re-s
z
h
p st
z
r
er e
pum
n no
, cyl
r, st
ther
e
rger
le p
t of
clea
fl If there is overheating and lack of output,
fu
lean
filte
king
ring
a
ntac
ctio
riab
carry out troubleshooting for OVERHEATING.
cha
tion
e
lve
r
air b
eed
air c
e
fuel
urbo
, lea
e va
e co
r va
ston
njec
j
Legend
i n
f
rope
ged
ged
ged
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to Operation Manual
Black
Engine pickup is poor and combustion is irregular
High idle speed under no load is normal, but speed
Check items
suddenly drops when load is applied

High idle speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
When fuel cap is inspected directly, it is found to be clogged
Inspect sliding of spool valve solenoid for variable pre- stroke
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
—
HD785-5 20-415
(15)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black
Causes
sole zed)
ad
)
tion
d he
noid
• Excessive injection of fuel
i
e sp nger se
njec
seat
ray
r an
e sp
ve i
e
arge
valv
ool
lu
essi
e
ctiv
k, p
renc
och
and
(exc
defe
(rac
ent
turb
erfe
trok
r
lve
g
r
ce
inde
mp
p
lem
zle,
e
imin
, int
pum
re-s
l
een
aran
f va
f f
u
z
u
er e
, cyl
n no
ed m
rger
le p
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
riab
ctio
cha
ecti
onta
ject
ject
logg
valv
air c
a
Legend
inje
urbo
e va
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Seal on injection pump has come off
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
is stopped
When check is made using piston displacement method,
injection timing is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Inspect sliding of spool valve solenoid for variable pre- stroke
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
—
20-416 HD785-5
1
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
Causes
fl Do not run the engine at idling for more than 20
minutes continuously. (Both low and high idling)
r
arge
och
General causes why oil consumption is excessive
Turb
al
d
hea
n se
ce
• Abnormal combustion of oil
em
e
ping l cooler
urfa
hos
der
oke
syst
er
• External leakage of oil
s
r lin
cylin
her
), br
seal
plug
• Wear of lubrication system
e
or o
reat
k
inde
d
nd
uide
inta
n or
eal,
n
ain
e
roke ower e
or b
ilter
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
ing
oil f
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
bl
on r
m
brea
Legend
l at
ston
cked
al a
e fro
oil c
e fro
e fro
e fro
lve
pist
a
n va
n se
n se
ged
n, b
n pi
t su
kag
kag
ken
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Bro
Lea
Lea
Bro
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
Oil is in engine coolant
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level rises in clutch or TORQFLOW transmission damper
chamber
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty
with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
HD785-5 20-417
(15)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas due to internal wear Causes

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
d
e en
• Operation under excessive load
rbin
pipe
er tu
se
er
r ho
r lin
harg
ain
e
inde
eath
r dr
e
boc
lack
guid
e
arge
, cyl
r, br
valv
ded
t tur
is b
r
e
oole
och
ring
athe
valv
r
l ad
fety
al a
filte
oke
turb
oil c
Legend
h oi
e
ston
e se
e sa
lve,
t sm
l
r
i
b
o
muc
ged
n va
ged
ged
ged
ctiv
ctiv
n pi
aus
Clog
Defe
Defe
Clog
Clog
Clog
Wor
Wor
Too
Exh
Questions

Non-specified oil is being used
Black
Excessive
Amount of blow-by gas
None
Carry out troubleshooting for EXHAUST SMOKE IS BLACK.

Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
Oil is higher than H line on level gauge

When breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Oil is higher than H line on level gauge
Replace
Replace
Replace
Replace
Replace
Correct
——
Clean
Clean
Clean
Remedy
20-418 HD785-5
1
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel Causes

• Excessive injection of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
r
er
cess
cove
l con
pipin
d pu
n g
ng
y
p plu
p (ex
spra
f fue
ead
timi
e
fuel
f e
pum
h
pum
e
lder
nt o
tion
nsid
from
side
le ho
stme
injec
tion
eal i
el in
o
age
t i
Legend
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idle speed is high
When injection pump is tested, injection amount is found to be excessive

Troubleshooting
Speed does not change when operation of certain cylinders is stopped

When control rack is pushed, it is found to be heavy, or does not return
When check is made, injection timing is found to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idle speed is found to be high
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
HD785-5 20-419
(15)
S-11 Oil is in coolant, or water spurts back,

or coolant level goes down
Causes
General causes why oil is in cooling water
• Internal leakage in lubrication system

• Internal leakage in cooling system
)
gged
g
ittin
r clo
by p
athe
ade
et
ain
gask
(bre
k
es m
bloc
r
ing
er tr
f line
head
seal
, O-r
, hol
der
w
ion o
o
mp
for p
cylin
core
ead,
ring
r pu
trus
-
er h
oler
oler
O
s in
o
wate
liner
Legend
r
ylind
rack
il co
il co
nt p
aged
aged
nal c
fficie
en o
en o
en c
Dam
Dam
Brok
Brok
Brok
Inter
Insu
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Check items
Engine oil level has risen, oil is cloudy white

Excessive air bubbles inside radiator, spurts back
Power train oil is milky white
When power train oil is drained, water comes out

Pressure-tightness test of cylinder head shows there is leakage
shooting
Trouble-
Remove cylinder head and inspect directly

Remove oil pan and inspect directly
When water pump is inspected, there is an abnormal noise
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-420 HD785-5
(15)
S-12 Oil pressure caution lamp lights

up (drop in oil pressure)
General causes why oil pressure caution lamp lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control Legend
• Improper oil used (improper viscosity) c : Possible causes (judging from Questions and check items)
• Deterioration of oil due to overheating w : Most probable causes (judging from Questions and check items)
fl Check that the engine oil level is correct Causes
before starting troubleshooting.
fl Standards for engine oil selection

AMBIENT TEMPERATURE
KIND
OF FLUID -22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 10 20 30 40°C
g
ipin
n
pan
l pa
sor
ic p
ing
SAE 30
sen
l
e oi
raul
e oi
r
alve
braz
nso
l
d
e
nsid
hyd
urna
e
tor v
el se
r
insi
SAE 10W
ipe
essu
valv
mp
Engine oil
l
pe i
hed
n oi
g, jo
il
ilter
iner
gula
l lev
l pu
in o
r
lief
ion
p
SAE 15W-40
il pi
crus
il pa
stra
oil f
l
arin
e re
e re
e oi
e oi
e oi
suct
uel
o
of o
n be
,
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
SAE 10W-30
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro

Questions
Replacement of filters has not been carried out according to

Operation Manual
Caution lamp is ON
Lights up at low idle
Condition when oil Lights up at high idle
pressure lamp lights up Llights up on slopes
Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Check items
Oil level sensor lights up

When oil level in oil pan is inspected, it is to found to be low
Metal particles are found when oil is drained
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected, it is found to be clogged

Carry out troubleshooting

Troubleshooting
for OIL LEVEL RISES.
Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
HD785-5 20-421
(15)
S-13 Oil level rises

fl If there is oil in the coolant, carry out troubleshooting Causes
for “Oil is in coolant”.
er)
)
r
ype
aids
e
hamb
eath
er
ge t
General causes why oil level rises
v
tion c
rting
d co
p br
tting
(flan
mbus
hea
a
pum
y pi
t
• Water in oil
mp
preco
ther
side
b
• Fuel in oil (diluted, and smells of diesel fuel)
ce
ater
ade
p
ding
a
or o
e
g in
f
• Oil leaking in from other component
n
-ring
r
ed w
leev
le s m
al su
ctio
t (inclu
k
bloc
n
mp
pipi
er s
inje
re, O
logg
, ho
e
gaske
f pu
s
der
hold
rear
from
stat
side
-ring
g, c
r co
head
cylin
g
o
alin
rt in
ged
zzle
oole
er O
erm
fuel
head,
a li
side
e se
ama
e no
e pa
e se
Legend
d lin
oil c
e th
e of
nder
ks in
ctiv
n, d
ctiv
ctiv
ctiv
ctiv
age
n cyli
kag
ken
Defe
Defe
Defe
Defe
Defe
Dam
Wor
Crac
Broke
Lea
Bro
Questions

When engine is first started, drops of water come from
muffler
Exhaust smoke is white
There is oil in radiator coolant
Leave radiator cap open. When engine is run at idle,
an abnormal number of bubbles appear, or water spurts back
Water pump breather is clogged with mud
Check items
When water pump breather is cleaned, water comes out

Oil level in damper chamber goes down
Oil level in hydraulic tank goes down
Engine oil smells of diesel fuel
Fuel must be added more frequently

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and check directly

Remove rear seal and inspect directly
When pump is removed, seal is found to be broken
Remove thermostat cover and inspect directly
Defective contact with thermostad seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20-422 HD785-5
(15)
S-14 Coolant temperature becomes

too high (Overheating)
Causes
General causes why water temperature becomes too
high
• Lack of cooling air (deformation, damage of fan)
re
• Drop in heat dissipation efficiency
ratu
n)
ge
• Defective cooling circulation system
ope
ket
gau
mpe
ey
• Rise in oil temperature in power train
gas
pull
t tem es not
ns
ure
il te
or fi
ead
erat
fan
r
fl Carry out troubleshooting for chassis.
er o
oole
do
alve
diat
d, h
p
orn
tat (
vert
g
core
oil c
ittin
re v
d ra
hea
ump
g, w
mos
con
ator
by p
essu
olan
ken
she
der
er p
ppin
ant
rque
ther
, bro
radi
, cru
cylin
Legend
e co
e pr
ade
l
wat
o
i
l
o
s
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Clog
Defe
Lack
Rise
Bro
Bro
Fan
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge Does not go down from red range
Radiator coolant level caution lamp is lighted up
Fan belt whines under sudden load
Cloudy white oil is floating on coolant
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Coolant is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Torque converter oil temperature gauge enters red range
before engine coolant temperature gauge
Temperature difference between top and bottom radiator tanks

is excessive
Carrey out troubleshooting for the
Temperature difference between top and bottom radiator tanks

is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
When function test is carried out on thermostat, it does not

open even at cracking temperature
When coolant temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
chassis.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
HD785-5 20-423
(15)
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an Causes
external noise.
.)
, etc
d)
ion)
eize
ever
General causes why abnormal noise is made
r
line
ject
er s
ker l
ce
n
der
aran
lung
ve i
• Abnormality due to defective parts
, ro c
nce
ylin
essi
• Abnormal combustion
e cl e
alve
ck, p
renc
pum ozzle
fere
g, c
• Air sucked in from intake system
(exc
m (v
valv
p (ra
erfe
n rin
nter
n
yste
ump
tion
, int
t of
elt i
isto
lve s
i
njec
h
men
on p
rger
b
of p
bus
ion
ic va
n, fa
ed i
a
just
i
ject
ject
ear
zed
c h
ynam
seiz
urbo
d fa
e ad
Legend
ve w
e in
, sei
e in
rme
ctiv
ged
ctiv
en d
ctiv
ed t
sing
essi
Defe
Defo
Defe
Defe
Clog
Brok
Seiz
Mis
Exc
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
stopped
Troubleshooting
When control rack is pushed, it is found to be heavy, or does

not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Inspect air compressor piping for leakage
Remove oil pan and inspect
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Remedy
20-424 HD785-5
1
Correct Imp
rope
Correct Lea r ge
ar tr
kag ain
Replace e of bac
HD785-5
Defe air b klas
ct in etw
e h
Replace Leak s i d e mu en t
age ffler urbo
cha
Replace Seiz
from
air c
(divi
ding rger
o b and
ed c m oard hea
rank
shaf
pres
sor p out o d
t bea iping f pos
ring ition
)
TROUBLESHOOTING
Causes
1
S-15
20-425
S-16 Vibration is excessive

fl If there is abnormal noise together with the Causes
vibration, carry out troubleshooting also for
uck)
“Abnormal noise is made”.
tc. st
ion
)
tion
ned
er, e
ush
njec
General causes why vibration is excessive
alig
per)
r lev
en c
mis
ve i
(dam
rocke
ring
brok
• Defective parts (abnormal wear, breakage)
essi
n
bea
,
r tra
e
t
• Improper alignment
(valv
lts,
(exc
a
ash
ing
h
ain
pe r
s
owe
g bo
• Abnormal combustion
ystem
h
ackl
ump
utpu
d, m
bus
e
da m
l
nd p
z
ntin
z
b
lve s
n no
p
de o
am
g ro
train
ion
mou
ion
a
ic va
er, c
gine
ctio
ctin
insi
brat
ject
a r
nam
e
Legend
lanc
inje
r ge
nne
ngin
f en
e in
part
e vi
d y
n ba
n co
rope
ter o
ged
ctiv
ctiv
se e
ctive
ken
Defe
Clog
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idle
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Troubleshooting
Inspect inside of output shaft (damper) directly

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Remove vibration damper and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-426 HD785-5
(15)
Monitor
panel Controller
display display
A-16 b071 E. ↔ 7.1  – b078  E. ↔ 7.8  Short circuit in pressure control valve solenoid
E.C ↔ 7.1   E.C ↔ 7.8 
system is displayed .................................................................. 20-566
b091 E. ↔ 9.1  – b098  E. ↔ 9.8  Disconnection in pressure control valve solenoid
E.C ↔ 9.1   E.C ↔ 9.8 
system is displayed .................................................................. 20-566
Abnormality in sensor system
A-17 b0A2 E. ↔ A.2 a) Abnormality in torque converter oil temperature sensor system is displayed ....... 20-568
E.C ↔ A.2
b0A3 E. ↔ A.3 b) Abnormality in fuel level sensor system is displayed ........................................... 20-569
E.C ↔ A.3
b0b2 E. ↔ b.2  c) Abnormality in coolant temperature sensor system is displayed ........................ 20-570
E.C ↔ b.2 
b0b3 E. ↔ b.3  d) Abnormality in air pressure sensor system is displayed ....................................... 20-571
E.C ↔ b.3 
b0b4 E. ↔ b.4  e) Abnormality in retarder brake oil temperature sensor is displayed ..................... 20-572
E.C ↔ b.4 
Warning display
A-18 b0d1 E. ↔ d.1  a) Transmission filter clogged warning is displayed .................................................. 20-573
E.C ↔ d.1 
b0d5 E. ↔ d.5  b) Tilt warning is displayed ........................................................................................... 20-574
E.C ↔ d.5 
b0d6 E. ↔ d.6  c) Drop in radiator coolant level warning is displayed .............................................. 20-575
E.C ↔ d.6 
b0d7 E. ↔ d.7  d) Battery charge level warning is displayed .............................................................. 20-576
E.C ↔ d.7 
b0E5 E. ↔ E.5  e) Steering oil temperature overheat warning is displayed ...................................... 20-577
E.C ↔ E.5 
b0F5 E. ↔ F.5  f) Drop in engine oil pressure warning is displayed
E.C ↔ F.5 
(mechanical governor specification machine) ........................................................ 20-578
b0F6E. ↔ F.6  g) Rear brake oil pressure warning is displayed ......................................................... 20-579
E.C ↔ F.6 
A-19 b0b7 
E. ↔ b.7 
Abnormality in engine oil pressure sensor system is displayed
E.C ↔ b.7 
(mechanical governor specification machine) ............................................................ 20-580
A-20 b0C1 E. ↔ C.1 Abnormality in connector connection is displayed .................................................... 20-581
E.C ↔ C.1
A-21 b0d2 E. ↔ d.2  a) Torque converter oil temperature overheat warning is displayed ........................ 20-582
E.C ↔ d.2 
b0d3 E. ↔ d.3  b) Engine coolant temperature overheat warning is displayed ................................ 20-582
E.C ↔ d.3 
b0E9 E. ↔ E.9  c) Air pressure drop warning is displayed .................................................................. 20-582
E.C ↔ E.9 
b0F3 E. ↔ F.3  d) Retarder brake oil temperature overheat warning is displayed ............................ 20-582
E.C ↔ F.3 
b0d8 E. ↔ d.8  e) Engine overrun prevention brake actuated is displayed ....................................... 20-583
E.C ↔ d.8 
b0d9 E. ↔ d.9  f) Engine overshoot actuated is displayed ................................................................. 20-583
E.C ↔ d.9 
HD785-5 20-503
(15)
fl Re-enacting failures in electrical system
With failures in the electrical system, there are cases where failures, such as defective contact of
wiring harnesses and connectors, occur only under special conditions particularly at the initial stage
of the occurrence of the failure.
(For example, when the engine is running at high speed or the truck is traveling at high speed on
rough road surfaces)
Therefore, investigate the values for the resistance and voltage at the locations indicated by the
abnormal display, Even if no abnormality is found, it is necessary to investigate the conditions under
which the failure occurred, and to try to re-enact the failure condition to carry out troubleshooting.
20-504 HD785-5
1

b060 Defective engine speed sen- 1. Engine speed sensor B system
E. ↔ 6.0  sor output 1) Between E12 (1) – J09M (9) – TMD (13) – ATC3A (13)
E.C↔ 6.0  fl Engine speed less than
350 rpm and transmission 2) Between E12 (2) – J09M (10) – TMD (14) – ATC3A (14)
speed more than 500 rpm 2. Defective engine speed sensor
continues for 10 sec.
b061 Defective output of trans- 1. Input shaft speed sensor system

E. ↔ 6.1  mission input shaft speed 1) Between N1 (1) – TM2 (1) – ATC3A (2)
E.C↔ 6.1  sensor
fl When the engine speed, in- 2) Between N2 (2) – TM2 (2) – ATC3A (14)
put shaft speed, and inter- 2. Defective input shaft speed sensor
mediate shaft speed are
converted and it is found
that there is abnormality in
lock-up clutch and HL clutch
b062 Defective output of trans- 1. Intermediate shaft speed sensor system

E. ↔ 6.2  mission intermediate shaft 1) Between N2 (1) – TM2 (3) – ATC3A (12)
E.C↔ 6.2  speed sensor
fl When the input shaft speed, 2) Between N2 (2) – TM2 (4) – ATC3A (14)
intermediate shaft speed, and 2. Defective intermediate shaft speed sensor
output shaft speed are con-
verted and it is found that there
is abnormality in HL clutch and
speed clutch (When disconnec-
tion detection is actuated and
there is no sensor signal)
b063 Defective output of trans- 1. Output shaft speed sensor system

E. ↔ 6.3  mission output shaft speed 1) Between N3 (1) – TM2 (5) – ATC3A (3)
E.C↔ 6.3  sensor
fl When the engine speed, in- 2) Between N3 (2) – TM2 (6) – ATC3A (14)
put shaft speed, intermedi- 2. Defective output shaft speed sensor
ate shaft speed, and output
shaft speed are converted
and it is found that there is
abnormality in relationship
b0A1 Abnormality in model selection 1. Defective controller box

E. ↔ A.1  fl The setting of the rotary 2. Defective setting of rotary switch
E.C↔ A.1  switch is different from
the model in the software.
b0A2 Short circuit with ground in 1. Between (+) ATC3B (7) – TM2 (7) – TC.SE (1)
E. ↔ A.2  torque converter oil tem- Between (–) ATC3A (16) – TMB (9) – TMC (5) – TM2 (8) – TC.SE (2)
E.C↔ A.2  perature system
fl When torque converter oil 2. Defective torque converter oil temperature sensor
temperature sensor signal
is more than 150˚C
b0A3 Disconnection in fuel level 1. Between (+) ATC3B (4) – TMD (7) – J02 (15) – 61 (1)
E. ↔ A.3  sensor system 2. Defective fuel sensor
E.C↔ A.3  fl Input voltage: Min. 4 V
b0b2 Short circuit with ground in 1. Between (+) ATC5B (5) – TMA (15) – J09M (12), (15) – J02 (1) – 26 (1)
E. ↔ b.2  coolant temperature sensor Between (–) ATC5A (16) – TMB (9) – J09M (13), (16) – J02 (3) – 26 (2)
E.C↔ b.2  system
fl When input resistance 2. Defective coolant temperature sensor
of coolant temperature
sensor signal is more
than 170 Ω.
b0b3 Disconnection in brake air 1. Between (+) ATC3B (2) – TMA (7) – RH4 (1) – SR5 (1)
E. ↔ b.3  pressure sensor Between (–) ATC5A (16) – TMB (9) – RH4 (10) – SR5 (2)
E.C↔ b.3  fl When input resistance of
brake air pressure sensor 2. Defective brake air pressure sensor
signal is more than 3,000 Ω.
fl The top code in the Display code column shows the monitor panel display and the bottom code (in [ ])
shows the transmission controller LED display.
20-522 HD785-5
(15)

when abnormality is
1. 1. Engine speed display on monitor panel is normal Speed range used 1. Gearshifting becomes
during travel is main- impossible.
2. Between ATC3A (13) – (14) : 500 – 1,000 Ω, AC : Min. 0.5V tained 2. If shift lever is set to
3. Between each terminal of ATC3A (13), (14) – chassis : Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
impossible to move
4. Between E12 (male) (1) – (2) : 500 – 1,000 Ω tral, transmission is machine off again un-
held in Neutral less it is stopped.
Speed range used
ATC3A (female) TM2 (male) N1 (male) Ω during travel is main-
1. Gearshifting be-
comes impossible.
Between (2) – (14) Between (1) – (2) Between (1) – (2) 500 – 1,000 Ω tained 2. If shift lever is set to
Each terminal – chassis Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
tral, transmission is impossible to move
held in Neutral machine off again
unless it is stopped.
ATC3A (female) TM2 (male) N2 (male) Ω Speed range used 1. Gearshifting be-
during travel is main- comes impossible.
Between (14) – (12) Between (3) – (4) Between (1) – (2) 500 – 1,000 Ω tained 2. If shift lever is set to
Each terminal – chassis Min. 1 MΩ If shift lever is at Neu- Neutral, it becomes
tral, transmission is impossible to move
held in Neutral machine off again
unless it is stopped.
ATC3A (female) TM2 (male) N3 (male) Ω Speed range used 1. Speedometer displays
during travel is main- 0 km/h during travel,
Between (3) – (14) Between (5) – (6) Between (1) – (2) 500 – 1,000 Ω tained and gearshifting be-
Between N3 (1) – TM2 (5) – ATC3A (3) – chassis Min. 1 MΩ If shift lever is at Neu- comes impossible.
2. If shift lever is set to
tral, transmission is Neutral, it becomes im-
held in Neutral possible to move ma-
chine off again unless
it is stopped.
Set value of rotary switch 1 2, 3, 4, or 5 Holds at neutral When operation to

move machine is car-
ried out, machine does
not move.
ATC3B,3A (female) TM2 (female) TC.SE (male) Ω Only gives self-di- No display at all is given
agnostic display; on torque converter oil
Between (7) – (16) Between (7) – (8) Between (1) – (2) does not take any temperature gauge dis-
1 KΩ – 100 KΩ action
(7) – chassis (7) – chassis (1) – chassis play on monitor panel.
ATC3B TMD J02 61 (V) Only gives self-diag- No display at all is given
nostic display; does on fuel level gauge dis-
(4) – chassis (7) – chassis (15) – chassis (1) – chassis 0.2 – 0.4 V not take any action play on monitor panel.
When engine water temperature is between 25˚C (normal temperature) Only gives self-di- No display at all is
and 100˚C, condition is as shown in table below. agnostic display; given on engine water
ATC3B,3A (male) TMA,TMB (male) J09M J02 61 (V) does not take any temperature gauge dis-
action play on monitor panel.
Between Between Between (12), Between Between 37 Ω
(5) – (16) (15) – (9) (15) – (13),(16) (1) – (3) (1) – (2)
|
(12),(15) (1) – (1) – 4 kΩ
(5) – chassis (15) – chassis – chassis chassis chassis
ATC3B,3A (male) TMA,TMB (male) RH4,RH1 SR5 Ω Only gives self-di- No display at all is
agnostic display; given on air pressure
Between (2) – (16) Between (7) – (9) Between (1) – (10) Between (1) – (2) does not take any gauge display on moni-
3 – 1,000 Ω
(2) – chassis (7) – chassis (1) – chassis (1) – chassis action tor panel.
HD785-5 20-523
1

b0b4 Short circuit with ground in 1. Between (+) ATC3B (8) – TMD (5) – J02 (10) – 64 (1)
E. ↔ b.4  retarder brake oil tempera- Between (–) ATC3A (16) – TMB (9) – J02 (9) – 64 (2)
E.C↔ b.4  ture sensor system
fl When retarder brake oil 2. Defective retarder brake oil temperature sensor
temperature sensor sig-
nal is more than 150˚C
b0b7 Disconnection, short circuit 1. Between ATC3B (12) – TMD (15) – J02 (2) – 27 (3)
E. ↔ b.7  with ground in engine oil Between (+) ATC3A (6) – TMA (16) – J09M (11) – (14) – J01 (11) – 27 (2)
E.C↔ b.7  pressure sensor system
fl Voltage between ATC3B 2. Defective voltage circuit inside controller
(12) – chassis 3. Defective engine oil pressure sensor
• Min. 4.6 ± 0.1 V
• Min. 0.4 ± 0.1 V
b0C1 Mistaken connection of con- 1. Between ATC5A (1) – ATC1 (16)

E. ↔ C1  nector
E.C↔ C1  fl After the starting switch 2. Defective contact of ATC5A connector
is turned ON, depending
on the wiring harness,
the model selection sig-
nal does not match
b0C4 Short circuit with ground in 1. Defective BCV relay R04

E. ↔ C.4  BCV rear solenoid system
E.C↔ C.4  fl BCV output terminal 2. Between ATC (11) – TMB (13) – R04 (1)
voltage
• When actuated: 11 V or above
• When not actuated:
11 V or below
b0C6 Disconnection in BCV rear 1. Defective BCV relay R04

E. ↔ C.6  solenoid system 2. Between ATC (11) – TMB (13) – R04 (1), from R04 (2) – GND,ER
E.C↔ C.6  fl BCV output terminal
voltage
11 V or below
b0C8 Short circuit in BCV rear so- 1. Defective BCV relay R04
E. ↔ C.8  lenoid system 2. Between ATC (11) – TMB (13) – R04 (2)
E.C↔ C.8  fl BCV output terminal
voltage
11 V or below
b0d1 Transmission filter clogging 1. Between (+) ATC5A (6) – TMD (6) – J02 (13) – 52 (1)
E. ↔ d.1  warning Between (–) J03 (8) – 52 (2)
E.C↔ d.1  fl When the transmission
oil filter switch is OFF 2. Defective transmission filter sensor
with the torque con-
verter outlet port oil tem-
perature 50˚C or above.
b0d5 Tilt warning display 1. Between (+) ATC5A (5) – TMD (2) – SR3 (1)
E. ↔ d.5  fl When the machine tilt Between (–) SR3 (2) – GND.ER
E.C↔ d.5  angle switch is OFF.
2. Defective tilt sensor
b0d6 Drop in radiator coolant 1. Between (+) ATC5B (15) – TMD (4) – J02 (7) – 01 (9) – 03 (1)
E. ↔ d.6  level warning display Between (–) 03 (2) – GND.16
E.C↔ d.6  fl When the machine coolant
level switch is OFF. 2. Defective radiator coolant level sensor
20-524 HD785-5
(15)

when abnormality is
ATC3B,3A (male) TMD,TMB (male) J02 64 Ω Only gives self-di- No display at all is
agnostic display; given on retarder oil
2k Ω – 20k Ω
Between (8) – (16) Between (5) – (9) Between (10) – (9) Between (1) – (2) does not take any temperature gauge dis-
(8) – chassis (5) – chassis (10) – chassis (1) – chassis (25˚C – 120˚C) action play on monitor panel.
Only gives self-di- Drop in engine oil pres-

ATC3B TMD J02 27 (V)
agnostic display; sure cannot be de-
(12) – chassis (15) – chassis (2) – chassis (3) – chassis does not take any tected.
0.4 – 4.6 V action
Between (2) – (3)
1. Between ATC5A (1) – ATC1 (16) :0Ω If there is abnor- When starting switch is
mality when start- turned ON, machine
2. ATC5A, ATC1 connectors are securely inserted. ing switch is turned cannot move off even
ON, transmission is when shift lever is op-
held at Neutral. erated.
ATC1 TMB R04 (V) Ω Only gives self-di- BCV is not actuated
agnostic display;
(11) – chassis (13) – chassis (1) – chassis 20 – 30 V does not take any
Between relay action
(1) and (2) 100 – 500 Ω
ATC1 TMB R04 (V) Ω Only gives self-di- BCV is not actuated
agnostic display;
(1) and (2) 100 – 500 Ω
ATC1 TMB R04 (V) Ω Only gives self-di- BCV is mistakenly

agnostic display; actuated
(1) and (2) 100 – 500 Ω
When transmission filter is normal, condition is as shown in table below. Only gives self-di- 1. If operations are con-
agnostic display; tinued, dirt will circu-
ATC5A TMD J02 52 does not take any late in transmission cir-
action cuit.
(6) – chassis (6) – chassis (13) – chassis (1) – chassis 2. Mechatronics abnor-
No continuity mality display is not
Between (1) – (2)
given.
3. Buzzer does not sound.
When machine tilt angle is ± 15˚, condition is as shown in table below. Only gives self-di- 1. If operations are contin-
agnostic display; ued, machine may roll
ATC5A TMD SR3 does not take any over.
action 2. Mechatronics abnormal-
(5) – chassis (2) – chassis (1) – chassis, (1) – (2) Continuity ity display is not given.
When radiator coolant level is normal, condition is as shown in table below. Only gives self-di- 1. If operations are contin-
agnostic display; ued, there will be over-
ATC5B TMD J02 01 03 heating.
does not take any 2. Mechatronics abnormal-
(15) – chassis (4) – chassis (7) – chassis (8) – chassis (1) – chassis, (1) – (2) Continuity action ity display is not given.
HD785-5 20-525
(15)

b0d7 Battery charge warning dis- 1. Between ATC3B (1) – TMD (1) – J01 (1) – alternator terminal R
E. ↔ d.7  play 2. Defective charging circuit
E.C↔ d.7  fl When battery charge
switch is OFF with en-
gine speed at 500 rpm or
above.
b0F5 Engine oil pressure drop 1. Between ATC3B (12) – TMD (15) – J02 (2) – 27 (3)
E. ↔ F.5  warning 2. Defective engine lubricating oil circuit
E.C↔ F.5  fl When an abnormality is
recognized in the engine oil 3. Defective engine oil pressure sensor
pressure with engine speed
at 700 rpm or above.
b0E5 Steering oil temperature 1. Between ATC3A (11) – TMA (8) – J01 (6) – 21 (1)
E. ↔ E.5  overheat warning
E.C↔ E.5  fl When steering oil tem- 2. Defective steering oil temperature sensor
perature switch is ON.
b0F6 Rear brake oil pressure 1. Between (+) ATC5A (8) – TMC (12) – J03 (2) – BLSL (1)
E. ↔ F.6  warning display Between BLSL (2) – BLSR (1)
E.C↔ F.6  fl When brake stroke
switch is ON for 2 sec- Between (–) BLSR (2) – GND.67
onds. 2. Defective brake stroke sensor
b0d3 Engine coolant temperature Abnormal rise in engine coolant temperature.

E. ↔ d.3  overheat warning
E.C↔d.3  fl When engine coolant
temperature sensor sig-
nal is above 102˚C.
b0d2 Torque converter oil tem- Abnormal rise in torque converter oil temperature
E. ↔ d.2  perature overheat warning
E.C↔ d.2  fl According to network
data from monitor sys-
tem.
b0E9 Air pressure drop warning Abnormal drop in air pressure inside air tank
E. ↔ E.9  fl According to network
E.C↔ E.9  data from monitor sys-
tem.
b0F3 Retarder oil temperature Abnormal rise in retarder oil temperature

E. ↔ F.3  overheat warning
E.C↔ F.3  fl According to network
data from monitor sys-
tem.
b0d8 Engine overrun prevention Engine overrun prevention brake actuated display
E. ↔ d.8  brake actuated display
E.C↔ d.8  fl Overrun actuated with
transmission input shaft
speed more than 2,600
rpm.
b0d9 Engine overshoot display Engine overshoot display (sudden spurt)

E. ↔ d.9  fl When d.8 does not de-
E.C↔ d.9  tect engine overshoot
display with engine
speed at 2,600 rpm or
above
20-526 HD785-5
(15)
TESTING AND ADJUSTING A-1
e) Abnormality in transmission cut relay power source is displayed
fl When battery and charging voltage are normal

fl When fuse FB1 (No. 10) is normal
Cause Remedy
YES
See A-3, A-4, A-10, A-20 —
1
Is E.-0.5, E.-0.6,
E.-1.4, E.-A.1 or Replace
2 YES Defective transmission cut
E.-C.1 displayed? transmission
Does condition be- relay
cut relay
• Turn starting come normal when
Defective contact or
switch ON. NO transmission cut re- disconnection in wiring Repair or
lay is replaced?
harness between ATC2 replace wiring
• After replacing NO (female) (11)(12) - TMC (2) harness
relay, turn starting - R25 (female) (5)
switch ON.
A-1 e) Related electrical circuit diagram
20-536 HD785-5
(15)
A-2 Abnormality in neutral safety system is

displayed
fl When the starting switch is turned to ON with the shift lever at a position other than N, or when the
power source is momentarily cut when traveling.
Cause Remedy
1 YES Mistaken operation Set shift lever

Was starting key ªSee Operation Manual to N
turned to START
when lever was at po- Defective contact or
sition other than N? disconnection in wiring Repair or
harness between battery replace wiring
NO relay terminal M - circuit harness
breaker - J07 - fuse I-(10)
A-2 Related electrical circuit diagram
HD785-5 20-537
1
A-3 Double engagement for clutch is displayed
Cause Remedy
1 YES
Are 2 or more of See A-14 a) —
b032 - b038 [E. 32,
E.C 32 - E. 38,
E.C 38 displayed
at same time? Failure of controller Replace
switch ON.
20-538 HD785-5
(15)
A-8 Abnormality in speed sensor system
a)-2 Disconnection in engine speed sensor [B] system is displayed

(mechanical governor specification machine) or
Failure of engine speed sensor is displayed (mechanical governor

specification machine)
fl This troubleshooting is for the mechanical governor specification machine.
Cause Remedy
2 YES Repair or
Defective controller
After measuring replace
YES Item 2, return con-
nector to original
1 condition. Is E. ↔
Is resistance 1.0 displayed?
System has been reset —
between ATC3A • Delete abnormal NO
(female) (13) and display from memory.
(14) normal? • Turn starting switch OFF → Defective contact or
ON, and start engine. disconnection in wiring Repair or
• 500 – 1,000 W • Wait for 20 seconds. harness between ATC3A
• Turn starting replace wiring
NO (female) (13), (14) – TMD
switch OFF. harness
(13), (14) – J09M (male)
• Disconnect (9), (10)
ATC3A.
A-8 a)-2 Related electrical circuit diagram
20-546 HD785-5
(15)
Abnormality in coolant temperature sensor system is

c)
displayed (mechanical governor specification machine)
Cause Remedy
YES Defective engine coolant Replace

1 temperature sensor
Does coolant tem-
Contact of chassis ground
perature gauge and wiring harness between After inspec-
show lowest level? 2 YES
ATC3B (female) (5) - TMA tion, clean or
Is there continuity (15) - J09M (12) - (15) - J09 replace
• Turn starting between P09 (fe- (1) - CN-26 (female) (1)
switch OFF. NO male) (4) and
• Disconnect CN-26. chassis ground?
• Turn starting Defective controller Replace
switch ON. switch OFF.
• Disconnect CN-26
and P09.
A-17 c) Related electrical circuit diagram
20-570 HD785-5
(15)
c) Drop in radiator coolant level warning is displayed
fl Before carrying out troubleshooting, check that the coolant level is not low.
Cause Remedy
YES
Drop in water level Add water
1
Is radiator coolant
3 YES
level outside speci- Defective controller Replace
fied range (below Is there continuity
LOW level)? YES between ATC5B
Defective contact or dis-
2 (female) (15) and
connection in wiring Repair or
Is there continuity chassis ground? harness between ATC5B replace wiring
between CN-03 • Turn starting NO (female) (15) - TMD (4) -
harness
J02 (7) - CN-01 - CN-03
NO (male) (1) and switch OFF.
(female) (1)
(2)? • Disconnect ATC5B.
• Turn starting Defective radiator coolant Replace
switch OFF. NO level sensor
• Disconnect
CN-03.
A-18 c) Related electrical circuit diagram
HD785-5 20-575
(15)
d) Battery charge warning is displayed
Cause Remedy
YES
1
Is voltage between
ATC3B (female) (1) Defective contact or dis-
connection in wiring Repair or
and chassis 2 YES
ground normal?
harness between ATC3B replace wiring
Is voltage between (female) (1) - TMD (1) - J01 harness
• 20 – 30 V alternator terminal (1) - alternator terminal R
• Start engine. NO R and chassis
• Connect T-adapter ground normal?
to ATC3B. Defective alternator Replace
• 20 – 30 V NO
• Start engine.
A-18 d) Related electrical circuit diagram
20-576 HD785-5
(15)
A-21
a) Torque converter oil temperature overheat warning is displayed
fl This shows that there has been an abnormal rise in the torque converter oil temperature.
fl If the rise in the torque converter oil temperature is abnormal, carry out troubleshooting H-8.
b) Engine coolant temperature overheat warning is displayed (me-

chanical governor specification machine)
fl This shows that there has been an abnormal rise in the engine coolant temperature.
fl If the rise in the engine coolant temperature is abnormal, see the engine Shop Manual.
c) Air pressure drop warning is displayed
fl This shows that there has been an abnormal drop in the air pressure.
fl If the drop in the air pressure is abnormal, carry out troubleshooting H-18.
d) Retarder brake oil temperature overheat warning is displayed
fl This shows that there has been an abnormal rise in the retarder brake oil temperature.
fl If the rise in the retarder brake oil temperature is abnormal, see the Operation and Maintenance
Manual.
20-582 HD785-5
(15)
e) Engine overrun prevention brake actuated is displayed
fl This shows that the engine overrun prevention brake has been actuated to protect the transmission.
Cause Remedy
1 YES
Normal —
Has machine been
traveling with
transmission input
shaft speed of more
than 2600 rpm?
• Use the machine NO
data monitor in the
background mode
of the machine
monitor system to
check the transmis-
sion input shaft
speed.
For details, see
USER MODE AND
SERVICE FUNC-
TION of the
monitor panel.
f) Engine overshoot actuated is displayed
fl This shows that there has been engine overshoot (sudden spurt).
Cause Remedy
1 YES Abnormality in engine

Repair
Has accelerator fuel injection system
been depressed to
raise engine speed
to more than 2600
rpm?
• Use the machine NO
data monitor in the
background mode
of the machine
monitor system to
check the engine
speed.
For details, see
USER MODE AND
SERVICE FUNCTION
of the monitor panel.
HD785-5 20-583
B
TROUBLESHOOTING LC-16, 17
LC-16 Related electrical circuit diagram
LC-17 Machine is not loading but external display lamps give load esti-
mate display.
After loading, display switches to time display before traveling
160 m
<Remedy> Load to rated payload, then carry out calibration after dumping load.
HD785-5 20-827
(15)
TROUBLESHOOTING LC-18
LC-18 F-31 is displayed :

Disconnection, short circuit with ground in clinometer system
fl Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Cause Remedy
fl Always connect any disconnected connectors before going on
to the next step.
YES
Normal —
Contact with chassis Repair or

4 YES ground in wiring harness
1 replace wiring
Is resistance be- between PM6 (8) and harness
Is machine travel- YES tween PM3 (fe- PM3 (2)
ing on or parked male) (2) and (3)
on uphill slope of 3 less than 1 Ω?
more than 10°? Defective clinometer Replace
YES Is voltage be- • Connect T-adapter NO
tween PM3 (3) to PM6, but do not
2 and (1) 18 ± 3 V? connect clinometer.
Is voltage be- • Turn starting switch Defective contact or
• Connect T-adapter OFF. Repair or
tween PM6 (8) disconnection in wiring
to P3. replace wiring
NO and (3) less than NO harness between PM6 (2)
• Turn starting harness
1.6 V? and PM3 (3)
switch ON.
to P3.
Defective payload meter Replace
switch ON.
20-828 HD785-5
(15)
TROUBLESHOOTING LC-19
LC-19 F-32 is displayed:

Short circuit with clinometer system power source
Cause Remedy
YES
Normal —
1
Is machine travel- Short circuit with power Repair or
ing on or parked 3 YES source in wiring harness replace wiring
on downhill slope When PM3 is between RM6 (8) and harness
of more than 10°? YES removed and then PM3 (2)
power source is
2 reset, is same error
Is voltage be- message displayed?
Defective clinometer Replace
tween PM6 (8) NO
NO and (3) less than
3.6 V?
Defective payload meter Replace
to P3. NO
• Turn starting
switch ON.
HD785-5 20-829
(15)
TROUBLESHOOTING OUTLINE
4. WHEN SYSTEM IS NORMAL 6. METHOD OF CLEARING SERVICE

A code is displayed on the controller LED un- CODE
der the assistant’s seat. Turn the machine starting switch to ON (the
engine is not started) and disconnect connec-
No. Code Conditions tors CR1 and CR2 under the assistant’s seat.
When accelerator pedal is being When this is done, “– –” is displayed on the
1 0.0 depressed controller LED.
When accelerator pedal is not being When the “– –” changes from flashing and
2 0.0. depressed stays lighted up (3 seconds), the failure code
has been cleared.
fl If the above code is not displayed when fl When using the ARSC for the first time, al-
the accelerator pedal is being depressed ways clear the service codes. After clear-
or not being depressed, it is necessary to ing the codes, connect connectors CR1 and
adjust the accelerator link. If it is not prop- CR2.
erly adjusted, the ARSC system will not
be able to judge correctly if the accelera-
tor pedal is being depressed or not, so
the ARSC may not work normally.
fl Note that this function is not installed to
the combination system of ASR and
ARSC (the system that uses the ASR-II
controller).
5. METHOD OF MODEL SELECTION,

TIRE LARGE DIAMETER/SMALL
DIAMETER, REFERENCE FOR FAIL-
URE CODE
When the machine starting switch is turned
ON, the codes below are automatically dis-
played in the following order ((1) – (6)) on the
controller LED.
1 LEDs all light up.
2 Model
Code Model name
32 HD325-6, HD465-6
46 HD465-5, HD605-5
78 HD785-5
98 HD985-5
3 Tire diameter
Code Tire diameter
B.– Large diameter
S.– Small diameter
For the HD325-6 and HD405-6, “– –” is dis-

played.
For the HD985-5, “– –” is displayed.
4 Initial service code
5 Service code that occurred immediately be-
fore the service code in 4
6 Service code that occurred immediately be-
fore the service code in 5
HD785-5 20-903
B
7. SERVICE CODE JUDGMENT TABLE

fl If the vehicle is equipped with ASR and ARSC, see the troubleshooting of the ASR-II even if
troubleshooting of the ARSC.
Category No. Nature of failure Troubleshoot-
ing code
1 0.1 (Abnormality in power source voltage) is displayed R-1
2 1.0 (Disconnection in engine speed sensor system) is displayed R-2
3 1.3 (Disconnection in transmission output shaft speed sensor system) is displayed R-3
4 1.5 (Failure in retarder oil temperature sensor system) is displayed R-4
5 1.7 (Failure in accelerator signal system) is displayed R-5
6 1.8 (Failure in suspension pressure sensor “left” system) is displayed R-6
7 1.9 (Failure in suspension pressure sensor “right” system) is displayed R-7
8 4.2 (Disconnection in exhaust brake selector signal system) is displayed R-8
9 4.3 (Disconnection in ARSC caution lamp system) is displayed R-9
10 4.4 (Disconnection in READY lamp system) is displayed R-10
11 4.5 (Disconnection in panel caution and buzzer system) is displayed R-11
12 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed R-12
13 5.3 (Short circuit with ground in ARSC caution lamp system) is displayed R-13
Error display is given
14 5.4 (Short circuit with ground in READY output circuit system) is displayed R-14
15 5.5 (Short circuit with ground in panel caution lamp and buzzer output system) is displayed R-15
16 6.0 (Failure in engine speed system) is displayed R-16
17 7.0 (Disconnection in travel speed display UP output system) is displayed R-17
18 7.1 (Disconnection in travel speed display DOWN output system) is displayed R-18
19 7.2 (Disconnection in travel speed display CLEAR output system) is displayed R-19
20 7.3 (Short circuit with ground in travel speed display UP output system) is displayed R-20
21 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed R-21
22 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed R-22
23 8.1 (Short circuit with ground in pressure control valve system) is displayed R-23
24 8.3 (Disconnection in pressure control valve system) is displayed R-24
25 8.5 (Failure in pressure control valve (pressure control valve remains open)) is displayed R -25
26 8.7 (Failure in pressure control valve (pressure control valve does not open)) is displayed R-26
27 8.9 (Short circuit with ground in pressure switch valve system) is displayed R-27
28 9.0 (Disconnection in pressure switch valve system) is displayed R-28
29 9.1 (Failure in pressure switch valve system (remains open)) is displayed R-29
30 9.2 (Failure in pressure switch valve system (does not open)) is displayed R-30
31 9.3 (Disconnection in system switch) is displayed R-31
32 9.4 (Short circuit with ground in system switch) is displayed R-32
33 9.5 (Disconnection, short circuit with ground in travel speed setting switch R-33
system) is displayed
1 Set speed cannot be set R-101
2 Failure code is always cleared (controller display window always shows “—”) R-102
or failure code cannot be cleared
3 Retarder does not work when machine is empty, or effect of retarder is poor R-103
No error display is given
when machine is loaded (does not judge loaded/unloaded condition properly)

4 Abnormality appears in other controller R-104
5 When traveling downhill, even when set speed is exceeded, no control is carried out R-105
6 Monitor lamp (buzzer) stays on (or off) R-106
7 READY lamp does not light up (or stays lighted up) R-107
8 Exhaust brake does not work properly R-108
Exhaust brake is actuated when exhaust brake switch is OFF; or
Exhaust brake is not actuated when exhaust brake switch is ON
9 There is difference between travel speed rod value and actual machine value R-109
10 Retarder lamp does not light up, or stays lighted up R-110
11 Travel speed display always gives display (or does not give any display) R-111
20-904 HD785-5
(15)
Failure codes related to ARSC

If the automatic retarder (ARSC) function of the ASR-II controller is turned on, the failure codes related to
ARSC are added.
For the method of troubleshooting, see the troubleshooting section for the ARSC system (R mode).
Category No. Nature of failure Troubleshoot-

ing code
1 1.8 (Failure in suspension pressure sensor “left” system) is displayed R-6
2 1.9 (Failure in suspension pressure sensor “right” system) is displayed R-7
3 4.2 (Disconnection in exhaust brake selector signal system) is displayed R-8
4 4.4 (Disconnection in READY lamp system) is displayed R-10
Error display is given
5 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed R-12
6 5.4 (Short circuit with ground in READY output circuit system) is displayed R-14
7 7.0 (Disconnection in travel speed display UP output system) is displayed R-17
8 7.1 (Disconnection in travel speed display DOWN output system) is displayed R-18
9 7.2 (Disconnection in travel speed display CLEAR output system) is displayed R-19
10 7.3 (Short circuit with ground in travel speed display UP output system) is displayed R-20
11 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed R-21
12 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed R-22
13 9.3 (Disconnection in system switch) is displayed R-31
14 9.4 (Short circuit with ground in system switch) is displayed R-32
15 9.5 (Disconnection, short circuit with ground in travel speed setting switch R-33
system) is displayed
1 Set speed cannot be set R-101
No error display is given
2 Retarder does not work when machine is empty, or effect of retarder is poor R-103
when machine is loaded (does not judge loaded/unloaded condition properly)
3 When traveling downhill, even when set speed is exceeded, no control is carried out R-105
4 READY lamp does not light up (or stays lighted up) R-107
5 Exhaust brake does not work properly R-108
Exhaust brake is actuated when exhaust brake switch is OFF; or
Exhaust brake is not actuated when exhaust brake switch is ON
6 There is difference between travel speed rod value and actual machine value R-109
7 Retarder lamp does not light up, or stays lighted up R-110
8 Travel speed display always gives display (or does not give any display) R-111
HD785-5 20-905
B
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC
TROUBLESHOOTING (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RE-

TARDER SPEED CONTROLLER) SYSTEM
20-906 HD785-5
1
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high

Ask the operator the following questions
• Does oil temperature go up when torque converter is stalled and go down when torque converter is
not stalled?
Yes = Normal (incorrect selection of speed range)
Checks before troubleshooting

• Is oil level in transmission or steering case correct?
Checking for abnormalities

• Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high.
fl If oil temperature is normal but oil temperature gauge on machine goes above operating range
→ defective oil temperature gauge
,
al ring
valve
tive se
relief
(defec
verter
pump
pump nverter
e)
e con
Causes
, turbin
ide of
torqu
ue co
tion s
e torq
o n of
a t s uc
rack in
perati
loose kage insid
ainer
ump
er
cked in
bolt, c
ed str
ed filt
tive p
tive o
Oil lea
Air su
Clogg
Clogg
Defec
Defec
The following symbols are used to indicate the

action to be taken when a cause of failure is
located. Torque
X: Replace : Repair Tank - pump converter
A: Adjust C : Clean
a b c d e f
Remedy
No. C
Problems
1 Pump makes abnormal noise when oil temperature

is low
2 High idle and low idle speeds are low
3 Torque converter outlet port oil pressure is low
4 Torque converter inlet port oil pressure is low
5 Transmission modulating pressure is low
6 Excessive leakage inside torque converter
If troubleshooting shows
that all other items are
normal, this is the cause.
20-1012 HD785-5
(15)
TROUBLESHOOTING H-11
H-11 Rear brake is ineffective, or effective only on one side

• Is there air in the brake oil circuit?
• Is the transmission oil level correct?
• Is there external leakage of oil between the brake
chamber and brake?
• Is the air pressure within the operating range?
rive
• Air pressure
ber
final d
• Brake chamber outlet port pressure
cham
er and
brake
g
packin
hamb
e and
oling c
o r
y valv
der, w
ake co
ter
uses
n rela
r cylin
adjus
een br
Ca
etwee
l
er sea
maste
disc
slack
al betw
tube b
b rake
ha m b
o n of
o n of
ing
alve
lve
ting se
s e al r
e ar of
lay va
u shed
rake v
rake c
perati
perati
ve floa
piston
sive w
tive re
ed, cr
tive b
tive b
tive o
tive o

Defecti

Clogg
Exces
Defec
Defec
Defec
Defec
Defec
Worn
located.
X: Replace : Repair
A: Adjust C : Clean
a b c d e f g h i
Remedy
No.
Problems
1 Oil pressure at master cylinder outlet port is low

(outlet port hose disconnected)
2 Air pressure at brake chamber inlet port is normal
3 Air pressure at brake chamber inlet port is low
4 Leakage of air from brake chamber

Items 1 - 4 are normal, but slack adjuster outlet port
5
pressure is low
6 Items 1 - 5 are normal, but brake piston pressure is

low
7 Excessive contamination of cooling oil
8 Oil level in final drive case rises
9 In Item 7, brake piston oil pressure is normal
10 Items 1 - 5 are normal, but brake is ineffective or

braking effect is poor
HD785-5 20-1015
(15)
H-12 Steering wheel is heavy

• Is the oil level in the hydraulic tank correct?
• Is there any external oil leakage between the pump and steering valve?
• Is the steering wheel play correct?

• Operating effort of steering wheel
• Time taken to turn the steering wheel from lock to lock
• Relief pressure of steering circuit
ling
ve sea
o l
efecti
k s p o
re or d
r stuc
e
Causes
ck valv
o
ressu
spool
e
e s et p
h
nd
c
o n of
tion e
er
f
pu m p
ning o
cylind
valve
ef valv
ump
tube
perati
a t s uc
ering
e
ering
ering
p
oist p
ainer
ction
in reli
tive o
tive o
cked in
tive ste
ve ste
ve ste
ed str
ed s u
tive h
Defec
Defec
Drop

Defecti
Defecti

Air su
Crush
Clogg
Defec
Defec
located. Demand
X: Replace : Repair valve
A: Adjust C : Clean
a b c d e f g h i j
Remedy A
No. C
Problems
1 Circuit pressure is too high at engine low idle or

pressure rises to relief pressure
2 Relief pressure in steering circuit is too low
3 Hoist force is also low
Item 3 is abnormal and noise of oil blowing is heard

4
from relief valve
Relief pressure is low at end of cylinder stroke (Items
5
1 - 4 normal)
6 Abnormal noise comes from between pump and

filter
When steering wheel is turned to right (left), oil
7 flows out continuously when hose on opposite side
is removed
8 Condition is normal at engine low idle
9 Pump discharge amount is too low
10 Item 3 is normal but speed is slow
11 Excessive play in steering wheel
20-1016 HD785-5
(15)
TROUBLESHOOTING H-13, H-14
H-13 Steering wheel does not work

• Is there any external oil leakage between the pump and steering valve?
• Is the steering wheel play correct?

• Relief pressure
ling
ve sea
spool
efecti
k
re or d
r stuc
e
O)
Causes
ck valv
o
ve PT
ressu
spool
o f che
efecti
e s et p
d
o n of
on en
nder
ump
valve
ive (d
ening
ef valv
li
tube
perati
ump
t sucti
y
ring p
c
n ot dr
ering
ering
p
oist p
ainer
ction
in reli
tive o
tive o
a
e
cked in
tive ste
tive ste
tive ste
ed str
doe s
ed s u
tive h
Defec
Defec
The following symbols are used to indicate the Drop
Air su
Crush
Clogg
Pump
Defec
Defec
Defec
Defec
located. Demand
A: Adjust C : Clean
a b c d e f g h i j k
Remedy A
No. C
Problems
1 Hoist cylinder also does not work
2 When pressure pickup port plug is removed and

engine is cranked, no oil comes out
Circuit pressure is too high at engine low idling, or
3 pressure rises to relief pressure (Item 2 normal)
4 Hoist is normal
5 Relief pressure is low at end of cylinder stroke (Item

4 normal)
6 Item 5 is abnormal and noise of oil blowing is heard

from relief valve
Abnormal noise comes from between pump and
7 filter
8 Steering wheel works when engine is at low idle

When steering wheel is turned to right (left) and
9 hose on opposite side is removed, rod does not
move but oil flows out
10 Pump discharge amount is too low
11 Excessive play in steering wheel
H-14 Steering wheel vibrates

Causes Remedy
Air in hydraulic oil C

Leakage of air inside steering cylinder ∆ ×
HD785-5 20-1017
(15)
H-15 Hoist cylinder lacks lifting force (lifting speed)

• Is the actuation of the control levers normal?
• Is the control linkage bent, gouging?
• When the linkage is disconnected at the hoist valve end, does the movement of the control valve lever
become normal?
• Is there any external oil leakage between the pump and cylinder?

• Relief pressure
• Body lifting speed
ling
ling
ling
ve sea
ve sea
ve sea
ol
efecti
efecti
efecti
ck spo
re or d
re or d
re or d
ump
or stu
mp
e
alve
alve
p
lv
Causes
of p u m
ing pu
aulic p
ressu
a
ressu
tion v
ressu
heck v
heck v
spool
e s et p
r
e s et p
f hydr
f stee
n side
e s et p
of suc
g of c
g of c
o n of
linder
ty valv
nce o
nce o
ef valv
o
ef valv
aling
tube
perati
penin
penin
ti
a t s uc
oist cy
forma
forma
ainer
in safe
tive se
ction
in reli
tive o
tive o
tive o
in reli
cked in
ed str
in per
in per
ed s u
tive h
Defec
Defec
Defec
Defec
Drop
Drop
Drop

Air su
Clogg
Crush
Defec
Drop
Drop
located. Demand
Hoist valve
A: Adjust C : Clean
a b c d e f g h i j k l m
Remedy A
C C A A C
No.
Problems A
1 Steering wheel is also heavy
2 Steering wheel is normal

Item i is defective and hoist circuit relief pressure is
3
low
4
from relief valve
5 Hoist circuit pressure is too high at engine high idle

(Items 1 - 4 are normal)
6 Only hoist circuit relief pressure is low
7 from relief valve
8 Dump body rises irregularly
9 Pump discharge amount is low
10 Excessive hydraulic drift of hoist cylinder
11 When tank cover is removed, external leakage of oil

from valve is found
12 Items 1 - 9 are normal but dump body lifting speed is

slow
Abnormal noise comes from between pump and
13 filter
20-1018 HD785-5
(15)
H-16 Hoist cylinder does not work

Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Seizure, damage to equipment
• Had drop in lifting speed or other symptoms appeared before?
Yes = Worn parts, deteriorated spring, etc.

• Is the operation of the control levers normal?
• When the linkage is disconnected at the hoist valve end, does the movement of the control valve lever
become normal?

• Relief pressure
ling
ling
ling
ve sea
ve sea
ve sea
l
efecti
k spoo
efecti
efecti
re or d
e or d
re or d
c
or stu
alve
lve
alve
O)
Causes
ressu
r
ve PT
eck va
ressu
ressu
tion v
heck v
spool
e s et p
efecti
e s et p
e s et p
of suc
tube
g of c
o n of
mp
f
pu m p
o
ive (d
linder
ty valv
ction
g
lic pu
ef valv
ef valv
aling
perati
penin
penin
ering
n ot dr
mp s u
oist cy
y dra u
ainer
in safe
tive se
in reli
tive o
tive o
tive o
in reli
tive ste
ed str
ed p u
doe s
tive h
tive h
Defec
Defec
Defec
Defec
Drop
Drop
Drop

Clogg
Crush
Pump
Defec
Defec
Defec
located. Demand
X: Replace : Repair Hoist valve
valve
A: Adjust C : Clean
a b c d e f g h i j k l m
Remedy A A A
No. C
Problems
1 When pressure pickup port plug is removed and

engine is cranked, no oil comes out
2 Steering also does not work
3 Steering is normal, only hoist does not work
4 In Item 2, hoist circuit relief pressure is low

5 from relief valve
6 Only hoist circuit relief pressure is low at engine

high idle
7 Item 4 is abnormal and noise of oil blowing is heard

from relief valve
Hoist circuit pressure is too high at engine low idle
8 or pressure rises to relief pressure (Items 1 - 5
normal)
9 Works when engine is at low idle
10 Pump discharge amount is low

When hoist lever is operated to RAISE, and hose on
11 opposite side is removed, cylinder does not move,
but oil comes out
HD785-5 20-1019
(15)
TROUBLESHOOTING OF MONITOR
PANEL SYSTEM
(P MODE)
Method of self-diagnostic display for monitor panel and controllers .............................................. 20-1103
Action taken by self-diagnostic device and problems on machine (monitor panel system) .......... 20-1104
Electrical circuit diagram for monitor panel system .......................................................................... 20-1108
P- 1 Check pattern for wiring harnesses between modules ............................................................ 20-1110
P- 2 Nothing on monitor panel works ............................................................................................... 20-1114
P- 3 LH, RH module and fuel gauge do not work ............................................................................. 20-1115
P- 4 LH, RH module and fuel gauge do not work ............................................................................. 20-1116
P- 5 RH module does not work .......................................................................................................... 20-1117
P- 6 LH module does not work ........................................................................................................... 20-1118
P- 7 Travel calculator does not work ................................................................................................. 20-1119
P- 8 Service meter display does not work correctly ......................................................................... 20-1120
P- 9 Central warning lamp does not work, or monitor panel detects failure code [A002] ............ 20-1121
P-10 Central warning lamp stays lighted up ...................................................................................... 20-1122
P-11 Alarm buzzer does not work, or monitor panel detects failure code [A003] .......................... 20-1123
P-12 Alarm buzzer continues to sound .............................................................................................. 20-1124
P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.)
are abnormal (nothing is displayed, or display does not change), or monitor panel detects
service code [A013], or monitor panel detects service code [A018] ....................................... 20-1125
P-14 Suspension mode, power/economy mode displays are abnormal (nothing is displayed,
or display does not change), or monitor panel detects service code [A016] ......................... 20-1126
P-15 Gauge displays are abnormal (nothing is displayed, or display does not change) ............... 20-1127
P-16 Coolant level drop caution lamp does not work, or monitor panel detects service code [A001] ..... 20-1128
P-17 Coolant level drop caution lamp stays lighted up .................................................................... 20-1129
P-18 Emergency steering pilot lamp does not work, or monitor panel detects service code [A001]... 20-1130
P-19 Emergency steering pilot lamp stays lighted up ...................................................................... 20-1131
P-20 Engine oil pressure drop caution lamp does not work, or monitor panel detects service code [A001] ........ 20-1132
P-21 Engine oil pressure drop caution lamp stays lighted up ......................................................... 20-1133
P-22 Exhaust brake pilot lamp does not work, or monitor panel detects service code [A001] ..... 20-1134
P-23 Exhaust brake pilot lamp stays lighted up ................................................................................ 20-1135
P-24 Charging circuit abnormality caution lamp does not work, or monitor panel detects service code [A001] .. 20-1136
P-25 Charging circuit abnormality caution lamp stays lighted up ................................................... 20-1137
P-26 Transmission filter clogging caution lamp does not work, or monitor panel detects service code [A001] ... 20-1138
P-27 Transmission filter clogging caution lamp stays lighted up .................................................... 20-1139
P-28 Brake stroke caution lamp does not work, or monitor panel detects service code [A001] ... 20-1140
P-29 Brake stroke caution lamp stays lighted up .............................................................................. 20-1141
P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code [A001] ...... 20-1142
P-31 Preheating switch pilot lamp stays lighted up .......................................................................... 20-1143
HD785-5 20-1101
(15)
P-32 Tilt warning lamp does not work, or monitor panel detects service code [A001] .................. 20-1144
P-33 Tilt warning lamp stays lighted up ............................................................................................. 20-1145
P-34 Body FLOAT (except FLOAT) pilot lamp does not work, or monitor panel detects service code [A001] ....... 20-1146
P-35 Body FLOAT (except FLOAT) pilot lamp stays lighted up ........................................................ 20-1147
P-36 Rear brake pilot lamp does not work, or monitor panel detects service code [A001] ........... 20-1148
P-37 Rear brake pilot lamp stays lighted up ...................................................................................... 20-1149
P-38 Parking brake pilot lamp does not work, or monitor panel detects service code [A001] ...... 20-1150
P-39 Parking brake pilot lamp stays lighted up ................................................................................. 20-1151
P-40 Maintenance caution lamp does not work, or monitor panel detects service code [A001] .. 20-1152
P-41 Maintenance caution lamp stays lighted up ............................................................................. 20-1153
P-42 Steering oil temperature caution lamp does not work, or monitor panel detects service code [A001] ......... 20-1154
P-43 Steering oil temperature caution lamp stays lighted up .......................................................... 20-1155
P-44 Differential lock pilot lamp does not work, or monitor panel detects service code [A001] .. 20-1156
P-45 Differential lock pilot lamp stays lighted up .............................................................................. 20-1157
P-46 High beam display does not light up ......................................................................................... 20-1158
P-47 Turn signal lamp (right) does not light up ................................................................................. 20-1160
P-48 Turn signal lamp (left) does not light up ................................................................................... 20-1161
P-49 Lamp check switch does not work ............................................................................................. 20-1162
P-50 AISS switch does not work ......................................................................................................... 20-1163
P-51 Exhaust brake switch does not work ......................................................................................... 20-1164
P-52 Mode change switch (1) does not work ..................................................................................... 20-1165
P-53 Mode change switch (2) does not work ..................................................................................... 20-1166
P-54 KPH/MPH speedometer unit selector does not work ............................................................... 20-1167
P-55 Defective operation of all switch inputs .................................................................................... 20-1168
P-56 Monitor panel detects service codes [A014] or [A019] ............................................................. 20-1169
P-57 Monitor panel detects service code [A015] ............................................................................... 20-1170
20-1102 HD785-5
1
METHOD OF SELF-DIAGNOSTIC DISPLAY
TROUBLESHOOTING FOR MONITOR PANEL AND CONTROLLERS
METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR

PANEL AND CONTROLLERS
1. After the starting switch is turned ON, all lamps light up for 3 seconds to carry out self-diagnosis of
the monitor itself. After that, the normal display is shown.
2. For details of the method of display if any abnormality occurs in the monitor itself or the other con-
trollers, see MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION in the Foreword of the
Troubleshooting Section.
3. Check for blown bulbs of the pilot lamps and warning lamps by pressing the caution and pilot lamp
bulb check switch at the right edge of the panel.
Self-diagnostic service code table
No. Service code Nature of failure Display conditions

Display conditions, Display in service
1 A000 Short circuit in output system code, trouble data display mode
2 A001 Short circuit in lamp output system
Display when lamp check switch
3 A002 Short circuit in central warning lamp output system is pressed for at least 2.5 seconds
and then released
4 A003 Short circuit in alarm buzzer output system
Display in service code, trouble
5 A011 Abnormality in network system data display mode
6 A012 Network system connection data does not match
7 A013 Abnormality in network system (transmission controller)
8 A014 Abnormality in network system (PMC)

Display when lamp check switch
9 A015 Abnormality in network system (engine controller) is pressed for at least 2.5 seconds
and then released
10 A016 Abnormality in network system (suspension controller)
11 A018 Abnormality in model selection data
12 A019 Abnormality in option data
13 A021 Abnormal drop in air pressure
14 A022 Engine coolant temperature overheat warning
15 A023 Torque converter oil temperature overheat warning
16 A024 Brake oil temperature overheat warning
HD785-5 20-1103
(15)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM
20-1108 HD785-5
(15)
TROUBLESHOOTING P-9
P-9 Central warning lamp does not work, or monitor panel detects
failure code
fl Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
between the modules are properly inserted.
Cause Remedy
Short circuit in wiring

YES harness between DP08
Replace
(female) (1) and WL
1 (female) (2)
Is voltage between
DP08 (female) (1) YES
and chassis Defective center module Replace
ground as shown 2
in table below?
• 20 – 30 V Does lamp light disconnection in wiring After inspec-
• Disconnect DP08 YES
up? harness between DP08 tion, clean or
and WL. NO 3
(female) (1) and WL replace
• Turn starting switch (female) (2)
ON. • Connect DP08 Does lamp light
(female) (1) and up?
NO 4 YES Defective central warning
chassis ground. Replace
Is voltage be- lamp
• Turn starting switch
ON. • Connect WL (2) tween WL (female)
• Disconnect DP08. and chassis (1) and chassis
NO disconnection in wiring
ground. ground normal? After inspec-
harness between WL
• Turn starting tion, clean or
• 20 - 30 V NO (female) (1) - fuse II-(12),
switch ON. or between fuse II- (12) - replace
starting switch ACC
ON.
• Disconnect WL.
P-9 Related electrical circuit diagram
HD785-5 20-1121
(15)
TROUBLESHOOTING P-16
P-16 Coolant level drop caution lamp does not work, or monitor panel
detects service code
fl Before carrying out troubleshooting, check that all

the connectors related to the wiring harnesses be-
tween the modules are properly inserted. Cause Remedy
fl Always connect any disconnected connectors before
going on to the next step.
YES See Trouble-

— shooting P-12
1
Does monitor Short circuit in wiring

panel detect After inspec-
YES harness between DP08
service code tion, repair or
2 (female) (3) and PL2
[A013] or [A018]? replace
(female) (2)
Is voltage between
DP08 (female) (3)
YES
and chassis ground Defective center module Replace
NO normal? 3
• 20 – 30 V Does coolant
level drop caution Disconnection in wiring
• Disconnect DP08 After inspec-
NO lamp light up? 4 YES harness between DP08
and PL2. tion, repair or
(female) (3) and PL2
• Turn starting Does coolant replace
• Disconnect DP08. (female) (2)
switch ON. level drop caution
• Connect DP08
(female) (3) and NO lamp light up?
chassis ground. Go to A
• Turn starting switch • Connect PL2 (2) NO
ON. and chassis ground.
• Turn starting switch ON.
5 YES After inspec-
Defective caution lamp tion, repair or
Is voltage between replace
From A PL2 (female) (1) Disconnection in wiring
and chassis harness between PL2
ground normal? After inspec-
(female) (1) and fuse II-
(12), or between fuse II- tion, repair or
• 20 – 30 V NO replace
• Disconnect PL2. (12) and starting switch
ACC
• Turn starting
switch ON.
20-1128 HD785-5
(15)
TROUBLESHOOTING P-17
P-17 Coolant level drop caution lamp stays lighted up

fl Before carrying out troubleshooting, check that all the connectors related to the wiring harnesses
between the modules are properly inserted.
Cause Remedy
Short circuit with chassis

2 YES After inspec-
ground in wiring harness
Is there continuity between DP08 (female) (3) tion, repair or
and PL2 (female) (2) replace
YES between PL2
1 (female) (2) and Caution lamp body in contact
chassis ground? with chassis ground, or After inspec-
Does coolant contact of chassis ground tion, repair or
level drop caution • Disconnect DP08 NO with wiring harness between replace
lamp light up? and PL2. caution lamp and PL2 (2)
• Turn starting
• Disconnect DP08. switch OFF.
Defective center module Replace
switch ON.
HD785-5 20-1129
(15)
TROUBLESHOOTING OF PMC SYSTEM
(M MODE)
PMC RELATED
PMC Related electric circuit diagram ................................................................................................ 20-1204
M- 1 PMC does not work ........................................................................................................ 20-1206
Monitor
panel Controller display
display
M- 2 E001 [0.1: flashes] Failure in NV RAM data is displayed ........................................... 20-1207
M- 3 E002 [0.2: flashes] Drop in battery direct power source voltage is displayed ......... 20-1208
M- 4 E003 [0.3: flashes] Abnormality in connector connection is displayed .................... 20-1210
M- 5 E011 [1.1: flashes] Disconnection in GSP communications is displayed ................. 20-1211
E012 [1.2: flashes] Abnormality in GSP communications is displayed .................... 20-1211
M- 6 E013 [1.3: flashes] Disconnection in MOM communications is displayed .............. 20-1212
E014 [1.4: flashes] Abnormality in MOM communications is displayed ................. 20-1212
M- 7 E015 [1.5: flashes] Disconnection in TMS communications is displayed ................ 20-1213
E016 [1.6: flashes] Abnormality in TMS communications is displayed ................... 20-1213
M- 8 E017 [1.7: flashes] Disconnection in CENSE communications is displayed ............ 20-1213
E018 [1.8: flashes] Abnormality in CENSE communications is displayed ............... 20-1213
M- 9 E026 [2.6: flashes] Communications abnormality 1 is displayed ............................. 20-1214
E027 [2.7: flashes] Communications abnormality 2 is displayed ............................. 20-1214
E02A [2.A: flashes] Communications abnormality 5 is displayed ............................. 20-1214
M-10 E035 [3.5: flashes] Abnormality in idle validation is displayed ................................ 20-1216
M-11 E041 [4.1: flashes] Short circuit with ground/disconnection in suspension
pressure sensor (right) system is displayed ............................... 20-1218
E042 [4.2: flashes] Short circuit with ground/disconnection in suspension
pressure sensor (left) system is displayed .................................. 20-1218
E043 [4.3: flashes] Short circuit in suspension pressure sensor (right) system
is displayed .................................................................................... 20-1218
E044 [4.4: flashes] Short circuit in suspension pressure sensor (left) system
is displayed .................................................................................... 20-1218
M-12 E054 [5.4: flashes] Disconnection in accelerator signal system is displayed .......... 20-1219
M-13 E055 [5.5: flashes] Short circuit in accelerator cell signal system is displayed ....... 20-1220
M-14 E056 [5.6: flashes] Abnormality in engine speed sensor system is displayed ........ 20-1221
M-15 E057 [5.7: flashes] Abnormality in input shaft speed sensor system is displayed..... 20-1222
M-16 E058 [5.8: flashes] Abnormality in travel speed sensor (transmission output
shaft speed sensor) is displayed ................................................. 20-1223
M-17 E0A1 [A.1: flashes] When engine is not running, drop in brake oil level is
displayed ........................................................................................ 20-1224
M-18 E0A2 [A.2: flashes] When engine is not running, drop in retarder oil level is
displayed ........................................................................................ 20-1225
HD785-5 20-1201
(15)
TROUBLESHOOTING M-10
M-10 Abnormality in idle validation is

displayed
Cause Remedy
Set data correctly
For details, see
TESTING AND
Defective setting of ADJUSTING,
YES Setting rotary
model selection data in
transmission controller switch (model
data, network
data) when re-
placing transmi-
1 Defective contact, disco- ssion controller.
nnection, or short circuit
Is machine with ground in wiring Repair or
3 YES
equipped with harness between WAS1 replace wiring
mechanical Is resistance (female) (6) – PMR4 (14) – harness
governor?
YES between WAS1 PMC1 (female) (3)
(male) (6) and (4)
• Turn starting normal?
switch OFF. NO
2 • Turn starting pedal
• See M-30 switch OFF.
Is resistance
between PMC1 • Accelerator pedal
Slow ↔ Full
NO (female) (2) and Defective contact, disco-
chassis normal? Slow : Min. 1 MΩ
Full : Max. 1 Ω nnection, or short circuit Repair or
• Turn starting 4 YES with ground in wiring replace wiring
switch OFF. harness between WAS1
Is resistance harness
• Accelerator pedal (female) (5) – PMR4 (13) –
between WAS1
Slow ↔ Full PMC1 (female) (2)
Slow : Max. 1 Ω NO (male) (5) and (4)
normal? Defective accelerator
Full : Min. 1 MΩ Replace
• Turn starting NO pedal
switch OFF.
• Accelerator pedal
Slow ↔ Full
Slow : Max. 1 Ω
Full : Min. 1 MΩ
20-1216 HD785-5
(15)
M-10 Related electrical circuit diagram
HD785-5 20-1217
(15)
M-26 When engine is not running, drop in

engine oil level is displayed
fl Before starting troubleshooting, check the engine oil level again.

Cause Remedy
3 YES
Defective PMC Replace
Is there continuity
YES between PMC2B
Defective contact or disco-
2 (female) (1) and
nnection in wiring harness
PMC1 (female) (17)? Repair or
Is there continuity between PMC2B (female) replace wiring
YES between MM9 (1) – MM8 (1) – MM9
• Turn starting NO harness
(female) (2) and switch OFF. (female) (1)
1 chassis ground? • Disconnect PMC1 Defective contact or disco-
Is there continuity and PMC2B. nnection in wiring harness Repair or
• Turn starting
between MM9 between PMC1 (female) replace wiring
switch OFF. NO
(male) (1) and (2)? (17) – MM8 (9) – MM9 harness
• Disconnect MM9.
(female) (2)
• Turn starting
switch OFF. Defective engine oil level
Replace
• Disconnect MM19. NO sensor
M-26 Related electrical circuit diagram
HD785-5 20-1233
(15)
METHOD OF TROUBLESHOOTING USING
TROUBLESHOOTING SELF-DIAGNOSTIC FUNCTION OF ECU
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC

FUNCTION OF ECU
(1) Stop the machine at a safe place, apply the parking brake, and stop the engine.
(2) Check that the troubleshooting switch is OFF, then turn the ABS/ASR main switch ON.
(3) Turn the starting switch ON. There is no need to start the engine.
(4) Turn the troubleshooting switch ON for at least 1 second, then turn it OFF again.
(5) When the troubleshooting switch is turned OFF, the troubleshooting lamp will flash, so count the
number of flashes as shown in the procedure in Fig. 4. If you fail to count the number of flashes,
wait for the flashing of the troubleshooting lamp to stop, then repeat the procedure for Step (4) to
start the flashing again.
(6) After completing the counting of the number of flashes, turn the ABS/ASR main switch and starting
switch OFF.
(7) Use the number of flashes to judge the location of the failure from Tables 1 and 2, check the appli-
cable place with the INDEX (troubleshooting code), then carry out repairs.
(8) After completing repairs, check that the troubleshooting switch is OFF, then turn the ABS/ASR main
switch ON.
(9) Drive the machine at a speed of less than 10 km/h and check that the warning lamps go OFF.
(10) After checking that the warning lamps go OFF, stop the machine again and apply the parking brake.
If the warning lamps do not go out, there is still some failure, so repeat Steps (1) - (7) above to carry
out troubleshooting again.
(11) After the warning lamps go OFF, delete the data according the method of deleting the trouble data
of ECU, and then check that the number of flashing times of the troubleshooting lamp indicates that
the system is normal. If the system is normal, it can be used for ordinary purpose.
Fig. 4 Flashing interval for troubleshooting lamp
Note 1 : Flashes 2 times when ABS is installed independently

Flashes 4 times when ABS/ASR is installed
Note 2 : 2nd block: Indicates a failure mode in the left front or right rear system.
• When normal: Flashes 1 time.
• When abnormal: Flashes by the number of times corresponding to the failure mode.
Note 3 : 3rd block: Indicates a failure mode in the right front or left rear system.
• When normal: Flashes 1 time.
• When abnormal: Flashes by the number of times corresponding to the failure mode.
HD785-5 20-1255
B
INDEX (troubleshooting code)

• Machines with ABS installed independently
Number of flashing times INDEX
Failure mode
1st block 2nd block 3rd block (Troubleshooting code)
2 1 1 System is normal
2 9 9 Source voltage system ABS – 18

Failure mode
2 2 fl Controller system ABS – 1
2 10 fl Left front ABS valve system ABS – 3
2 11 fl Right rear ABS valve system ABS – 5
2 6 fl Left front wheel speed sensor system ABS – 7
2 7 fl Right rear wheel speed sensor system ABS – 9
2 3 fl Left front wheel speed sensor output system ABS – 11
2 4 fl Right rear wheel speed sensor output system ABS – 13
2 9 fl Valve relay 1 system ABS – 15

Failure mode
2 fl 2 Controller system ABS – 1
2 fl 10 Right front ABS valve system ABS – 2
2 fl 11 Left rear ABS valve system ABS – 4
2 fl 6 Right front wheel speed sensor system ABS – 6
2 fl 7 Left rear wheel speed sensor system ABS – 8
2 fl 3 Right front wheel speed sensor output system ABS – 10
2 fl 4 Left rear wheel speed sensor output system ABS – 12
2 fl 9 Valve relay 2 system ABS – 14
In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is dis-
played when abnormal.
(Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear
systems are normal).
Number of flashing times
1st block 2nd block 3rd block
2 10 1
(Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system”
have failures simultaneously.
2 10 6
(Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system”
and “valve relay 2 system” have failures simultaneously.
2 9 9
20-1256 HD785-5
B
• Machines with ABS/ASR installed

Failure mode
4 1 1 System is normal
4 9 9 Source voltage system ABS – 18

Failure mode
4 2 fl Controller system ABS – 1
4 10 fl Left front ABS valve system ABS – 3
4 11 fl Right rear ABS valve system ABS – 5
4 6 fl Left front wheel speed sensor system ABS – 7
4 7 fl Right rear wheel speed sensor system ABS – 9
4 3 fl Left front wheel speed sensor output system ABS – 11
4 4 fl Right rear wheel speed sensor output system ABS – 13
4 14 fl ASR valve system ASR – 1

Failure mode
4 fl 2 Controller system ABS – 1
4 fl 10 Right front ABS valve system ABS – 2
4 fl 11 Left rear ABS valve system ABS – 4
4 fl 6 Right front wheel speed sensor system ABS – 6
4 fl 7 Left rear wheel speed sensor system ABS – 8
4 fl 3 Right front wheel speed sensor output system ABS – 10
4 fl 4 Left rear wheel speed sensor output system ABS – 12
4 fl 14 ASR valve system ASR – 1
In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is dis-
played when abnormal.
(Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear
systems are normal).
4 10 1
(Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system”
have failures simultaneously.
4 10 6
(Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system”
and “valve relay 2 system” have failures simultaneously.
4 9 9
HD785-5 20-1257
B
TROUBLESHOOTING SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER

Order of Terminal for System checker, brake operation
inspection Order of inspection connecting system
checker for tester required for inspection
1 Controller ground 1234

1234 ← Ω →Chassis
2 Controller power source + ← Vo → 1234
3 Relay resistance R1← Ω →R2 Actuate power relay

Press check switch R1 (Note 2)
Actuate power relay

4 Power relay 1
Press check switch R1
Actuate power relay

5 Power relay 2
Press check switch R2
Actuate power relay

6 Warning lamp control
Press check switches R1 and R2 at same time
7 ASR information lamp D2← Lead →1234 Connect 1234

1234 terminal and terminal D2 of
1234
checker with tester lead wire
8 Warning lamp line D1 + ← Ω → 1234

1234
9 ASR engine control terminal DF + ← Ω → E3
10 Wheel speed sensor resistance

1L Front left wheel DF + ← Ω → DF – Press wheel selector switch 1L
1R Front right wheel DF + ← Ω → DF – Press wheel selector switch 1R
2L Rear left wheel DF + ← Ω → DF – Press wheel selector switch 2L
2R Rear right wheel DF + ← Ω → DF – Press wheel selector switch 2R
Wheel speed sensor

11 insulation resistance
1L Front left wheel DF – ← Ω → 1234 Press wheel selector switch 1L
1R Front right wheel DF – ← Ω → 1234 Press wheel selector switch 1R
2L Rear left wheel DF – ← Ω → 1234 Press wheel selector switch 2L
2R Rear right wheel DF – ← Ω → 1234

1234 Press wheel selector switch 2R
Note 1 : Turn the starting switch OFF also when measuring. After measuring, turn it ON and carry out the
next inspection.
Note 2 : Remove fuse 2 before carrying out inspection. After the inspection, return it to the correct position.
20-1258 HD785-5
4
TROUBLESHOOTING W -1
W-1 Warning lamp does not light up

fl Check that fuses FBX (10) (1 - 7) and (2 - 8) are not blown. If they are blown, check for a short circuit
with the ground inside the controller and in the wiring harness between the fuse and the controller.
fl When the ABS/ASR main switch is ON.
fl When the starting switch is ON. Cause Remedy
2 YES
YES Is resistance
between ECU (26)
and (9) normal?
Blown warning lamp bulb Replace
• 2 – 4.5 Ω NO
disconnection in wiring
harness between ECU
1 YES (female) (9) – SW3, SW4 – Repair or replace
FBX (2), FBX (8) – CN1,
Is voltage 4 ECU (female) (27) – CN2,
between ECU (9) YES J06 – battery relay, J07 –
Is resistance
and (27) normal? between WR2 circuit breaker (+)
(male) (30) and Defective ABS/ASR main
3 (87a) normal? switch
• 21 – 29 V
Is resistance • =0 Defective WR2 relay Replace
between WR1 NO
NO (male) (30) and
(87a) normal?
• =0
Defective WR1 relay Replace
NO
W-1 Related electrical circuit diagram
20-1266 HD785-5
(15)
TROUBLESHOOTING I-1
I-1 ASR information switch does not go out
Cause Remedy
1 YES
Is resistance
between ECU (27)
and (28) normal? Short circuit in wiring
harness between ECU Repair or replace
• 2 – 4.5 Ω NO (female) (28) and AL1
I-1 Related electrical circuit diagram
HD785-5 20-1267
(15)
TROUBLESHOOTING ASR-1
ASR-1 Failure in ASR control valve (only machines with ABS/ASR

installed)
Cause Remedy
YES
1
Is resistance disconnection in wiring
between ECU (2) harness between ECU (2) –
– (27) and ECU YES SVR (female) (9), ECU (20) Repair or replace
(20) – (27) – SVR (female) (10), ECU
normal? 2
(27) – SVR (female) (13)
• 45 – 52 Ω Is resistance
between SVR Defective contact or
(male) (9) – (13) YES disconnection in wiring Repair or replace
NO and SVR (male) 3 harness between SVR
(10) – (13) Is resistance (male) (9) – VTC (female)
(1), SVR (male) (10) – VTC
• 45 – 52 Ω between VTC
(female) (2), SVR (male)
(male) (1) – (4)
NO and VTC (male) (13) – VTC (female) (4)
(2) – (4) normal?
• 45 – 52 Ω Defective valve Replace
NO
ASR-1 Related electrical circuit diagram
20-1268 HD785-5
(15)
TROUBLESHOOTING ASR-2
ASR-2
Cause Remedy
1 YES
Defective system checker Repair or replace
Is resistance
between ECU (12)
and (14) normal? Defective contact or
disconnection in wiring Repair or replace
• =0 NO harness between ECU
(12) and (14)
ASR-2 Related electrical circuit diagram
HD785-5 20-1269
(15)
TROUBLESHOOTING ABS-1
ABS-1 Failure inside ECU

fl Check that fuses FBX (10) (2 - 8) are not blown.
Cause Remedy
1 YES
Is voltage
between ECU (9) Defective contact or
and (27) normal? disconnection in wiring
harness between ECU
(female) (10) – SW3, SW4 Repair or replace
• 21 – 29 V NO – FBX (2), FBX (8) – CN1,
• Turn starting ECU (female) (27) – CN2,
switch ON. J06 – battery relay, J07 –
• Turn ABS/ASR circuit breaker (+)
main switch ON. Defective ABS/ASR main
switch
ABS-1 Related electrical circuit diagram
20-1270 HD785-5
(15)
ABS-2 Failure in front right pressure control valve
Cause Remedy
YES
1
– (27) and ECU
YES SVF (female) (7), ECU (6) – Repair or replace
(7) – (27) normal? 2 SVF (female) (8), ECU (27)
– SVF (female) (10)
between SVF Defective contact or
NO and SVF (male) 3 harness between SVF
(7) – (10) normal? Is resistance (male) (7) – VFR (female)
between VFR (1), SVF (male) (8) – VFR
• 14 – 21 Ω (female) (2), SVF (male)
(male) (2) – (4)
NO and VFR (male) (10) – VFR (female) (4)
(1) – (4) normal?
NO
HD785-5 20-1271
(15)
ABS-3 Failure in front left pressure control valve
Cause Remedy
YES
1
between ECU harness between ECU (23)
(23) – (27) and YES – SVF (female) (6), ECU Repair or replace
ECU (24) – (27) (24) – SVF (female) (5),
normal? 2
ECU (27) – SVF (female) (9)
NO and SVF (male) 3 harness between SVF
(5) – (9) normal? Is resistance (male) (6) – VFL (female)
• 14 – 21 Ω between VFL (2), SVF (male) (5) – VFL
(male) (2) – (4) (female) (1), SVF (male)
NO and VFL (male) (9) – VFL (female) (4)
(1) – (4) normal?
NO
20-1272 HD785-5
(15)
ABS-4 Failure in rear left pressure control valve
Cause Remedy
YES
1
between ECU harness between ECU (21)
(21) – (27) and YES – SVR (female) (6), ECU (22) Repair or replace
ECU (22) – (27) – SVR (female) (5), ECU (27)
normal? 2
– SVR (female) (11)
(6) – (11) normal? Is resistance (male) (5) – VRL (female)
between VRL (1), SVR (male) (6) – VRL
• 14 – 21 Ω (female) (2), SVR (male)
(male) (1) – (4)
NO and VRL (male) (11) – VRL (female) (4)
(2) – (4) normal?
NO
HD785-5 20-1273
(15)
ABS-5 Failure in rear right pressure control valve
Cause Remedy
YES
1
YES SVR (female) (8), ECU (5) – Repair or replace
– (27) and ECU
(5) – (27) normal? 2 SVR (female) (7), ECU (27)
– SVR (female) (12)
(8) – (12) normal? Is resistance (male) (7) – VRR (female)
between VRR (1), SVR (male) (8) – VRR
• 14 – 21 Ω (female) (2), SVR (male)
(male) (1) – (4)
NO and VRR (male) (12) – VRR (female) (4)
(2) – (4) normal?
NO
20-1274 HD785-5
(15)
TROUBLESHOOTING ABS-6, ABS-10
ABS-6 Failure in front right wheel speed sensor

ABS-10 Abnormality in front right wheel speed sensor output
Cause Remedy
For ABS-6
4 YES
YES Is width of
YES variation in
sensor output
normal?
For ABS-10 3 Defective rotor Repair or replace
• Use system checker. NO
Is sensor output • Variation from
minimum value
normal? should be within
2 25% 5 YES
Defective sensor Replace
• Use system
YES Is resistance checker. Is sensor mount
between ECU (34) • > 10 KΩ
and (27) normal? NO normal?
Push in until
Defective sensor mount sensor contacts
• > 30 KΩ fl Check that tip of NO rotor
• Turn starting sensor is in
switch ON. contact with rotor. Short circuit with chassis
YES between ECU (34) – SVF Repair or replace
6 (female) (3), ECU (17) –
SVF (female) (4)
1 Is resistance
between SVF Short circuit with chassis
Is resistance NO (male) (3) and 7 YES ground in wiring harness
between ECU (17) chassis normal? between SVF (male) (3) –
Is resistance Repair or replace
and (34) normal? SFR (female) (1), SVF
• > 30 KΩ between SFR (male) (4) – SFR (female)
NO (male) (1) and (2)
• 950 – 1450 Ω chassis normal?
• > 30 KΩ NO
YES harness between ECU (17)
– SVF (female) (4), ECU Repair or replace
8
(34) – SVF (female) (3)
Is resistance
NO (male) (3) and (4) 9 YES disconnection in wiring
normal? harness between SVF Repair or replace
Is resistance (male) (4) – SFR (female)
• 950 – 1450 Ω between SFR (2), SVF (male) (3) – SFR
NO (male) (1) and (2) (female) (1)
normal?
• 950 – 1450 Ω NO
ABS-6, ABS-10 Related electrical circuit diagram
HD785-5 20-1275
(15)
ABS-7 Failure in front left wheel speed sensor

ABS-11 Abnormality in front left wheel speed sensor output
Cause Remedy
For ABS-7
4 YES
YES Is width of
YES variation in
sensor output
normal?
minimum value
2 25% 5 YES
• Use system
Push in until
YES between ECU (15) – SVF Repair or replace
6 (female) (2), ECU (32) –
SVF (female) (1)
1 Is resistance
between SVF Short circuit with chassis
between ECU (15) chassis normal? between SVF (male) (1) –
and (32) normal? SFL (female) (1), SVF
• > 30 KΩ between SFL (male) (2) – SFL (female)
• > 30 KΩ NO
YES harness between ECU (15) Repair or replace
8 – SVF (female) (2), ECU
(32) – SVF (female) (1)
Is resistance
normal? harness between SVF Repair or replace
Is resistance (male) (1) - SFL (female)
• 950 – 1450 Ω between SFL (1), SVF (male) (2) - SFL
normal?
• 950 – 1450 Ω NO
20-1276 HD785-5
(15)
ABS-8 Failure in rear left wheel speed sensor

ABS-12 Abnormality in rear left wheel speed sensor output
Cause Remedy
For ABS-8
4 YES
YES Is width of
YES variation in
sensor output
normal?
minimum value
2 25% 5 YES
• Use system
Push in until
YES between ECU (18) – SVR Repair or replace
6 (female) (2), ECU (35) –
SVR (female) (1)
1 Is resistance
between SVR Short circuit with chassis
between ECU (18) chassis normal? between SVR (male) (1) –
and (35) normal? SRL (female) (1), SVR
• > 30 KΩ between SRL (male) (2) – SRL (female)
• > 30 KΩ NO
8 – SVR (female) (2), ECU
(35) – SVR (female) (1)
Is resistance
normal? harness between SVR Repair or replace
Is resistance (male) (1) – SRL (female)
• 950 – 1450 Ω between SRL (1), SVR (male) (2) SRL
normal?
• 950 – 1450 Ω NO
HD785-5 20-1277
(15)
ABS-9 Failure in rear right wheel speed sensor

ABS-13 Abnormality in rear right wheel speed sensor output
Cause Remedy
For ABS-9
4 YES
YES Is width of
YES variation in
sensor output
normal?
minimum value
2 25% 5 YES
• Use system
Push in until
YES between ECU (16) – SVR Repair or replace
6 (female) (4), ECU (33) –
SVR (female) (3)
1 Is resistance
between SVR Short circuit with chassis
between ECU (16) chassis normal? between SVR (male) (3) –
and (33) normal? SRR (female) (1), SVR
• > 30 KΩ between SRR (male) (4) – SRR (female)
• > 30 KΩ NO
8 – SVR (female) (4), ECU
(33) – SVR (female) (3)
Is resistance
normal? harness between SVR Repair or replace
Is resistance (male) (3) – SRR (female)
• 950 – 1450 Ω between SRR (1), SVR (male) (4) SRR
normal?
• 950 – 1450 Ω NO
20-1278 HD785-5
(15)
ABS-14 Failure in valve relay (VR2)

fl Check that no fuses are blown.
Cause Remedy
YES Defective controller Replace
Is resistance YES
between ECU (8) Defective controller Replace
and (25) normal?
2
• 260 – 360 Ω harness between ECU (8)
• Remove fuse [2]. Is resistance 4 YES – VR2 (female) (3), ECU
(8) – WR2 (female) (3), Repair or replace
between ECU (8) Is resistance VR2 (female) (2) – WR2
NO and FBX (4) between WR2 (female) (2), FBX (4) – VR2
normal? YES (male) (85) and
(female) (2), FBX (4) –
(86) normal? WR2 (female) (2)
• 130 – 180 Ω 3
• Remove fuses [2]
Is resistance • 305 ± 15 Ω
and [4]. Defective WR2 relay Replace
between VR2
NO
NO (male) (85) and
(86) normal?
• 305 ± 15 Ω
Defective VR2 relay Replace
NO
HD785-5 20-1279
(15)

Cause Remedy
Is resistance YES
between ECU (8) Defective controller Replace
and (25) normal?
2
• 260 – 360 Ω harness between ECU
• Remove fuse [2]. Is resistance 4 YES (25) – VR1 (female) (3),
ECU (25) – WR1 (female) Repair or replace
between ECU Is resistance (3), VR1 (female) (2) –
NO (25) and FBX (3) between WR1 WR1 (female) (2), FBX (3)
normal? YES (male) (85) and
– VR1 (female) (2), FBX (3)
(86) normal? – WR1 (female) (2)
• 130 – 180 Ω 3
• Remove fuses [2]
Is resistance • 305 ± 15 Ω
and [3]. Defective WR1 relay Replace
between VR1
NO
NO (male) (85) and
(86) normal?
• 305 ± 15 Ω
Defective VR1 relay Replace
NO
20-1280 HD785-5
(15)
Cause Remedy
YES YES
3 Defective wiring harness Repair or replace
Is there short
circuit in wiring
harness between
ECU (01) - VR2
(female) (1), VR2 4 YES
(female) (4) - VR2 Defective wiring harness Repair or replace
(female) (2), VR2 Is there defective
(female) (4) - FBX contact or
2 (4) disconnection in
wiring harness
Is resistance
YES between VR2 NO between WR2
(female) (1) - CN2,
(male) (30) and WR2 (female) (5) -
(87a) normal? ECU (26) Defective controller Replace
NO
1 • =0
Is resistance
between WR2 Defective VR2 relay Replace
(male) (30) and NO
(87a) normal?
• =0
NO
HD785-5 20-1281
(15)
Cause Remedy
YES YES
3 Defective wiring harness Repair or replace
Is there short
circuit in wiring
harness between
ECU (19) - VR1
(female) (1), VR1 4 YES
(female) (4) - VR1 Defective wiring harness Repair or replace
(female) (2), VR1 Is there defective
(female) (4) - FBX contact or
2 (3) disconnection in
wiring harness
Is resistance
YES between VR1 NO between WR1
(female) (1) - CN2,
(male) (30) and WR1 (female) (5) -
(87a) normal? ECU (26) Defective controller Replace
NO
1 • =0
Is resistance
between WR1 Defective VR1 relay Replace
(male) (30) and NO
(87a) normal?
• =0
NO
20-1282 HD785-5
(15)
ABS-18 Abnormality in power source voltage

Cause Remedy

1
Is voltage harness between ECU (9)
between ECU (9) 2 YES – CN1, CN1 – circuit
and (27) normal? Repair or replace
breaker (+)Defective
Is resistance contact or disconnection
• 21 – 29 V between ECU in wiring harness
• Turn starting (27) and chassis
NO normal?
switch ON. Defective contact or
disconnection in wiring Repair or replace
• Turn ABS/ASR •≤3Ω NO harness between ECU (27)
main switch ON. • Turn starting – CN2, CN2 – battery relay
switch ON.
HD785-5 20-1283
(15)
TROUBLESHOOTING FOR AUTOMATIC
SPIN REGULATOR (ASR-II) SYSTEM
(AS MODE)
Outline....................................................................................................................................................... 20-1402
AS-1 Failure Code 0.1 "Abnormality in power source voltage" is displayed ....................................... 20-1404
AS-2 Failure Code 1.0 "Disconnection in engine speed sensor system" is displayed........................ 20-1405
AS-3 Failure Code 1.1 "Disconnection in RR wheel speed sensor" is displayed ............................... 20-1406
AS-4 Failure Code 1.2 "Disconnection in RL wheel speed sensor" is displayed................................ 20-1407
AS-5 Failure Code 1.3 "Disconnection in transmission output shaft speed sensor
system" is displayed .................................................................................................................. 20-1408
AS-6 Failure Code 1.6 "Failure in steering angle sensor" is displayed............................................... 20-1409
AS-7 Failure Code 1.7 "Failure in accelerator signal system" is displayed ........................................ 20-1410
AS-8 Failure Code 4.3 "Disconnection on ARSC caution lamp system" is displayed .........................20-1411
AS-9 Failure Code 4.5 "Disconnection in panel caution lamp and buzzer system" is displayed ........ 20-1412
AS-10 Failure Code 5.3 "Short circuit with ground in ARSC caution lamp system" is displayed.......... 20-1413
AS-11 Failure Code 5.5 "Short circuit with ground in panel caution lamp
and buzzer system" is displayed ............................................................................................... 20-1414
AS-12 Failure Code 6.0 "Failure in engine speed sensor system" is displayed ................................... 20-1415
AS-13 Failure Code 6.1 "Failure in RR wheel speed sensor system" is displayed .............................. 20-1416
AS-14 Failure Code 6.2 "Failure in RL wheel speed sensor system" is displayed ............................... 20-1417
AS-15 Failure Code 8.0 "Failure in pressure control valve (L.H.) system:
pressure control valve (L.H.) does not open" is displayed......................................................... 20-1418
AS-16 Failure Code 8.1 "Short circuit with chassis ground in
pressure control valve (R.H.) system" is displayed.................................................................... 20-1419
pressure control valve (L.H.) system" is displayed .................................................................... 20-1420
AS-18 Failure Code 8.3 "Disconnection in pressure control valve (R.H.) system" is displayed ........... 20-1421
AS-19 Failure Code 8.4 "Disconnection in pressure control valve (L.H.) system" is displayed............ 20-1422
AS-20 Failure Code 8.5 "Failure in pressure control valve (R.H.) system:
pressure control valve (R.H.) does not close" is displayed........................................................ 20-1423
pressure control valve (L.H.) does not close" is displayed ........................................................ 20-1424
pressure control valve (R.H.) does not open" is displayed ........................................................ 20-1425
pressure switch valve system" is displayed ............................................................................... 20-1426
AS-24 Failure Code 9.0 "Disconnection in pressure switch valve system" is displayed....................... 20-1427
AS-25 Failure Code 9.1 "Failure in pressure switch valve system:
valve does not close" is displayed ............................................................................................. 20-1428
valve does not open" is displayed ............................................................................................. 20-1429
AS-101 Nothing is displayed on display window of controller................................................................. 20-1430
AS-102 Failure Code is kept cleared ("- -" is always displayed in display window
of controller) or cannot be cleared ............................................................................................. 20-1431
a) When failure code cannot be cleared .................................................................................... 20-1431
b) When failure code is continuously cleared ............................................................................ 20-1431
AS-103 Another controller has a failure.................................................................................................. 20-1432
a) Transmission controller system ............................................................................................. 20-1432
b) Payload meter system ........................................................................................................... 20-1432
AS-104 Monitor lamp (buzzer) stays ON (or OFF) ................................................................................. 20-1433
AS-105 Disconnection in switch system of ASR system ........................................................................ 20-1434
AS-106 Short circuit with chassis ground in switch system of ASR system ........................................... 20-1435
AS-107 ASR working lamp does not light up.......................................................................................... 20-1436
AS-108 ASR working lamp remains lit.................................................................................................... 20-1438
HD785-5 20-1401
(13)
OUTLINE
2) Operation pattern 2
1. Outline Flashing of the ASR caution lamp alone
The methods of inspecting and repairing failures indicates that the ASR operates continu-
in ASR are explained below. ously although it has a failure.
Since ASR has the self-diagnosis function, it In this case, turn off the system switch in
notifies failures that the controller can detect order to stop the ASR system.
with the monitor lamp, buzzer, and ASR caution If the system switch is turned off, the ASR
lamp and displays the error codes of those fail- caution lamp also turns off.
ures on the display unit of the controller. If an a In either of above operation patterns 1
error code is displayed, inspect the failed parts and 2, turn off the system switch imme-
according to the following procedure. diately in order to stop ASR.
2. Precautions for troubleshooting Note 1) If the engine is started with the air
1) Before troubleshooting, attempt to dupli- pressure in the air tank low, failure
cate the problem. code "9.2" may be displayed. In
2) Failure in the electric system are often this case, increase the air pressure
caused by vibration of the vehicle body to the normal level and then start
caused by the engine, gear shifting, rough- the engine.
ness of road, etc.
Accordingly, check the condition under 4. When system is normal
which each failure occurred before starting Code "0.0" is displayed on the controller LED
troubleshooting (particularly when the fail- behind the operator's seat.
ure does not reappear or a failure is not
detected). 5. How to refer to model selection, tire size, and
3) If the electric system has a failure, check service code
the connectors for disconnection carefully. When the starting switch of the vehicle is turned
4) Be sure to check the effects of the electric on, the following codes are displayed automati-
devices which were installed later such as cally on the controller LED in the order shown
a radio unit. (attempt to duplicate the prob- below ((1) – (6)).
lem after removing these devices.) If any (1) All LED elements
device that was installed later has an effect (2) Model
on ASR, change its installation method or
its location. Code Model name
5) Before troubleshooting, read the precau-
78 HD785-5
tions in the section of troubleshooting in the
Shop Manual.
3. Troubleshooting procedure (3) Tire size
If ASR has a failure, judge the service code for
the contents of that failure according to the table Code Tire Size
on the next page, then inspect according to the B.- Large diameter
service code in order to find the failed part and
repair or replace it. S.- Small diameter
1) Operation pattern 1
Flashing of the centralized warning lamp (4) Latest service code
and ASR caution lamp and the sounding of (5) Service code prior to (4)
the alarm buzzer indicate that the ASR sys- (6) Service code prior to (5)
tem has had a serious failure.
In this case, turn off the system switch in 6. How to clear service code
order to stop the ASR system. Before starting the engine, disconnect connec-
If the system switch is turned off, the cen- tors CR1 and CR2 behind the operator's seat.
tralized warning lamp, ASR caution lamp, At this time, "__" flashes on the controller LED.
and warning buzzer are also turned off. When, the flashing "__" lights up (3 seconds
later), the failure code is cleared.
a When using ASR for the first time, be sure
to clear the service code. After the service
code is cleared, connect connectors CR1
and CR2.
20-1402 HD785-5
(13)
Failure code judgment table

Classification Failure code* Contents of failure Diagnosis
0.1 Abnormality in power source voltage AS-1
1.0 Disconnection in engine speed sensor system AS-2
1.1 Disconnection in RR wheel speed sensor AS-3
1.2 Disconnection in RL wheel speed sensor AS-4
Disconnection in transmission output shaft speed sensor
1.3 AS-5
system
1.6 Failure in steering angle sensor AS-6
1.7 Failure in accelerator signal system AS-7
4.3 Disconnection in ARSC caution lamp system AS-8
4.5 Disconnection in panel caution lamp and buzzer system AS-9
5.3 Short circuit with ground in ARSC caution lamp system AS-10
Short circuit with ground in panel caution lamp and buzzer
5.5 AS-11
system
6.0 Failure in engine speed sensor system AS-12
6.1 Failure in RR wheel speed sensor system AS-13
6.2 Failure in RL wheel speed sensor system AS-14
Failure code is Failure in pressure control valve (L.H.) system: pressure control
8.0 AS-15
displayed valve (L.H.) does not open
Short circuit with chassis ground in pressure control valve (R.H.)
8.1 AS-16
system
Short circuit with chassis ground in pressure control valve (L.H.)
8.2 AS-17
system
8.3 Disconnection in pressure control valve (R.H.) system AS-18
8.4 Disconnection in pressure control valve (L.H.) system AS-19
Failure in pressure control valve (R.H.) system: pressure control
8.5 AS-20
valve (R.H.) does not close
Failure in pressure control valve (L.H.) system: pressure control
8.6 AS-21
valve (L.H.) does not close
Failure in pressure control valve (R.H.) system: pressure control
8.7 AS-22
valve (R.H.) does not open
Short circuit with chassis ground in pressure switch valve
8.9 AS-23
system
9.0 Disconnection in pressure switch valve system AS-24
9.1 Failure in pressure switch valve system: valve does not close AS-25
9.2 Failure in pressure switch valve system: valve does not open AS-26
Nothing is displayed on display window of controller AS-101
Failure code is kept cleared ("_" is always displayed in display window of
AS-102
controller) or cannot be cleared
Another controller has a failure AS-103
Failure code is not Monitor lamp (buzzer) stays ON (or OFF) AS-104
displayed
Disconnection in switch system of ASR system AS-105
Short circuit with chassis ground in switch system of ASR system AS-106
ASR working lamp does not light up AS-107
ASR working lamp remains lit AS-108
* Displayed in the display window of the controller
HD785-5 20-1403
(13)
TROUBLESHOOTING AS-1
AS-1 Failure Code 0.1 "Abnormality in power source voltage" is displayed

a Troubleshooting is carried out while the abnormality is being generated, so when the connector is
disconnected and the T-adapter is inserted, or when the T-adapter is removed and the connector is
connected again to its original position, if the error code is not displayed on the monitor, the system
has been reset.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a The ARSC controller is used to observe the power source voltage. If the power source voltage is less than
19V and the engine speed is more than 500 rpm continuously for 0.2 seconds, the error is detected.
a Divide into battery – fuse, and fuse – controller when checking. If the voltage at the inlet port of the control-
ler is normal, judge that the controller is defective.
Cause Remedy
3 YES
Is voltage be-
YES tween ARC1 (8) –
(9), and between
2 ARC1 (18) – (19) Defective contact or
normal? disconnection in wiring After inspection,
Is fuse BT3 (11), harness between fuse BT3 repair or replace
YES (12) normal (not • 20 – 30V NO wiring harness
• Turn starting and controller
1 blown)? switch ON.
Are other control- Short circuit with chassis After inspection,
lers (electronic ground in wiring harness repair or replace
display panel, NO between fuse BT3 and wiring harness.
transmission con- ARC1 (female) (8), (18) Replace fuse
troller) normal?
–– See other
troubleshooting
NO
AS-1 Related electrical circuit diagram
20-1404 HD785-5
(13)
AS-2 Failure Code 1.0 "Disconnection in engine speed sensor system" is

displayed
has been reset.
a The controller observes if there is any disconnection or other problem in the engine speed sensor.
a The output of the engine speed sensor is shared by the transmission controller and electronic display panel.
On the electronic governor specification machine, it is also shared by the engine controller.
a Divide into sens or – junction TMD, and TMD1 – ARC3 (5), (12) when checking. If there is no abnormality,
judge that the controller is defective.
Cause Remedy
3 YES
Defective Controller Replace
When connector
YES is connected
again, does
2 problem appear
again? Mating of ARC3 connector Repair or
Is resistance
is defective replace
YES between ARC3 NO
1 (female) (5) and
(12) normal?
Are other Defective contact or discon-
Repair or
controllers (trans- • 500 – 1000 z nection in wiring harness
replace wiring
mission controller) • Turn starting NO between ARC3 (female)
normal? harness
switch ON. (5), (12) – TMD1 (13), (14)
• Disconnect
connectors. See
Troubleshooting
––
of transmission
NO controller system
HD785-5 20-1405
(13)
AS-3 Failure Code 1.1 "Disconnection in RR wheel speed sensor" is

displayed
has been reset.
a The controller is checking the wheel speed sensors for disconnection, etc.
a Divide the system into the sections from ARC3 through junction connector BRJ2, from junction connector
BRJ2 through WHR, and wheel speed sensor and inspect those sections in order.
Cause Remedy
Disconnection or defective
4 YES contact in wiring harness Repair or
between BRJ2 (male) (5) – replace
Is resistance WHR (female) (1), between
YES between WHR BRJ2 (6) – WHR (female)
(male) (1) and (2)
3 normal?
Is resistance Defective sensor Replace sensor
YES between BRJ2 NO
(male) (5) and (6)
2 normal?
Is resistance contact in wiring harness
YES between ARC3 between ARC3 (11) – BRJ2 Repair or
(female) (11) and (female) (5), between replace
NO
1 (12) normal? ARC3 (12) – BRJ2 (female)
(6)
Is voltage • Turn starting
between ARC3 switch OFF.
(11) and chassis Defective controller Replace
• 950 – 1,450 z NO controller
ground normal?
• Turn starting
switch ON. Hot short in wiring harness Repair or
• Max. 5V between ARC3 (11), (12) – replace harness
NO WHR (1), (2)
20-1406 HD785-5
(15)
AS-4 Failure Code 1.2 "Disconnection in RL wheel speed sensor" is

displayed
has been reset.
a The controller is checking the wheel speed sensors for disconnection, etc.
BRJ2 through WHR, and wheel speed sensor and inspect those sections in order.
Cause Remedy
contact in wiring harness
4 YES between BRJ2 (male) (7) – Repair or
WHL (female) (1), between replace
Is resistance BRJ2 (male) (8) – WHL
YES between WHL
(female) (2)
(male) (1) and (2)
3 normal?
Is resistance Defective sensor Replace sensor
YES between BRJ2 NO
(male) (7) and (8)
2 normal?
Is resistance contact in wiring harness
YES between ARC3 between ARC3 (13) – BRJ2 Repair or
(female) (7), between replace
1 (female) (13) and NO
(12) normal? ARC3 (12) – BRJ2 (female)
Is voltage (8)
between ARC3 • Turn starting
(13) and chassis switch ON. Replace
• 950 – 1,450 z Defective controller
ground normal? NO controller
• Turn starting
switch ON. Hot short in wiring harness
• Max. 5V Repair or
between ARC3 (11), (12) – replace harness
NO WHR (1), (2)
HD785-5 20-1407
(15)
AS-5 Failure Code 1.3 "Disconnection in transmission output shaft speed

sensor system" is displayed
has been reset.
a The controller observes if there is any disconnection or other problem in the transmission output shaft speed
sensor.
a The transmission output shaft speed sensor is shared by the transmission controller and electronic display
panel.
a Divide into sensor – junction TMA, and TMA1 – ARC3 (4), (12) when checking. If there is no abnormality,
judge that the controller is defective.
Cause Remedy
3 YES Defective controller Replace

When connector is
YES connected again,
does problem ap-
2 pear again? Repair or
Mating of ARC3 connector
Is resistance NO is defective replace
YES between ARC3
(female) (4) and
1 (12) normal?
Are other control- Defective contact or discon-
lers (transmission • 500 – 1,000 z nection in wiring harness Repair or
controller) • Turn starting between ARC3 (female) replace wiring
normal? switch OFF. NO (4), (12) – TMA1 (1), (2) harness
• Disconnect
connector. See Trouble-
–– shooting of
transmission
NO controller system
(A mode)
20-1408 HD785-5
(13)
AS-6 Failure Code 1.6 "Failure in steering angle sensor" is displayed

has been reset.
a The controller is checking the steering angle sensor for a failure.
Cause Remedy
YES Replace
controller
2
Is resistance
YES between ARC2
Short circuit or disconnec-
(female) (20) and tion in wiring harness
(9) normal? between STR (female) (1) – Repair or
YES
• Turn starting switch 3 BJR (male) (11) – ARC2 replace harness
1 OFF. (female) (9), between STR
Is resistance (female) (3) – BJR (male)
Is resistance • Disconnect between STR
connector ARC2. (9) – ARC2 (female) (10)
between ARC2 (male) (2) and (3)
(female) (10) and • Approx. 2,500 z NO normal?
(9) normal? when steering Defective steering angle Replace steering
angle is near 0 • Turn starting sensor angle sensor
• Turn starting switch degrees. NO
switch OFF.
OFF. • Disconnect connector STR.
• Disconnect • Approx. 2,500 z when steering Short circuit or disconnec-
connector ARC2. angle is near 0 degrees.
• Approx. 5,000 z tion in wiring harness be-
4 YES tween STR (female) (1) – Repair or
BJR (male) (11) – ARC2 replace harness
Is resistance (female) (9), between STR
between STR (female) (3) – BJR (male)
(male) (1) and (3) (9) – ARC2 (female) (10)
NO normal?

OFF. Replace steering
• Disconnect Defective steering angle
sensor angle sensor
connector STR. NO
• Approx. 5,000 z
HD785-5 20-1409
(13)
AS-7 Failure Code 1.7 "Failure in accelerator signal system" is displayed

has been reset.
a The controller observes if there is any disconnection or short circuit with the ground in the acceleration sen-
sor signal sensor.
Cause Remedy
2 YES
Defective ASR controller Replace
YES Is voltage Disconnection, short circuit
between ARC2 (9)
1 and (19) normal?
with ground in wiring
harness between ARC2 Repair or
Is other controller (female) (19) – TMA1
(transmission replace
• 0.6 – 4.75V NO (female) (13), ARC2
controller) • Turn starting (female) (9) – TMB1
normal? switch ON. (female) (9) See
Troubleshooting
–– of transmission
NO controller
system
20-1410 HD785-5
(13)
AS-8 Failure Code 4.3 "Disconnection on ARSC caution lamp system" is

displayed
has been reset.
a The controller observes if there is any disconnection in the output circuit of ARSC caution lamp.
a Check for defective contact or disconnection in wiring harness between the controller and lamp, in the lamp
itself, and lamp – cab ground.
(ARSC caution lamp lights up 3 sec. when starting switch is at on.)
Cause Remedy
1
YES
Is there any Defective lamp Replace
abnormality, such
as a blown ARSC Defective contact or
caution lamp 2 disconnection in wiring
bulb? YES harness between ARC1 Repair or
(Does condition Is there defective (female) (10) and RED, and replace
become normal contact or between RED and chassis
when lamp is disconnection in ground.
replaced?) NO wiring harness
between ARC1
(female) (10) and Defective ASR controller Replace
chassis ground? NO
HD785-5 20-1411
(13)
AS-9 Failure Code 4.5 "Disconnection in panel caution lamp and buzzer
system" is displayed
has been reset.
a The controller observes if there is any disconnection in the panel caution and buzzer output circuit system.
Cause Remedy
YES
Defective RW relay Replace
Does condition 3 YES

become normal Defective ASR controller Replace
when RW relay is Is resistance
replaced? YES between ARC3
(female) (8) and
2 chassis ground
Is resistance normal? harness between RW Repair or
between ARC3 • Max. 400 z NO (female) (6) and chassis replace
(female) (8) and • Turn starting ground
NO RW (female) (5) switch OFF.
normal?
• Disconnect
Defective contact or Repair or
• Max. 1 z connectors.
disconnection in wiring replace
• Turn starting
harness between ARC3
switch OFF.
• Disconnect NO (female) (8) and RW
(female) (5)
connectors.
20-1412 HD785-5
(13)
AS-10 Failure Code 5.3 "Short circuit with ground in ARSC caution lamp
has been reset.
a The controller observes if there is any short circuit with the ground in the ARSC caution lamp system output
circuit.
Cause Remedy
1
YES
Is there any Defective lamp Replace
abnormality, such
as a blown ARSC 2
caution lamp Short circuit with ground or
bulb? Is there short YES defective contact in wiring Repair or
(Does condition circuit with harness between ARC1 replace
become normal chassis ground or (female) (10) and RED.
when lamp is defective contact
replaced?) NO in wiring harness
between ARC1
(female) (10) and Defective ASR controller Replace
RED (female)? NO
HD785-5 20-1413
(13)
AS-11 Failure Code 5.5 "Short circuit with ground in panel caution lamp
and buzzer system" is displayed
has been reset.
a The controller observes if there is any short circuit with the ground in the panel caution lamp and buzzer
system.
Cause Remedy
1
YES
Defective RW relay Replace
Does condition
become normal
when RW relay is 2 YES
replaced? Is resistance
between ARC3
(female) (8) and
NO RW (female) (5) Short circuit with chassis
normal? ground in wiring harness Repair or
NO between ARC3 (female) (8) replace
• 200 – 400 z and RW (female) (5)
• Turn starting
switch OFF.
• Disconnect
connectors.
20-1414 HD785-5
(13)
AS-12 Failure Code 6.0 "Failure in engine speed sensor system" is

displayed
has been reset.
a The mutual relationship between the engine speed sensor and the transmission output shaft speed sensor
is observed by the controller.
a Judge from the condition of the machine 3
Cause Remedy
when the abnormality occurred to locate the Is condition between YES Replace
Defective ASR controller
failed sensor or wiring harness. ARC3 (female) (5) controller
YES and TMD1 (female)
When 2 (13) and between
engine is ARC3 (female) (12)
and TMD1 (female) Abnormality in wiring Repair or
running Is monitor panel replace
(14) normal? NO harness
display normal?
• Is there any effect from radio
waves? (remove any
electric equipment that was
installed after the machine
1 was delivered and carry out
reenactment test) Defective engine speed
Does problem Replace
sensor
occur when NO
engine is running 5
or when machine Is condition between YES Replace
Defective ASR controller
is traveling? ARC3 (female) (4) controller
YES and TMA1 (female)
(1) and between
ARC3 (female) (12)
Abnormality in wiring Repair or
4 and TMA1 (female)
replace
(2) normal? NO harness
Is monitor panel • Is there any effect from radio

display normal? waves? (remove any
When
machine electric equipment that was
is traveling installed after the machine
was delivered and carry out
reenactment test) Defective transmission
output shaft speed sensor Replace
NO
HD785-5 20-1415
(13)
AS-13 Failure Code 6.1 "Failure in RR wheel speed sensor system" is

displayed
has been reset.
a The controller is checking the wheel speed sensor for a failure from the correlation between the RR wheel
speed sensor and transmission output shaft speed sensor.
Cause Remedy
YES See remedies

See causes of failure codes for failure codes
1.1, 1.2, 1.3 1.1, 1.2, 1.3
3 YES Short circuit in wiring Repair or
1 When ARC3 and harness between ARC3 replace harness
YES BRJ2 are removed, (11), (12) – BRJ2 (5), (6)
Is failulre code is there continuity
1.1, 1.2, or 1.3 between ARC3 (11)
displayed? and ARC3 (12)? Short circuit in wiring Repair or
harness between BRJ2 (5), replace harness
NO
2 (6) – WHR (1), (2)
Is there continuity
between ARC3
(female) (11) and 5 YES
NO ARC3 (female) Short circuit with chassis Repair or
(12)? When ARC3 and ground in wiring harness replace harness
BRJ are removed, between ARC3 (11), (12) –
• Turn starting YES is there continuity BRJ2 (5), (6)
switch OFF. 4 between ARC3
• Disconnect (11) and chassis
connector ACR3 When ARC3 and ground? Short circuit with chassis Repair or
and WHR. WHR are ground in wiring harness replace harness
removed, is there NO between BRJ2 (5), (6) –
NO continuity WHR (1), (2)
between ARC3 YES
(11) and chassis 6 Go to A
ground?
Is resistance of
wheel sensor unit
NO normal ?
Defective sensor Replace sensor
• 950 – 1,450 z NO
7 YES Replace
controller
Is sensor installed
A normally?
Is its tip in contact
with rotor?
Wrong installation of sensor Install sensor
NO correctly
20-1416 HD785-5
(13)
AS-14 Failure Code 6.2 "Failure in RL wheel speed sensor system" is

displayed
has been reset.
a The controller is checking the wheel speed sensor for a failure from the correlation between the RL wheel
speed sensor and transmission output shaft speed sensor.
Cause Remedy
See remedies
YES See causes of failure codes for failure codes
1.1, 1.2, 1.3 1.1, 1.2, 1.3
3 YES Short circuit in wiring har- Repair or

1 ness between ARC3 (13), replace harness
When ARC3 and (12) – BRJ2 (7), (8)
Is failure code 1.1, YES BRJ2 are removed,
1.2, or 1.3 is there continuity
displayed? between ARC3 (13)
and ARC3 (12)? Short circuit in wiring Repair or
harness between BRJ2 (7), replace harness
NO (8) – WHL (1), (2)
2
When ARC3 and 5 YES Short circuit with chassis Repair or
WHL are When ARC3 and ground in wiring harness replace harness
removed, is there BRJ2 are between ARC3 (13), (12) –
YES removed, is there
NO continuity between BRJ2 (7), (8)
ARC3 (13) and continuity between
ARC3 (12)? 4 ARC3 (13) and
When ARC3 and chassis ground? Short circuit with chassis Repair or
WHL are ground in wiring harness replace harness
removed, is there
NO between BRJ2 (7), (8) –
continuity WHL (1), (2)
NO between ARC3
(13) and chassis 6 YES Go to A
ground?
Is resistance of
wheel sensor unit
NO normal ?
Defective sensor Replace sensor
• 950 – 1,450 z NO
7 YES Replace
Is sensor installed controller
A normally? Is its tip
in contact with
rotor? Install sensor
Wrong installation of sensor correctly
NO
HD785-5 20-1417
(13)
pressure control valve (L.H.) does not open" is displayed
has been reset.
a The controller observes if there is any failure in the pressure control valve from the mutual relationship
between the pressure switch and the command value to the pressure control valve.
Cause Remedy
2 YES
Defective pressure switch Replace
When pressure
YES switch is replaced,
1 does problem
appear again? 3 YES
Is there continuity Defective ASR controller Replace
between BRL When pressure
(male) (1) and control valve is
ARC2 (female) (5) replaced, does
when connector NO problem appear
BRL is again? Defective pressure control
valve Replace
disconnected? NO
• Turn starting
switch OFF.
• Disconnect Repair or
Defective contact or discon- replace wiring
connectors. nection in wiring harness
NO harness
AS-15Related electrical circuit diagram
20-1418 HD785-5
(13)
AS-16 Failure Code 8.1 "Short circuit with chassis ground in pressure
control valve (R.H.) system" is displayed
has been reset.
a The controller observes if there is any short circuit with the ground in the command system circuit to the
pressure control valve.
a Divide into controller – intermediate connector, intermediate connector – valve, and pressure control valve
proper when checking.
Cause Remedy

2 YES ground in wiring harness Repair or
Is there continuity between BRJ1 (male) (7), replace
between ARC1 (8) – BSOR (female) (1), (2)
YES (female) (7) and
ARC1 (female)
(16) when ARC1
and BRJ1 are Short circuit with chassis
disconnected? ground in wiring harness Repair or
1 between ARC1 (female) replace
Is there continuity • Turn starting NO (7), (16) – BRJ1 (female)
between ARC1 switch OFF. (7), (8)
(female) (7) and • Disconnect
ARC1 (female) connectors. 4 YES Short circuit with chassis Repair or
(16) when ARC1 Is there continuity ground in wiring harness replace
and BSOR are between ARC1 between ARC1 (female)
disconnected? (7), (16) – BRJ1 (female)
YES (female) (7) and (7), (8)
chassis ground
• Turn starting
switch OFF. 3 when ARC1 and
BRJ1 are Short circuit with chassis
• Disconnect Is there continuity ground in wiring harness
disconnected? Repair or
connectors. between ARC1 between BRJ1 (male) (7), replace
(female) (7) and • Turn starting NO (8) – BSOR (female) (1), (2)
switch OFF.
NO chassis ground • Disconnect
when ARC1 and
BSOR are connectors.
disconnected?
5 YES
• Turn starting Is resistance of
switch OFF. pressure control
• Disconnect valve normal
connectors. NO when checked as
individual part? Defective pressure control Replace
• Approx. 20 z NO valve
• Turn starting
switch OFF.
• Disconnect
connectors.
HD785-5 20-1419
(13)
control valve (L.H.) system" is displayed
has been reset.
a The controller observes if there is any short circuit with the ground in the command system circuit to the
pressure control valve.
a Divide into controller – intermediate connector, intermediate connector – valve, and pressure control valve
proper when checking.
Cause Remedy

Is there continuity between BRJ2 (male) (7), replace
between ARC1 (8) – BSOL (female) (1), (2)
ARC1 (female)
(16) when ARC1
and BRJ2 are Short circuit with chassis
disconnected? ground in wiring harness Repair or
1 between ARC1 (female) replace
Is there continuity • Turn starting NO (7), (16) – BRJ2 (female)
between ARC1 switch OFF. (7), (8)
(female) (5) and • Disconnect
ARC1 (female) connectors. 4 YES Short circuit with chassis Repair or
(15) when ARC1 Is there continuity ground in wiring harness replace
and BSOL are between ARC1 between ARC1 (female)
disconnected? (7), (16) – BRJ2 (female)
YES (female) (7) and (7), (8)
chassis ground
• Turn starting
switch OFF. 3 when ARC1 and
BRJ2 are Short circuit with chassis
• Disconnect Is there continuity ground in wiring harness
disconnected? Repair or
connectors. between ARC1 between BRJ2 (male) (7), replace
(female) (5) and • Turn starting NO (8) – BSOL (female) (1), (2)
switch OFF.
NO chassis ground • Disconnect
(ER) when ARC1
and BSOL are connectors.
disconnected?
5 YES
• Turn starting Is resistance of
switch OFF. pressure control
• Disconnect valve normal
connectors. NO when checked as
individual part? Defective pressure control Replace
• Approx. 20 z NO valve
• Turn starting
switch OFF.
• Disconnect
connectors.
20-1420 HD785-5
(13)
AS-18 Failure Code 8.3 "Disconnection in pressure control valve (R.H.)

has been reset.
a The controller is checking the pressure control valve for disconnection.
BRJ1 through BSOR, and pressure control valve and inspect those sections in order.
Cause Remedy
3 YES
controller
2 YES Is resistance of
pressure control
YES Is there continuity valve about 20 z?
Defective pressure control Replace
between ARC1 pressure control
(16) and BSOR valve
NO valve
(2)?
1
When ARC1 and Disconnection or defective
contact in wiring harness Repair or
BSOR are replace harness
removed, is there NO between ARC1 (16) –
continuity BSOR (2)
between ARC1 (7)
and BSOR (1)? Disconnection or defective
When ARC1 and between BRJ1 (7), (8) – replace harness
BRJ1 are BSOR (1), (2)
removed, is there
continuity
between ARC1 (7) Disconnection or defective
and BRJ1 (7)? contact in wiring harness Repair or
NO NO
between ARC1 (7) (16) – replace harness
BRJ1 (7), (8)
HD785-5 20-1421
(13)
AS-19 Failure Code 8.4 "Disconnection in pressure control valve (L.H.)

disconnected and the T-dapter is inserted, or when the T-adapter is removed and the connector is
has been reset.
a The controller is checking the pressure control valve for disconnection.
BRJ2 through BSOL, and pressure control valve and inspect those sections in order.
Cause Remedy
3 YES
controller
2 YES Is resistance of
pressure control
YES Is there continuity valve about 20 z?
Defective pressure control Replace
between ARC1 pressure control
(15) and BSOL valve
NO valve
(2)?
1
When ARC1 and Disconnection or defective
contact in wiring harness Repair or
BSOL are replace harness
removed, is there NO between ARC1 (15) –
continuity BSOL (2)
between ARC1 (5)
and BSOL (1)? Disconnection or defective
When ARC1 and between BRJ2 (3), (4) – replace harness
BRJ1 are BSOL (1), (2)
removed, is there
continuity
between ARC1 (5) Disconnection or defective
and BRJ2 (3)? contact in wiring harness Repair or
NO NO
between ARC1 (5) (15) – replace harness
BRJ2 (3), (4)
20-1422 HD785-5
(13)
pressure control valve (R.H.) does not close" is displayed
has been reset.
a The controller observes failures in the pressure control valve from the mutual relationship between the pres-
sure switch and the command value to the pressure control valve.
a "Pressure control valve does not close" means that the solenoid is energized and the pressure control valve
has stayed open (supplying air).
Cause Remedy
YES Defective pressure switch Replace
2
When pressure
YES switch is replaced, 4 YES Defective ASR controller Replace
YES When pressure
does problem
appear again? 3 control valve is
1 Is there air flowing
replaced, does
problem appear
Is there continuity in opposite direc- again?
tion from double Defective pressure control
between BRR Replace
(female) (1) and NO check valve of NO valve
chassis ground auto retarder air
when connector system circuit? Defective double check
BRR is Replace
When manual NO valve
disconnected?
retarder or service
• Turn starting brake are
switch OFF. operated
• Disconnect Defective wiring harness
Replace
connectors. (short circuit with ground)
NO
HD785-5 20-1423
(13)
pressure control valve (L.H.) does not close" is displayed
has been reset.
a The controller observes failures in the pressure control valve from the mutual relationship between the pres-
sure switch and the command value to the pressure control valve
a "Pressure control valve does not close" means that the solenoid is energized and the pressure control valve
has stayed open (supplying air).
Cause Remedy

2
When pressure
YES switch is replaced, 4 YES Defective ASR controller
YES When pressure Replace
does problem
appear again?
3 control valve is
1 Is there air flowing
replaced, does
problem appear Defective pressure control
Is there continuity in opposite direc- again? Replace
between BRL tion from double valve
(female) (1) and NO check valve of NO
chassis ground auto retarder air
when connector system circuit? Defective double check
BRL is Replace
When manual NO valve
disconnected?
retarder or service
• Turn starting brake are
switch OFF. operated
• Disconnect Defective wiring harness
(short circuit with ground) Replace
connectors. NO
20-1424 HD785-5
(13)
pressure control valve (R.H.) does not open" is displayed
has been reset.
a The controller observes if there is any failure in the pressure control valve from the mutual relationship
between the pressure switch and the command value to the pressure control valve.
Cause Remedy

2
When pressure
YES switch is replaced,
does problem
appear again? 3 YES Defective ASR controller Replace
1 When pressure
Is there continuity control valve is
between BRR replaced, does
NO problem appear
(male) (1) and
ARC2 (female) (5) again? Defective pressure control
Replace
when connector NO valve
BRR is discon-
nected?
• Turn starting
switch OFF. Defective contact or Repair or
• Disconnected disconnection in wiring replace wiring
connectors. NO harness harness
S-22 Related electrical circuit diagram
HD785-5 20-1425
(13)
switch valve system" is displayed
has been reset.
a Always connect any disconnected connectors before going on to the next step
a The controller observes if there is any short circuit with the ground in the pressure switch valve output cir-
cuit.
a Divide into ARC3 – intermediate connector BRJ1, intermediate connector BRJ1 – SHUT, and pressure
switch valve proper when checking.
Cause Remedy

2
YES ground in wiring harness Repair or
Is there continuity between ARC3 (female) replace
between ARC3 (15) and BRJ1 (female) (5)
chassis ground Short circuit with chassis
1 when BRJ1 is ground in wiring harness Repair or
removed? between BRJ1 (male) (5), replace
Is there continuity NO (2) and SHUT (female) (1),
between ARC3 • Turn starting (2)
(female) (15) and switch OFF.
chassis ground • Disconnect
when ARC3 and connectors.
SHUT are 3 YES
disconnected? Defective ASR controller Replace
Is resistance of
• Turn starting pressure switch
switch OFF. valve normal
• Disconnect when checked as
connectors. individual part?
• Approx. 35 z NO
20-1426 HD785-5
(13)
AS-24 Failure Code 9.0 "Disconnection in pressure switch valve system"

is displayed
has been reset.
a The controller observes if there is any short circuit with the ground in the pressure switch valve output cir-
cuit.
a Divide into ARC3 – intermediate connector BRJ1, intermediate connector BRJ1 – SHUT, and pressure
switch valve proper when checking.
Cause Remedy
2 YES Defective ASR controller Replace

Is resistance of
YES pressure switch
valve normal
when checked as
individual part? Defective pressure switch
Replace
1 NO valve
• Approx. 35 z
Is there continuity • Turn starting
between ARC3 switch OFF. Defective contact or
(female) (15) and • Disconnect disconnection in wiring
SHUT (female) (1) connectors.
4 YES Repair or
harness between BRJ1 replace
when ARC3 and Is there continuity (male) (5), (2) – SHUT
SHUT are YES between BRJ1 (female) (1), (2)
disconnected? 3 (female) (2) and
Is there continuity chassis ground? Defective contact or Repair or
• Turn starting disconnection in wiring
switch OFF. between ARC3 • Turn starting replace
NO harness between BRJ1
• Disconnect (female) (15) and switch OFF.
NO BRJ1 (female) (5) (female) (2) and chassis
connectors. • Disconnect ground
when BRJ1 is connectors.
disconnected?
• Turn starting disconnection in wiring Repair or
switch OFF. NO harness between ARC3 replace
• Disconnect (female) (15) and BRJ1
connectors. (female) (5)
HD785-5 20-1427
(13)
AS-25 Failure Code 9.1 "Failure in pressure switch valve system: valve
does not close" is displayed
has been reset.
a The controller observes if there is any failure in the pressure switch valve from the mutual relationship
between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES disconnection in wiring Repair or
1 harness between ARC2 replace
(female) (2) and SOSW
Is there continuity (female) (1)
between SOSW
(female) (1) and YES
chassis ground Defective pressure switch Replace
when SOSW is 2
disconnected? When pressure
switch is replaced, YES Defective pressure control Replace
• Turn starting
switch OFF. NO does problem 3 valve
• Disconnect appear again?
Does air flow in
connectors. opposite direction
from pressure 4 YES Defective ASR controller Replace
NO control valve?
When pressure
switch is replaced,
does problem
NO appear again?
NO valve
20-1428 HD785-5
(13)

valve does not open" is displayed
has been reset.
a The controller observes if there is any failure in the pressure switch valve from the mutual relationship
between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES
3
When pressure
YES swith is replaced,
does problem 4 YES
appear again? Defective ASR controller Replace
2 When pressure
Is there continuity switch valve is re-
YES between SOSW NO placed, does prob-
1 (female) (2) and lem appear again? Defective pressure switch
valve Replace
chassis ground? NO
Is there continuity
between SOSW • Turn starting
(female) (1) and switch OFF. Defective contact or discon-
ARC2 (female) (2) • Disconnect nection in wiring harness Repair or
when SOSW and connectors. NO between SOSW (female) replace
ARC2 are (2) and chassis ground
disconnected?
Defective contact or discon-
• Turn starting nection in wiring harness Repair or
switch OFF. between ARC2 (female) (2) replace
• Disconnect NO
and SOSW (female) (1)
connectors.
HD785-5 20-1429
(13)
AS-101 Nothing is displayed on display window of controller

a When the starting switch is turned on, if nothing is displayed on the display window of the ASR controller,
check the source voltage of the controller.
1) Check according to AS-1.
2) Check that there is continuity between ARC1 (9), (19) and TMC1 (1).
20-1430 HD785-5
(13)
AS-102 Failure Code is kept cleared ("– –" is always displayed in display
window of controller) or cannot be cleared
a Disconnect connectors CR1 and CR2, and after approx. 3 seconds, the operation to clear the failure code is
completed.
a) When failure code cannot be cleared
Cause Remedy

between ARC2 (20) and replace
Is there continuity CR1 (1)
between CR1 (1)
and chassis
grond?
switch OFF.
• Disconnect
connectors.
b) When failure code is continuously cleared
Cause Remedy
2 YES Repair or
Defective connector
Is there defective replace
YES contact of
1 connectors CR1
and CR2?
Is there continuity Defective ASR controller Replace
between ARC2 NO
(20) and CR1 (1)
or between CR2 Defective contact or
(1) and ARC2 (9)? disconnection in wiring har- Repair or
ness between ARC2 (20) – replace
• Turn starting NO CR (1) or between CR2 (1)
switch OFF. – ARC2 (9)
• Disconnect
connectors.
HD785-5 20-1431
(13)
AS-103 Another controller has a failure

a Since ASR connects its connectors to the existing connectors in T-branch form, check the effects of the con-
nection.
a) Transmission controller system

a-1) Failure in accelerator sensor
Check the harness between TMA1 (13) and TMA2 (13)
Check the harness between TMB1 (9) and TMB2 (9)
a-2) Failure in transmission output shaft speed sensor
Check the harness between TMA1 (1), (2) and TMA2 (1), (2)
a-3) Failure in engine speed sensor
Check the harness between TMD1 (13), (14) and TMD2 (13), (14)
a-4) Other failures
Between TMA1 and TMA2, TMB1 and TMB2, and TMC1 and TMC2
a-5) Engine speed is abnormal
Check the harness between TMD1 (13), (14) and TMD2 (13), (14)
b) Payload meter system

b-1) Payload meter has a failure
Check the harness between ARC3 (6) and PM4-1 (5)
20-1432 HD785-5
(13)
AS-104 Monitor lamp (buzzer) stays ON (or OFF)

a Always connect any disconnected connectors before going onto the next step.
Cause Remedy
2 YES Defective wiring harness

Repair or
replace
Is there short
circuit with ground
YES or disconnection 3 YES Repair or
in wiring harness Defective wiring harness replace
Is there short
between RW (2), circuit with ground
(4) and chassis or disconnection in
1 ground? wiring harness 4
YES Defective between lamp Repair or
When RW relay is NO between RW (3) – When WL (BZ) –
(buzzer) and monitor panel replace
replaced, does WL-EL1 (2) or be- EL1 and WL (BZ)
problem appear tween RW (1) – – EL2 are
again? BZ-EL (2)? removed, and WL
NO (BZ) is joined, Defective wiring harness
does problem Repair or
appear again? between WL (BZ) – EL1
and WL (BZ) – EL2 replace
NO
Defective relay Replace

NO
HD785-5 20-1433
(13)
AS-105 Disconnection in switch system of ASR system

Cause Remedy
3 YES
When ASR
YES system switch is
2 replaced, does
trouble reappear? Defective ASR system
Is there continuity Replace
between ARC1 NO switch
YES
1 (female) (19) and
ASR (female) (4)?
Is there continuity Disconnection or defective
between ARC2 • Turn starting contact in wiring harness Repair or
(female) (5) and switch OFF. between ARC1 (female) replace harness
NO (19) – ASR (female) (4)
ASR (female) (2)? • Disconnect
connector ARC1
• Turn starting and ASR. Disconnection or defective
switch OFF. contact in wiring harness Repair or
• Disconnect between ARC2 (female) (5) replace harness
connector ARC2 NO – ASR (female) (2)
and ASR.
20-1434 HD785-5
(13)
AS-106 Short circuit with chassis ground in switch system of ASR system
a Always connect any disconnected connectors before going onto the next step.
Cause Remedy
YES Short circuit with ground in

wiring harness between Repair or
1 ARC2 (5) – ASR (2) replace harness
Is there continuity
between ARC2 (5)
and ARC1 (19)
when SW is dis- 2 YES
connected? Defective ASR controller Replace
When system
switch is replaced,
does failure
NO reappear?
Defective ASR system Replace
NO switch
HD785-5 20-1435
(13)
AS-107 ASR working lamp does not light up

Cause Remedy
1 YES Defective ASR working Replace

lamp
Does ASR
working lamp
have failure such YES See cause of failure code See AS-15 or
as bulb breakage? 2 8.0 or 8.7 AS-22
(Is failure repaired
by replacing?) Is failure code YES
8.0 or 8.7 Defective RAS relay
NO displayed? 3 Replace
When RAS relay

is replaced, is 4 YES
NO failure repaired? Is there continuity Go to A
between connec-
tor RH1 – EL2
NO (male) (3) and Disconnection in wiring
connector GASR harness between connector Repair or
(female)? RH1-EL2 (male) (3) – replace
NO connector GASR
5 YES Disconnection in wiring

Is there continuity harness between connector Repair or
between RAS (female) (3) – chassis replace
connector GASR ground
A
(male) and
connector RAS Disconnection in wiring
(female) (6)? harness between connector Repair or
RAS (female) (6) – replace
NO connector GASR (male)
20-1436 HD785-5
(13)
HD785-5 20-1437
(13)
AS-108 ASR working lamp remains lit

Cause Remedy
YES See cause of failure code See AS-20 or

8.5 or 8.6 AS-21
1
Is failure code 8.5

or 8.6 displayed? YES
Defective RAS relay Replace
2
When RAS relay
is replaced, does 3 Short circuit with chassis
NO trouble reappear? YES Repair or
Is there continuity ground in harness between
replace
in harness GASR-RAS (6)
between RAS (6)
NO and chassis
ground when relay Short circuit with chassis
ground in harness between Repair or
is removed?
NO RAS (3) – chassis ground replace
20-1438 HD785-5
(13)
HD785-5 20-1439
(13)
VHMS MACHINE HEALTH
DIAGNOSIS SYSTEM
(OP)
1. Basic Precautions .............................................................................................................................. 20-1502

1-1. Operation, Safety, Inspection and Maintenance of Machine ................................................. 20-1502
1-2. Operation of Monitoring System ............................................................................................. 20-1502
1-3. Constant Power Supply (Battery Direct Power Supply) ......................................................... 20-1502
1-4. Precautions at the time of Turning on the Power for VHMS ................................................. 20-1503
1-5. Precautions at the time of Replacing VHMS and Transmission Controller .......................... 20-1503
1-6. Operation of Communication (ORB ... ORB Communication) Controller ............................. 20-1504
2. Overview ............................................................................................................................................ 20-1505
2-1. Applicable Model ...................................................................................................................... 20-1505
2-2. Basic Configuration (1) and (2) ................................................................................................. 20-1505
2-3. Installation Drawing .................................................................................................................. 20-1508
3. Structure and Function ..................................................................................................................... 20-1510
3-1. VHMS Controller ....................................................................................................................... 20-1510
3-2. Blow-by Gas Sensor .................................................................................................................. 20-1510
3-3. Engine Oil Temperature Sensor ............................................................................................... 20-1511
3-4. Amplifier for Exhaust Gas Temperature Sensor ..................................................................... 20-1512
3-5. Communication (ORB ... ORB Communication) Controller/Antenna .................................... 20-1512
4. Troubleshooting ................................................................................................................................ 20-1514
4-1. Troubleshooting Equipment List .............................................................................................. 20-1514
4-2. Connector Type and Installation Position ................................................................................ 20-1515
4-3. Connector Arrangement Diagram ........................................................................................... 20-1516
4-4. Electrical Circuit Diagram ......................................................................................................... 20-1521
4-5. Error Code List ........................................................................................................................... 20-1523
4-6. Standard Value Table of electrical parts .................................................................................. 20-1524
4-7. Trouble Phenomena List ........................................................................................................... 20-1526
5. Disassembly and Assembly ............................................................................................................. 20-1538
5-1. Removal and Installation of VHMS Controller ........................................................................ 20-1538
5-2. Removal and Installation of Blow-by Gas Sensor .................................................................. 20-1539
5-3. Removal and Installation of Breather ...................................................................................... 20-1539
5-4. Removal and Installation of Engine Oil Temperature Sensor ............................................... 20-1540
5-5. Removal and Installation of Exhaust Gas Temperature Sensor ............................................ 20-1540
5-6. Removal and Installation of Exhaust Gas Temperature Amplifier ........................................ 20-1541
5-7. Removal and Installation of Snapshot Switch ........................................................................ 20-1541
5-8. Removal and Installation of Communication
(ORB ... ORG Communication) Controller and Antenna ........................................................ 20-1542
6. Setting of VHMS Controller ............................................................................................................. 20-1543
6-1. Setting of VHMS Controller ...................................................................................................... 20-1543
6-2. Setting Item ............................................................................................................................... 20-1543
6-3. Setting Flow (Outline) ............................................................................................................... 20-1543
6-4. Check of Operation and Performance ..................................................................................... 20-1544
6-5. Data Collection .......................................................................................................................... 20-1544
7. Data Collection and Transmission ................................................................................................... 20-1545
7-1. Data Recovery ............................................................................................................................ 20-1545
8. Inspection and Maintenance ............................................................................................................ 20-1550
8-1. Inspection Timing : Inspection and Maintenance Timing of Machine .................................. 20-1550
8-2. Inspection Item .......................................................................................................................... 20-1550
8-3. Corrective action ....................................................................................................................... 20-1550
9. Replacement of Parts ........................................................................................................................ 20-1551
9-1. When VHMS controller is replaced .......................................................................................... 20-1551
9-2. When Communication controller is replaced ......................................................................... 20-1551
Initial setup of VHMS ............................................................................................................................ 20-1552
HD785-5 20-1501
(13)
TROUBLESHOOTING BASIC PRECAUTIONS
1. BASIC PRECAUTIONS
1-1. OPERATION, SAFETY, INSPECTION many electronic equipment and electrical
AND MAINTENANCE OF MACHINE parts.
To realize the above function, a power sup-
Refer to the Operation and Maintenance
ply always energized (constant power
Manual of the machine body for safety items,
supply) directly connected from the bat-
operation, inspection, maintenance, etc. of the
tery is necessary in addition to the power
machine.
supply (power supply for switch) that is
turned off at the time of "Key OFF" or "En-
1-2. OPERATION OF MONITORING SYS- gine Stop."
TEM Both the power supply for switch and the
Observe the following for operation of the constant power supply enable to make
monitoring system: clear the timing to grasp data and also to
1) For disassembly, repair and modification store data in the internal memory. In the
of the machine and the system, refer to other words, the constant power supply
the respective manuals. enables to store data accumulated during
2) Don't touch the system (device) while op- the time from "Key ON" to "Key OFF" on
erating the machine. the VHMS, and the VHMS controller turns
3) Be careful not to get wiring harnesses, off the constant power supply.
connectors and sensors of the system (de- 2) Precautions at Turning Off Constant
vice) caught between other components Power Supply
and not to damage them by pulling forc- Turn off the constant power supply after
ibly. Short-circuit and disconnection may more than three minutes (VHMS system
get the machine body and the system (de- off time ... time for storing data in the
vice) out of order and may cause a fire. memory) elapsed from "Key OFF." If the
4) Keep the system (device) away from wa- system off time is less than 3 minutes, the
ter, dust, oil, etc. accumulated data may be destroyed.
For your reference, the system off time
1-3. CONSTANT POWER SUPPLY (BAT- varies with size of stored data, rewriting
TERY DIRECT POWER SUPPLY) frequency, operating time, etc.
(1) When removing the constant power
1) Meaning and Necessity of Constant
supply from VHMS
Power Supply
When removing the constant power
Since the VHMS has the function to grasp
supply, make sure that the monitor
and accumulate machine statuses from
display (7-segment LED in the figure
the time "Key ON" to the time "Key OFF",
below) of the VHMS controller is not
the power is supplied to it unlikely other
shown.
20-1502 HD785-5
(13)
(2) When installing battery isolator or cir-

cuit breaker,
i) Basic Connection
Basically install an engine stop
switch that does not interrupt con-
stant power supply.
ii) When all power supplies are nec-
essary interrupted according to
user's safety rules,
• Install a battery isolator so that
After setting the key switch to
OFF, hold the constant power
supply is held in the normal
status at least 3 minutes after
the key switch is set to OFF
and then the constant power
supply is interrupted.
• When no timer is provided,
interrupt the constant power
supply after more than 3
minutes elapsed.
• When the holding time is
shorter than 3 minutes,
accumulated data may be
destroyed.
1-4. PRECAUTIONS AT THE TIME OF

TURNING ON THE POWER FOR
VHMS
• After the power for the VHMS controller
is turned on, an initial check is conducted
for several tens seconds (the LED flashes
on and off). Avoid the following opera-
tions during the initial check:
• Manual shot switch
• Download with the PC
(Before the operations, make sure that
the LED displays cumulative figures
one after another.)
1-5. PRECAUTIONS AT THE TIME OF RE-

PLACING VHMS AND TRANSMIS-
SION CONTROLLER
1) Before replacement ii) Regular Method to Turn off Power
i) Downloading of VHMS Data Supply for VHMS
When the VHMS controller is re- (1) Turn off the normal power supply
placed, data to that time will be lost. by using "Key OFF."
So, download the accumulated data (2) Hold the constant power supply
before the replacement. Then, trans- in the regular status for 3 minutes
fer the accumulated data to the Web at least.
Care. For the downloading method, (3) Turn off the normal power supply
refer to the "Analysis Tool Operation (directly connected to battery).
and Maintenance Manual."
HD785-5 20-1503
(13)
2) Replacing Method and Measure after Re-

placement
Replace the VHMS Controller so as to pre-
vent the VHMS controller body, wiring
harnesses, etc. from receiving abnormal
forces and from being impacted and "ini-
tialize" the system according to the
"Analysis Tool Operation and Mainte-
nance Manual."
1-6. Operation of Communication (ORB

... ORB Communication) Controller
1) Be sure to apply for opening the ORB con-
troller right before operation, but you can-
not operate the controller.
Note that, if the power is supplied to the
installed controller before the completion
of the application, the communication
system will get out of order due to unau-
thorized transmission.
If the application method is not clear, ask
your operation administrator or inquire us
for the method.
2) Turn on the power of the ORB at the end
(after connecting connectors).
After checking the VHMS controller, etc.,
connect the connectors (ORB-A and ORB-
B) of the ORB controller.
20-1504 HD785-5
(13)
TROUBLESHOOTING OVERVIEW
2. OVERVIEW
2-1. APPLICABLE MODEL
Installed models
HD785-5 #4001~ Electrical governor specification machines
(Additional installation is possible to machines already delivered)
HD985-5#1021 ~ Electrical governor specification machines
PMC(OPT) The VHMS cannot be installed on machines equipped with speed lim-
iter (OPT) and on mechanical governor specification machine.
2-2-1. Basic Configuration (1)
HD785-5 20-1505
(13)
2-2-2. Basic Configuration (2)
20-1506 HD785-5
(13)
HD785-5 20-1507
(13)
2-3. INSTALLATION DRAWING

A monitoring controller (VHMS controller) is in-
stalled on the machine, and data are collected
when the engine, transmission and PLM II are op-
erated.
1) Data Collecting Function
(1) Data from sensors connected
• Blow-by gas pressure
• Engine oil temperature
• Exhaust gas temperature
(2) Data from Controller Installed on Machine
• Engine speed
• Rack voltage (fuel injection amount)
• Engine oil pressure
• Data from transmission controller
• Data from PLMII Controller
• SMR
2) Data Storage
• The above data are stored and accumu-
lated.
3) External Communication Function

• A personal computer (PC) is connected to
the VHMS controller to download data,
and data are transmitted through the
Internet.
• Data are automatically transmitted from
remote places through the communica-
tion satellite.
20-1508 HD785-5
(13)
HD785-5 20-1509
(13)
TROUBLESHOOTING STRUCTURE AND FUNCTION
3. STRUCTURE AND FUNCTION

3-1. VHMS CONTROLLER
<Specification>
1. Working Power Supply Voltage :
DC 20V - DC 30V
2. Dimensions :
W 272mm x D 169mm x H 72mm
<Function>
Signals from each sensor and from machine con-
trollers are collected and accumulated. Also, data
transmission is instructed through the communi-
cation satellite.
3-2. BLOW-BY GAS SENSOR

<Specification>
1. Power supply voltage : DC 5V
2. Output voltage : 0.5V (at engine stop) –
3. Size : Total length : 220mm
Pipe outside diameter : ø35mm
<Function>
The engine's blow-by gas flow rate is converted
into voltage value, and the blow-by gas pressure
is input in the VHMS controller.
20-1510 HD785-5
(13)
3-3. ENGINE OIL TEMPERATURE SENSOR
<Specification>
1. Sensor type : Thermistor
2. Measuring range :
40 – 130 ºC
80 – 130 ºC (Assured accuracy ±2ºC)
3. Maximum power consumption : 0.5mW
4. Withstand pressure : 4.9MPa (50kg/cm2)
5. Operating temperature : -30 – 140 ºC
6. Performance Table
Tem- Resistance Tem- Resistance Tem- Resistance

perature value perature value perature value
(ºC) (kΩ) (ºC) (kΩ) (ºC) (kΩ)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
<Function>
This sensor is installed to the engine oil filter, and
temperature changes are input as resistance
changes of the thermistor into the VHMS control-
ler.
HD785-5 20-1511
(13)
3-4. AMPLIFIER FOR EXHAUST GAS TEM-

PERATURE SENSOR
<Specification>
1. Rated voltage : DC 24V
2. Detecting temperature range :
100 – 1,000 ºC
300 – 800 ºC (Assured accuracy ± 10ºC)
3. Output voltage characteristics :
See the table below:
4. Operating temperature range : -40 – +110 ºC
5. Current consumption : 30mA max.
Output Voltage Characteristics
(Ambient temperature : 20ºC) ... Reference value
Detection temperature (ºC) 50 100 400 700 800
Output voltage (V) 1.191 1.397 2.626 3.899 4.316
<Function>
This sensor is a thermocouple type temperature
sensor, is installed at the inlet of the turbocharger
and outputs exhaust gas temperature data to the
VHMS controller.
3-5. COMMUNICATION (ORB ... ORB COM-

MUNICATION) CONTROLLER/AN-
TENNA
<Specification>
1. Operating power supply voltage :
DC 12V– DC 30V
2. Dimensions :
W 306mm x D 152mm x H 44mm
<Mounting Position>
Mount the sensor below the auxiliary chair.
20-1512 HD785-5
(13)
<Antenna>
<Specification>
1. Type : 1/4\ whip antenna
2. Impedance : 50Ω
3. Allowable power : 50W max.
4. Input terminal : M-P type
<Mounting Position>
Erect a pole in front of the machine right side and
mount the antenna on the pole.
<Function>
Data collected with and accumulated in the VHMS
controller are transmitted to the computer center
through the communication satellite.
HD785-5 20-1513
(13)
TROUBLESHOOTING TROUBLESHOOTING
4. TROUBLESHOOTING
4-1. TROUBLESHOOTING EQUIPMENT LIST
Testing and adjusting

items Symbol Part No. Part Name Remarks
Measurement of voltage 79A-264-0211 Tester
1 1
and resistance
1 799-601-7400 T-adapter adaptor assembly For AMP040
AMP070 Connector adaptor
799-601-7500
assembly
• 799-601-7510 For AMP07010
• 799-601-7520 For AMP07012

2
• 799-601-7530 Adaptor For AMP07014
Diagnosis of sensor and
2 • 799-601-7540 For AMP07018
wiring harness
• 799-601-7550 For AMP07020
799-601-9200 DT Series connector adaptor as-

sembly
3 • 799-601-9020 For DT Series Pin 2
Adaptor
• 799-601-9030 For DT Series Pin 3
4 799-601-9320 Box
799-608-3210 Diskette (download software)

1
• 799-608-3220 Download cable
Article on the PC (Personal computer) <PC Specification>
market • IBM PC/AT compatible
unit
Windows R 95/98
PC download of VHMS • CPU : Pentium 100MHz
data 3 or more
• Main memory :
2 16MB or more
• Hard disk :
8MB or more empty
area is necessary
• I/O : One serial port
• I/O : A floppy disk drive
is necessary.
20-1514 HD785-5
(13)
4-2. CONNECTOR TYPE AND INSTALLATION POSITION
Connector No. Connector Pin Installation Position Description Page

Type Count
EC1 MIC 17 Engine controller T-adapter
EC2 MIC 21 Engine controller T-adapter
EC3A AMP040 20 Engine controller T-adapter
EC3B AMP040 15 Engine controller T-adapter
EC4 AMP040 12 Engine controller T-adapter
EC5A AMP040 20 Engine controller T-adapter
HM-EC1 MIC 17 Engine controller 20-1520
HM-EC2 MIC 21 Engine controller 20-1520
HM-EC3A AMP040 20 Engine controller 20-1520
HM-EC3B AMP040 16 Engine controller 20-1520
HM-EC4 AMP040 12 Engine controller 20-1520
HM-EC5A AMP040 20 Engine controller 20-1520
HM-CN1 AMP070 20 VHMS controller 20-1520
HM-CN2A AMP070 18 VHMS controller 20-1520
HM-23A DT1 3 Amplifier for exhaust gas temperature sensor 20-1520
HM-23B DT1 3 Amplifier for exhaust gas temperature sensor 20-1520
HM-50 M 6 Short connector
HM-81 M 3 Intermediate connector 20-1520
HM-100 M 4 Intermediate connector 20-1520
HM-PM8 M 5 Intermediate connector 20-1520
HM-2130 Socket 2 Resistor 20-1520
HM-2140 Socket 2 Resistor 20-1520
HM-CN2B AMP070 12 VHMS controller
HM-CN3B AMP070 12 VHMS controller 20-1520
HM-72 Terminal 2 Snapshot switch 20-1516
HM-6 MS 5 Intermediate connector 20-1516
HM-CN4B AMP070 10 VHMS controller
ORB-B AMP070 10 Satellite communication controller
ORB-A AMP070 14 Satellite communication controller
HM-12 DT1 3 Blow-by gas sensor 20-1516, 20-1517
HM-31 DT1 2 Oil temperature sensor 20-1519
HM-22A DT1 2 Amplifier for exhaust gas temperature sensor 20-1520
HM-22B DT1 2 Amplifier for exhaust gas temperature sensor 20-1519, 20-1520
HM-21A DT1 2 Exhaust gas temperature sensor 20-1516, 20-1517
HM21B DT1 2 Exhaust gas temperature sensor 20-1517, 20-1518
HD785-5 20-1515
(13)
4-3. CONNECTOR ARRANGEMENT DIAGRAM
20-1516 HD785-5
(13)
HD785-5 20-1517
(13)
20-1518 HD785-5
(13)
HD785-5 20-1519
(13)
20-1520 HD785-5
(13)
4-4. ELECTRICAL CIRCUIT DIAGRAM

fl For detail of this page, see 90-207.
HD785-5 20-1521
(13)
4-5. ERROR CODE LIST

LED
Error Code Display Error Description Detecting Conditions
M210 n210 CONNECTOR MISMATCH Incorrect connection of wiring harness connector
700ºC for more than rated rotation, 750ºC for less

than maximum torque point rotation. When the
M250 n250 HIGH RB CYL. EXHAUST TEMP.1 linear interpolation by engine speed between the
rating and the maximum torque exceeded the ex-
haust gas temperature limit line.

M260 n260 HIGH LB CYL. EXHAUST TEMP.2 linear interpolation by engine speed between the
haust gas temperature limit line.
M270 n270 HIGH BLOWBY PRESS The blow-by gas pressure exceeds the threshold
value (1,250mmAq).
M350 n350 OIL TEMP. SENSOR FAILURE Sensor output : 4.7V or more. To be judged 30 min-
utes after starting (Ne>300rpm).
M351 n351 OIL TEMP. SENSOR FAILURE Sensor output : 0.3V or more. To be judged 30 min-
utes after starting (Ne>300rpm).
M390 n390 BLOW PRESS SENSOR FAILURE Sensor output : 4.7V or more
M391 n391 BLOW PRESS SENSOR FAILURE Sensor output : 0.1V or less
M3E0 n3E0 BLOW PRESS SENSOR FAILURE Sensor output : 0.3V or less
M3F0 n3F0 EXHAUST TEMP. SENSOR RB FAILURE Sensor output : 0.3V or less
MFA0 MANUAL TRIGGER

M680 n680 HIGH RB CYL. EXHAUST TEMP. 2 linear interpolation by engine speed between the
haust gas temperature limit line and continued for
more than 10 sec.

M690 n690 HIGH LB CYL. EXHAUST TEMP. 2 linear interpolation by engine speed between the
haust gas temperature limit line and continued for
more than 10 sec.
<Error Code Display Example>

• Since the 7-segment LED cannot display
“M,” it displays “n” instead of “M.”
• In case of M210, “n2” and “10” are dis-
played alternately.
Error code display position
HD785-5 20-1523
(13)
4-6. STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Inspec-
Sys- Connector tion
tem Device Name No. Judgment Measuring Method
Method
The table below shows the normal status: 1) Turn the key
Measuring
switch to OFF.
voltage
Sensor 2) Insert the T-
Between (2) and (12) 22 – 25V adapter.
power supply
3) Turn the key
switch to ON.
HM-CN1
Measuring
switch to OFF.
voltage
Sensor
2) Insert the T-
power supply Between (4) and (12) and adapter.
4 – 6V
5V between (5) and (12) 3) Turn the key
switch to ON.
Measuring
switch to OFF.
voltage
S – NET HM-CN3A 2) Insert the T-

(8) and between (18) adapter.
4 – 8V
and (17) 3) Turn the key
switch to ON.
Measuring
resistance
switch to OFF.
Engine speed HM-CN3A, Between HM-CN3A 2) Disconnect HM-
sensor HM-CN1 (Female) (7) and HM-CN1 500 – 1,000 Ω CN3A and HM-
(Male) (20) CN1.
3) Insert the T-
adapter.
1) Turn the key
Measuring
The table below shows the normal status:

voltage
switch to OFF.
VHMS Controller
Rack sensor HM-CN2A 2) Insert the T-

adapter.
Controller
Between (1) and (12) 0.1 – 4.5V

3) Turn the key
switch to ON.
1) Turn the key
Measuring

voltage
switch to OFF.
Blow-by gas 2) Insert the T-
sensor HM-CN2A
Between (18) and (12) 0.3 – 0.7V adapter.
3) Turn the key
switch to ON.
1) Turn the key
Measuring

voltage
Exhaust gas switch to OFF.

temperature HM-CN2A About 0.9 – 1.2V 2) Insert the T-
sensor 1 Between (7) and (12) (20ºC), About 2.6 – adapter.
3.5V (500ºC) 3) Turn the key
switch to ON.
1) Turn the key
Measuring

voltage
Exhaust gas switch to OFF.

temperature HM-CN2A About 0.9 – 1.2V 2) Insert the T-
sensor 2 Between (5) and (12) (20ºC), About 2.6 – adapter.
3.5V (500ºC) 3) Turn the key
switch to ON.
1) Turn the key
Measuring
resistance
Engine oil The table below shows the normal status: switch to OFF.
temperature HM-CN2A About 35 – 50KΩ 2) Disconnect HM-
Between female (3) CN2A.
sensor (25ºC), About 3.3 –
and female (12) 4.3V (100ºC) 3) Insert the T-
adapter.
1) Turn the key
Measuring
resistance
Engine oil The table below shows the normal status: switch to OFF.
pressure HM-CN2A 2) Insert the T-
sensor Between (8) and (12) 0.3 – 4.7V adapter.
3) Turn the key
switch to ON.
20-1524 HD785-5
(13)
4-7. TROUBLE PHENOMENA LIST
Abnormal Phenomenon
Supposed Cause
Symptom Check Point Checking Method
Satellite communica- The machine is located on the other Check if the operating area is under roof or lo- Due to surrounding environ-
tion is not in service. side of the satellite. cated behind a mountain. ment.
Mounting and appearance of the an- Check if the antenna has not been broken or fallen down
tenna are abnormal. and if the connector contains any foreign matter. Abnormality of the antenna.
Appearance of the antenna cable is Check if the antenna cable has been damaged. Abnormality of the antenna
abnormal. cable.
No communication is possible between the VHMS Abnormality (disconnection or short-cir-
controller and the communication controller. Check if the communication cable is normal. cuit) of wiring harness between VHMS.
Abnormality (disconnection or short-
The communication controller does Check if the power line is normal. circuit) of the power line harness.
not operate. (The power is not turned
on.) Check if the LED is ON. Abnormality of the communica-
tion controller
Other than the above Other than the above Abnormality of VHMS control-
ler
Download and setting Abnormality (disconnection or
Though the VHMS controller LED short-circuit) of wiring harness
are impossible on the works normally, no communication is Check if the communication impossible message
PC. (The analysis tool possible with the PC. is displayed on the PC screen. Abnormality of the VHMS con-
cannot be used.) troller, Defect of the PC
Data cannot be col- A few errors have occurred at
lected. Check if no file is created despite of the same time.
Manual snapshot is not recorded. downloading.Check if no file is created despite
of downloading. Defect of the snapshot switch
circuit) of the VHMS wiring harness.
Specific data cannot be taken out of the Check if blow-by values come not to be obtained. Abnormality of sensors
manual snapshot data or their values Check if blow-by values increase and do not
are abnormal. change. Abnormality of the VHMS con-
troller.
Abnormality of the sensor pip-
ing system
Check if the exhaust gas temperature value de- Abnormality of sensors
creases and does not change. Check if the ex-
haust gas temperature value increases and does Abnormality of the VHMS con-
not change. troller.
Abnormality of the amplifier for
exhaust gas temperature sensor
Check if the engine oil temperature value de- circuit) of the VHMS wiring harness.
creases and does not change. Check if the en-
gine oil temperature value increases and does Abnormality of sensors
not change. Abnormality of the VHMS con-
troller.
Check if the engine oil pressure value comes not
to be obtained. Check if the engine oil pressure Abnormality of the VHMS con-
value increases and does not change. troller.
Abnormality of the engine con-
troller system.
Check if the engine speed came not to be ob- Abnormality of the VHMS con-
tained. troller.
troller system.
Check if the fuel consumption (injection amount) Abnormality of the VHMS con-
came not to be obtained. troller.
troller system.
Abnormality of the VHMS con-
Check if the T/M data came not to be obtained. troller.
Abnormality of the S-NET exist-
ence selection.
Abnormality of the machine
controller system
During travel, the machine is The T/M controller does not match
suddenly cracked to neutral Errors B009, B071 and B073 occur sometimes, When the engine come to restart, errors are re- properly to the VHMS system. (The
and comes not to restart. and the T/M controller comes not to operate. leased, and the machine comers to restart. T/M controller executes corrective
measures for the S-NET.)
Applicable error code
20-1526 HD785-5
(13)
Components to be checked
VHMS Side Machine Side Service Tool Side
Wiring harness system VHMS
(Damage, disconnection, con- Sensor system Satellite Communication Harness/ Con- Hardware
defective contact) troller system Sensor troller
Trouble
Poser Analog ON/OFF Com- Hard- Exhaust gas Blow- Commu- Error Com- Analog Com- T/M Diagno-
supply signal signal muni- ware/ Blow-by gas temperature by gas nication An- occur- munica- commu- muni-
con- Cable sis No.
Soft- sensor control- tenna rence tion nication cation PC
system system system cation sensor sensor fre- environ- troller
line ware ler
quency ment system line
Pulse Breather, Ampli- Machine Pulse
signal Body Tube, Body environ- signal
system Hose fier ment system
A1
A2
A3
5V
A4
24V
A5
A6
A7
A8
A9
A10
A11
M390 M390 M390 M3E0 M3E0 M350

M391 M391 M391 M3F0 M3F0 M351
M3E0
M3F0
M350
M351
HD785-5 20-1527
(13)
A1 : Abnormality in Satellite Data Transmission

Data cannot be transmitted through satellite communication.
Abnormal Phenom- Check Item (Supposed Cause) Corrective Action

enon
Data cannot be trans- The machine is located in a tun- The machine is not out of order. Bring the machine out-
mitted through satel- nel or a building. doors, and the communication will be restored.
lite communication.
(Data set for trans- The machine is located behind a The machine is not out of order. Bring the machine to
mission is not dis- building or a mountain, and only any place where the sky can be seen widely.
played on the Web part of the sky can be seen.
CARE screen even
after more than one The communication antenna is Replace the communication antenna with a new one or
day elapsed from the broken or disconnected. repair it (connect it correctly).
expected data trans-
mission data, and the Any foreign matter exists inside Remove the foreign matter and make sure that the com-
data set for transmis- the connector of the communi- munication is restored.
sion is found at the cation antenna.
time of download
with the PC.) Disconnection of the communi- Check the appearance, and repair or replace cable if dam-
cation antenna cable aged.
Disconnection or short-circuit of Turn the key switch to OFF and remove ORB-B and HM-
the communication line between CN4B. When the resistance values between ORB-B (fe-
the VHMS controller and the male)(1) and HM-CN4B(4), between ORB-B (female)(2) and
communication controller HM-CN4B(10) and between ORB-B (female)(3) and HM-
CN4B(3) are more than 1Ω, disconnect the wiring harness.
Repair or replacement
In other cases, short-circuit the wiring harness continu-
ously when the resistance values between ORB-B (fe-
male)(1) and HM-CN4A(3)(10) and between ORB-B (fe-
male)(2) and HM-CN4A(3) are less than 1MΩ.
Disconnection or short-circuit of Turn the key switch to OFF and remove ORB-A, EC1, HM-
the power line between the EC1, HM-CN1 and HM-CN2A. When the resistance val-
VHMS controller and the com- ues between ORB-A (female)(7)(8) and EC1 (male), be-
munication controller tween ORB-A (female)(10)(11) and EC1 (male)(8) and be-
tween ORB-A (female)(2) and HM-EC2A (female)(17) are
more than 1Ω, disconnect, repair or replace the wiring
harness.
In other cases, short-circuit the wiring harness continu-
ously when the resistance values between ORB-A (fe-
male)(7) and EC1 (male)(8), between ORB-A (female)(7)
and HM-EC2A (female)(17) and between ORB-A (fe-
male)(10) and HM-EC2A (female)(17) are less than 1MΩ.
The communication controller When one communication controller LED is not ON all
LED is not ON. the time, the power line or the communication controller
body is out of order. When the wiring harness is normal,
replace the communication controller with a new one.
After the replacement, the initialization is necessary.
Contact our department in charge.
20-1528 HD785-5
(13)
A2 : Abnormality in Downloading or Setting with the PC

Downloading and setting are impossible with the PC. (The analysis tool cannot be used.)

enon
Downloading and Disconnection or short-circuit of Remove HM-PLM and connect the same service cable to
setting are impos- the download cable on the ser- the PLM communication connector (female). When the
sible with the PC. vice cable side. PLM II data cannot be downloaded, disconnect or short-
(The VHMS control- circuit the service cable.
ler LED displays nor- Repair or replacement
mally.)
Disconnection or short-circuit of Turn the key switch to OFF and remove HM-6 and HM-
the wiring harness on the VHMS CN4A. When the resistance values between HM-6
side of the download cable. (female)B and HM-CN4A(9), between HM-6 (female)C and
HM-CN4A(10) and between HM-6 (female)D and HM-
CN4A(11) are more than 1Ω, disconnect the wiring har-
ness.
Otherwise, short-circuit the wiring harness continuously
when the resistance values between HM-6 (female)B and
HM-CN4A(10)(11) and between HM-6 (female)C and HM-
CN4A(11) are less than 1MΩ.
In other cases, the VHMS controller is out of order. Re-
pair or replace it.
HD785-5 20-1529
(13)
A3 : Manual snap has not been recorded.

enon
Manual snapshot is Any other error code occurred The machine is not out of order. Remove the cause of
not recorded. (No and a snapshot was preferen- triggering other snapshot, and then trigger the manual
manual snap data is tially recorded at the same re- snapshot.
found after down- cording timing as the manual
load with the PC) snapshot.
Disconnection or ground fault of Turn the key switch to OFF and remove HM-CN3B. When
the snap switch body or the wir- the resistance value between HM-CN3B (female)(6) and
ing harness (9) is more than 1Ω when the snap switch is set to ON, or
when the resistance value is less than 1MΩ when the snap
switch is set to OFF, the wiring harness or the snap switch
is out of order. When the resistance value between the
both terminals of HM-72 is more than 1Ω in the status
when the snap switch is set to ON, or when the resis-
tance value is less than 1MΩ when the snap switch is set
to OFF, the snap switch is out of order. In other cases,
the wiring harness is out of order.
20-1530 HD785-5
(13)
A4 : Abnormal Blow-by Gas Pressure Cause Remedy
Defective VHMS control- Replace

ler
or two pressure continui-
YES ty holes in the sensor are Replace
clogged
4 or the blow-by pipe (be- Connect the pipe
tween the breather hose firmly again (or
Is the voltage be- and the sensor) is loose tighten it addi-
YES tween HM- or disconnected tionally).
CN2A(13) and
HM-CN2A(14)
normal? Disconnection between
HM-CN2A(female)(18)
• Normal voltage : and HM-100(2) and HM-
3 0.3 – 0.7V Repair or
12(female)C or between
Is the voltage • Key switch ON NO H M - C N 2 A ( f e m a l e ) ( 1 2 ) replace
YES between HM-12C • Use a T-adapter and HM-100(3) and HM-
and HM-12A at HM-CN2A. 12(female)A
normal?
• Normal voltage : Defective blow-by gas sen- Replace
0.3 – 0.7V sor
2 or short-circuit or ground
• Key switch ON fault between HM-CN2A
Is the voltage • Use a T-adapter at (female)(18) and HM- Repair or
YES between HM- HM-12. NO 100(2) and HM-12(female)
12(female)B and C or between HM-CN2A replace
HM-12(female)A (female)(12) and HM-100
normal? (3) and HM-12(female)A
• Normal voltage :
4 – 6V
1 • Key switch ON Short-circuit or ground
fault between HM-CN1(fe-
Is the voltage • Disconnect HM-12. male)(4) and HM-12(fe- Repair or
between HM- male)B or HM-CN2A(fe- replace
CN1(4) and HM- NO male)(12) and HM-12
CN2A(12) (female) A
normal?
4 – 6V Defective VHMS control-
ler Replace
• Key switch ON or short-circuit or ground
• Use T-adapters at fault between HM-CN1(fe-
HM-CN1 and HM- male)(4) and HM-100(fe- Repair or
CN2A. NO male)(1) and between replace
• Disconnect HM- HM-CN2A(female)(12)
and HM-100(female)(3)
100.
HD785-5 20-1531
(13)
A5 : Abnormal Exhaust Gas Temperature

Cause Remedy
4 YES Defective VHMS control-

Replace
Is the voltage be- ler
YES tween HM-CN2A
Disconnection between
(5) or (7) and (12) HM-CN2A(5)(female) or
3 normal? (7) and HM-23A or B(fe- Repair or
• Normal voltage : NO male)(2) or between HM- replace
Is the voltage be- 0.9 – 1.2V
YES tween HM-23A or CN2A(female)(12) and
• Normal tempera- HM-23A or B(female)(3)
B(2) and HM-23A ture : 20±10ºC
2 or B(3) normal? • Key switch ON
Is the voltage be- • Normal voltage : • Use a T-adapter at
HM-CN2A.
YES tween HM-23A or 0.9 – 1.2V Go to A.
B(female)(1) and • Normal tempera- NO
HM-23A or B(fe- ture : 20±10ºC
male)(3) normal? • Key switch ON
• Use a T-adapter Disconnection between
1 • Normal voltage : HM-CN1(female)(2) and
22 – 25V at HM-23A or B. Repair or
Is the voltage be- HM-23A or B(female)(1)
• Key switch ON NO or between HM-CN2A(fe- replace
tween HM-CN1 male)(12) and HM-23A or
• Disconnect HM-
(2) and HM-CN2A B(female)(3)
23A or B.
(12) normal?
• Normal voltage : Defective VHMS control- Replace
22 – 25V ler
• Key switch ON or short-circuit between
HM-CN1(female)(2) and Repair or
• Use T-adapters at HM-23A or B(female)(1) replace
NO
HM-CN1 and HM- or between HM-CN2A(fe-
CN2A. male)(12) and HM-23A or
• Disconnect HM- B(female)(3)
23A or B.
Defective exhaust gas
temperature sensor ampli- Replace
fier
or short-circuit or ground
YES fault between HM-CN2A
(female)(5) or (7) and HM- Repair or
23A or B(female)(2) or be- replace
tween HM-CN2A(female)
1 (12) and HM-23A or B(fe-
male)(3)
Is the resistance
value between HM-
A 22A or B (male) (1) Short-circuit or disconnec-
and HM-22A or B tion (of compensation lead
(male) (2) normal? wire) between HM-22A or
YES Repair or
• Abnormal resis- B (male)(1) and HM-21A or
B(female)(1) or between replace
tance value : Less Is the resistance
than 1Ω or more value between HM HM-22A or B(male) (2) and
than 1MΩ -21A or B (male) (1) HM-21A or B(female)(2)
• Key switch OFF
NO and HM-21A or B
• Disconnect HM- (male) (2) normal?
• Abnormal resis- Defective exhaust gas
22A or B. Replace
tance value : Less NO temperature sensor
than 1Ω or more
than 1MΩ
• Key switch OFF
• Disconnect HM-
21A or B.
20-1532 HD785-5
(13)
A6 : Abnormal Engine Oil Temperature

Cause Remedy
YES Defective VHMS control-

Replace
ler
1
Is the resistance Short-circuit or disconnec-
value between HM tion between HM-CN2A(fe-
-CN2A(female) (3) YES male)(3) and HM-100(4) Repair or
and HM -CN2A (fe- 2 and HM-31(female)(1) or replace
male)(12) normal? Is the resistance between HM-CN2A (fe-
• Abnormal resis- value between male) (12) and HM-100 (3)
HM-31(male)(1) and HM-31(female) (2)
tance value :
NO and HM-31
Less than 1Ω or (male) (2) nor-
more than 1MΩ mal?
• Key switch OFF Defective engine oil tem-
• Abnormal resis- Replace
perature sensor
• Disconnect HM- tance value : Less NO
CN2A. than 1Ω or more
than 1MΩ
• Key switch OFF
• Disconnect HM-31.
HD785-5 20-1533
(13)
A7 : Abnormal Engine Oil Pressure

Cause Remedy
YES Defective VHMS control-

Replace
ler
1 Disconnection between
Is the voltage be- HM-CN2A(female)(8) and
YES Repair or
tween HM-CN2A EC3B(male)(12) or be-
tween HM-CN2A(female) replace
(8) and HM-CN
2A (12) normal? (12) and EC3A (male) (16)
• Normal voltage : 2
Is the voltage be- Disconnection between
0.45 – 4.7V HM-EC3B(female)(12) and
• Key switch ON tween HM-EC3B YES Repair or
EC3B(male)(12) or be-
• Use a T-adapter NO (12) and HM-EC replace
tween HM-EC3A(female)
at HM-CN2A. 3A (16) normal? (16) and EC3A (male) (16)
• Normal voltage : 3 Hot short-circuit or ground
0.45 – 4.7V Is the voltage be- fault between HM -CN2A
• Key switch ON tween EC3B(12) (female) (8) and EC3B
• Use a T-adapter at (male) (12) or between
and EC3A(16) HM-CN 2A (female)(12)
HM-EC3B and normal? YES and EC3B (male) (16) or Repair or
HM-EC3A. NO
• Normal voltage : 4 between HM-EC3B(fe- replace
male) (12) and EC3B
0.45 – 4.7V Is the voltage be- (male) (12) or between
• Key switch ON tween EC3B(12) HM -EC3A(female)(16) and
• Use a T-adapter NO and EC3A(16) EC3A (male) (16)
at EC3B and normal? Conduct the
EC3A. • Normal voltage : troubleshooting
Problem of engine con-
0.45 – 4.7V of the engine
NO troller system controller sys-
• Key switch ON
• Use a T-adapter at tem
EC3B and EC3A.
• Connect EC3B and
EC3A directly to
the engine con-
troller.
• Disconnect HM-
CN1.
20-1534 HD785-5
(13)
A8 : Abnormal Engine Speed

Cause Remedy
YES Defective VHMS control- Replace

ler
1
Is the resistance Short-circuit or discon-
value between nection between HM-CN
HM-CN3A(fe- YES 3A(female)(7) and EC3A Repair or
male) (7) and HM (male)(2) or between HM- replace
-CN1(female)(20) 2 CN1(female) (20) and EC1
normal? Is the resistance (male)(16)
• Normal voltage : value between
500 – 1000Ω HM-EC3A(female) Short-circuit or discon-
• Key switch OFF NO (2) and HM-EC1 nection between HM-EC
• Disconnect HM- (female)(16) nor- 3 YES 3A(female)(2) and EC 3A Repair or
CN3A, HM-CN1, mal? (male)(2) or between HM- replace
Is the resistance
HM-EC3A and value between EC1(female) (16) and EC1
HM-EC1. EC3A(female)(2) (male) (16)
500 – 1000Ω
• Key switch OFF NO and EC1(female) Execute the
• Disconnect HM- (16) normal? Problem of the engine ro- troubleshoot-
CN3A, HM-CN1, tation sensor system ing of the en-
• Normal voltage : NO gine controller
HM-EC3A and 500 – 1000Ω
HM-EC1. system
• Key switch OFF
• Disconnect EC1
and EC3A.
HD785-5 20-1535
(13)
A9 : Abnormal Fuel Injection Amount Cause Remedy
2 YES Defective VHMS control- Replace

Is the engine ler
YES speed sensor
normal? (Diagno- Execute the
sis of A8) troubleshoot-
Problem of the engine ro-
ing of the en-
1 NO tation sensor system gine controller
system
Is the voltage be- Disconnection between
tween HM-CN 2A HM-CN2A(female)(1) and Repair or
YES
(1) and HM -CN EC2(male)(6) or between replace
2A(12) normal? HM-EC3A(female)(16) and
EC3A(male)(16)
0.1 – 4.5V Disconnection between
Is the voltage be- HM-EC2(female)(6) and
• Key switch ON YES Repair or
tween HM-EC2(6) EC2(male)(6) or between
• Use a T-adapter replace
at HM-CN2A.
NO and HM-EC3A HM-CN2A(female)(12) and
(16) normal? EC3A(male)(16)
Hot short-circuit or ground
0.1 – 4.5V Is the voltage be- fault between HM-CN2A
• Key switch ON tween EC2(6)and (female)(1) and EC2(male)
• Use a T-adapter NO EC3A(16) nor- (6) or between HM-CN2A
at HM-EC2 and mal? YES (female)(12) and EC3A Repair or
HM-EC3A. (male)(16) or between replace
• Normal voltage : 5 HM-EC2(female)(6) and
0.1 – 4.5V Is the voltage be- EC2(male)(6) or between
• Key switch ON tween EC2(6) and HM-EC3A(female)(16) and
• Use a T-adapter NO EC3A(16) nor- EC3A (male)(16)
at EC2 and EC3A. mal? Execute the
Problem of the engine troubleshooting
• Normal voltage : of the engine
0.1 – 4.5V NO controller system controller sys-
• Key switch ON tem
• Use a T-adapter at
EC2 and EC3A.
• Connect EC2 and
EC3A directly to the
engine controller.
• Disconnect HM-CN1.
20-1536 HD785-5
(13)
A10 : T/M date is not displayed

enon
T/M date is not dis- Disconnection in short connector Turn starting switch OFF, and HM-50 connector is discon-
played. nected. When resistance between HM-50 (female) (5)-(4)
(When PC download is 1Ω or below, short connector is defective.
is curried out, T/M Repsot or replace.
date is not found)
Disconnection or short circuit Turn starting switch OFF, and disconnect HM-CN3A con-
with chassis ground in wiring nector, and insert T-adapter, and turn starting switch ON.
harness When voltage between HM-CN3A(8), (18) – (17) is not 4 –
8 V, S-NET is abnormal.
Turn starting switch OFF, and disconnect HM-EC1, HM-
EC3A, EC-3A.
A11 : While travelling, travel valve suddenly becomes neutral and cannot travel

enon
While travelling, trav- S-net application of T/M control- Replace T/M controller to 7818-53-3008 or above, or rewite
elling valve suddenly ler is not carried out yet. T/M controller (Controller 7818-53-3008 or above is
becomes neutral and rewitable.
cannot travel.
Error code B009, If abnormality occurs except for Carry out troubleshooting for T/M controller.
B071, or B073 is dis- mensioned in the left column, T/
played on T/M con- M controller is defective.
troller.
HD785-5 20-1537
(13)
TROUBLESHOOTING DISASSEMBLY AND ASSEMBLY
5. DISASSEMBLY AND ASSEMBLY

5-1. REMOVAL AND INSTALLATION OF VHMS CONTROLLER
<Precautions at Turning off the Constant Power Supply>
When more than 3 minutes (the VHMS system OFF time or the time for storing data in the memory)
elapsed after the key switch was turned to OFF, turn off the constant power supply (directly con-
nected to the
battery).
When the VHMS system Off time is shorter than 3 minutes, the accumulated data may be damaged.
The VHMS system Off time varies with the stored data size,
rewrite frequency, operating time, etc.
When removing the constant power supply (directly connected to the battery), make sure that the
VHMS controller (7-segment LED shown in the figure below) is not shown on the monitor
★ After checking the above, disconnect the battery terminal.

★ Connect the main harness to the HM-CN1 (power supply system) connector at the end, and discon-
nect it first.
★ When the bolt tightening torque is not indicated. Apply the KES torques for tightening.
5-1-1. Removal of VHMS Controller

(1) Disconnect all harness connectors from the
VHMS controller.
(2) Remove the controller mounting bolts and
then remove the VHMS controller.
5-1-2. Installation of VHMS Controller

(1) Fit the controller mounting bolts.
(2) Connect the harness connectors from the
VHMS controller.
20-1538 HD785-5
(13)
5-2. REMOVAL AND INSTALLATION OF

BLOW-BY GAS SENSOR
5-2-1. Removal of Blow-by Gas Sensor
(1) Disconnect the Deutch connector (breather
adapter mounting portion) of the blow-by gas
sensor.
(2) Loosen the hose clamp (at two places shown
in the right figure).
(3) Remove the bolt from the tube stay portion.
(4) Remove the sensor and the tube together and
then disconnect the sensor from the tube.
5-2-2. Installation of Blow-by Gas Sensor

(1) Attach the sensor, the hose and the tube to-
gether temporarily.
(2) Tighten the bolt of the tube stay portion tem-
porarily.
(3) Adjust the positions of the sensor, the hose
and the tube.
(4) Tighten the bolt of the tube stay portion (at
two places).
(5) Tighten the hose clamp.
(6) Connect the Deutch connector (breather
adapter mounting portion) of the blow-by gas
sensor.
★ Clamp tightening torque :
5.9±0.49Nm {0.6±0.05kgm}
★ When it is hard to insert the pipe in the tube,
so apply oil to the pipe for easy insertion.

BREATHER
5-3-1. Removal of Breather
(1) Loosen the hose clamp (at two places shown
in the right figure) and disconnect the hose
from the breather.
(2) Remove the breather mounting bolts (3
pieces).
5-3-2. Installation of Breather

(1) Make sure that the O-ring is set on the
breather mounting surface (adapter side).
(2) Install the breather with three bolts.
★ Tightening torque :
30.5±3.5Nm {3.15±0.35kgm}
(3) Insert the hose in the breather and tighten
them with the hose clamp.
HD785-5 20-1539
(13)
5-4. REMOVAL AND INSTALLATION OF EN-

GINE OIL TEMPERATURE SENSOR
5-4-1. Removal of Oil Temperature Sensor
(1) Disconnect the sensor connector and the har-
ness clip.
(2) Remove the sensor.
5-4-2. Installation of Engine Oil Temperature Sensor

(1) Install the sensor.
5.85±1.95Nm {0.6±0.2kgm}
★ Apply gasket sealant (LG-5) to the sensor
thread.
(2) Install the sensor connector and the harness
clip.
5-5. REMOVAL AND INSTALLATION OF EX-

HAUST GAS TEMPERATURE SENSOR
5-5-1. Removal of Exhaust Gas Temperature Sensor
(1) Disconnect the sensor connector and the har-
ness clip.
(2) Remove the sensor.
★ Apply penetrant to the sensor thread in
advance, and you can remove the sensor
easily.
Left bank (Right-side turbo exhaust gas tem-
5-5-2. Installation of Exhaust Gas Temperature Sen- perature connector)
sor
(1) Install the sensor.
4.4±1.5Nm {0.45±0.15kgm}
★ Apply antiseize compound to the sensor
thread.
(2) Install the sensor connector and the harness
clip.
Right bank (Left-side turbo exhaust gas tem-

perature connector)
20-1540 HD785-5
(13)
5-6. REMOVAL AND INSTALLATION OF EX-

HAUST GAS TEMPERATURE AMPLI-
FIER
5-6-1. Removal of Exhaust Gas Temperature Ampli-
fier
(1) Disconnect the compensating lead wire and
the harness connector.
(2) Remove the amplifier mounting bolt.
★ When it is hard to remove the bolt, it is
recommended to remove the bolt from
the amplifier mounting bracket and then
remove the set from the cover for replace-
ment of the amplifier.
5-6-2. Installation of Exhaust Gas Temperature Am-

plifier
(1) Install the amplifier to the bracket with the
bolt.
★ Tightening bolt :
1.96±0.294Nm {0.2±0.03kgm}
(2) Connect the compensating lead wire and the
harness connector.

SNAPSHOT SWITCH
5-7-1. Removal of Snapshot Switch
(1) Loosen the switch mounting screw and re-
move the switch.
(2) Disconnect the wiring harness.
5-7-2. Installation of Snapshot Switch

(1) Connect the wiring harness to the switch.
(2) Insert the switch into the bracket and tighten
the mounting screw.
HD785-5 20-1541
(13)

COMMUNICATION (ORB ... ORG COM-
MUNICATION) CONTROLLER AND AN-
TENNA
★ Be sure to remove the onboard battery in ad-
vance.
5-8-1. Removal of Communication Controller

(1) Remove the rubber catcher from the sub-seat
and pull down the sub-seat forward.
<ARSC ... when the auto retarder is equipped>
(2) Remove the bracket to which the ARSC is
mounted.
(Remove the bracket together with the con-
troller and the wiring harness temporarily.)
(3) Disconnect the wiring harness from the com-
munication controller.
(4) Remove the bolt and take off the controller.
5-8-2. Installation of Communication Controller

(1) Install the controller with bolt.
(2) Connect the wiring harness to the communi-
cation controller.
Make sure that the VHMS controller is in or-
der, and then connect the power connector
(ORB-A).
<ARSC ... when the auto retarder is equipped>
(3) Install the bracket to which the ARSC is
mounted.
(4) Pull up the sub-seat, set the rubber catcher
and fix it.
5-8-3. Removal of Communication Antenna

(1) Loosen the antenna mounting screw on the
pole and then remove the antenna.
(Be careful not to turn the cable fixing nut to-
gether.)
5-8-4. Installation of Communication Antenna

(1) Loosen the antenna mounting screw on the
pole and install the antenna.
(Be careful not to turn the cable fixing nut to-
gether and tighten the mounting screw firmly.)
20-1542 HD785-5
(13)
TROUBLESHOOTING SETTING OF VHMS CONTROLLER
6. SETTING OF VHMS CONTROLLER

6-1. SETTING OF VHMS CONTROLLER 6-2. SETTING ITEM
• Be sure to set the controller in the follow-
• VHMS : For the detailed setting method, re-
ing cases:
fer to the “Operation and Maintenance
1) When installing the VHMS system for
Manual of Analysis Tool (for Service).”
the first time
1) Calendar (Date, Time difference from
2) When replacing the following compo-
GMT, summer time)
nents or at the time of overhaul,
2) Machine model, applicable serial num-
• When replacing the VHMS control-
ber, and variation code
ler
3) Engine type, applicable serial number
• When replacing the PLMII (option)
4) Applicable serial number of transmis-
• When replacing or overhauling the
sion
engine
5) Communicating method (Stop/start, in-
• When replacing or overhauling the
terval, transmission time)
transmission
6) PLM totaling time
• Items necessary for setting:
7) Communication controller country
1) PC (personal computer)
code (GCC)
2) Download software (799-608-3210)
• PLM : For the detailed setting method, re-
3) Cable (799-608-3220)
• For the detailed setting method, refer to the
Manual of Payload Meter II.”
“Operation and Maintenance Manual of
1) Set the correct time to the VHMS.
Analysis Tool (for Service).”
• A person, who accomplished the necessary
education, shall execute the setting under
the guidance of a responsible person. Oth-
erwise, contact Komatsu Ltd.
6-3. SETTING FLOW (OUTLINE)

• Before the setting, stop the engine (but keep the key switch ON).
Procedure Method (Detailed description, matters to be noted)

1 Turn the key switch to ON. (Key ON) Make sure that no error has occurred to the VHMS controller
and any other controller. When any error has occurred, make
necessary repair or modification to return the relevant con-
troller to normal.
2 Setting of VHMS • Calendar (Date, Time difference from GMT, summer time)
• Machine model, applicable serial number, variation code
• Engine type, applicable serial number
• Applicable serial number of transmission
• Setting of Communication method
3 Setting of PLM time • Set the correct time to the VHMS.

★ For the setting method, refer to the “Operation and Main-
tenance Manual of Payload Meter II.”
4 Turn the key switch to OFF. (Key OFF)
5 Turn the key switch to ON. (Key ON)
6 Setting of VHMS • Set the communication controller country code (GCC).

★ For the setting method, refer to the Operation and Main-
tenance Manual of Analysis Tool (for Service).”
7 Turn the key switch to OFF. (Key OFF)
HD785-5 20-1543
(13)
TROUBLESHOOTING SETTING OF VHMS CONTROLLER
6-4. CHECK OF OPERATION AND PERFORMANCE

• Functions of the VHMS system can be checked according to the following procedures:
Start
Turn the key switch to the “ON” position.
Yes Yes
The E/G, T/M controller, The VHMS controller operates and the LED
etc. display past errors flashes on and off. (See the figure below.)
Normal and then display “00.” (No Normal
Then, integration figures are displayed one
error has occurred.) after another. (No error has occurred.)
No No
Turn the key switch to “OFF” and check con-
nection of the wiring harness.
Turn the key switch to the “ON” position again.
Turn the key switch to the “ON” position.
Yes The E/G, T/M controller, The VHMS controller operates and the LED Yes
etc. display past errors flashes on and off. (See the figure below.)
Normal and then display “00.” Then, integration figures are displayed one Normal
(No error has occurred.) after another. (No error has occurred.)
No No
The machine system is The VHMS controller is
out of order. considered to be out of
• Refer to the Machine order.
Shop Manual.
6-5. DATA COLLECTION
★ When the system is in order, machine operation data will be automatically accumulated in the
VHMS controller after the machine starts operating.
20-1544 HD785-5
(13)
TROUBLESHOOTING DATA RECOVERY AND TRANSMISSION
7. DATA RECOVERY AND

TRANSMISSION
7-1. DATA RECOVERY
(1) Automatic Transmission by Communication
Satellite
• Any occurred error and designated data
are automatically transmitted to the file
server in the computer center through the
communication satellite.
(2) Download with PC (Personal Computer)
<Necessary Tools>
• Personal computer (PC)
• Software (799-608-3210)
• Download cable (799-608-3220)
Download the collected data with the PC and
transmit the data to the file server in the com-
puter center through (the Internet) mail.
(The communicating capacity of the satellite
is limited, and all data are transmitted in this
way.)
★ For download and data transmission, re-
Manual of Analysis Tool.”
7-1-1. Execution of Quick PM

• To collect data under the steady operating
conditions and to collect data in operation
under conditions of torque converter stall, Hi,
etc., you are requested to execute a quick PM
(equivalent to PM Clinic).
★ For safety, stop the machine on a flat ground
and use tire block as chock.
★ Before starting the engine, sound the horn and
make sure that there is no person around.
★ When the engine is warmed up, execute the
quick PM.
1) Keep pressing the manual snapshot
switch (a green push button) “for about 5
sec.”
2) Warm up the engine.
(The engine is warmed up in “about 5
minutes.”)
(Warming-up conditions : Coolant tem-
perature : The green range, TC oil tem-
perature : The green range)
3) Apply the parking brake and step down
the service brake fully (and certainly).
HD785-5 20-1545
(15)
4) Set the gear shift lever to the “D Range.”

5) Step down the accelerator pedal com-
pletely and stall the torque converter.
6) Keep stalling the torque converter until the
top lamp in the green range of the torque
converter oil temperature gauge lights to
raise the temperature of the torque con-
verter oil. (Be careful not to overheat the
torque converter oil.
7) When the torque converter oil tempera-
ture rises, release the accelerator pedal
and return the gear shift lever to the neu-
tral (N) position.
8) Idle the engine low (Li) and idle it high
(Hi) to lower the torque converter oil tem-
perature to the middle of the green range.
★ Repeat the procedures from 4) to 8)
three times and execute the quick PM.
★ For the cycle operation of Li → TC stall
→ Li → Hi, see the figure below. (For
the operating time of each cycle, give
priority to the torque converter oil
temperature.)
9) After measuring the temperature, reduce
the engine speed to cool it down and stop
the engine.
< Operation cycle and data storage range when quick PM is applied >
20-1546 HD785-5
(15)
7-1-2. Downloading Method with Personal Computer

(PC)
★ For safety, stop the machine on a flat ground
and use tire block as chock.
★ Before turning the key switch to ON, make
sure that the parking brake is set to “ON” and
the gearshift lever is set to the “N” position.
★ Stop the engine (but keep the key switch ON)
before downloading.
★ For the operating method of personal com-
puter, refer to the “Operation and Mainte-
nance Manual of Analysis Tool.”
1) Prepare the PC for downloading and the
wiring harness for downloading.
2) Remove the cap of the download connec-
tor on the left inner wall (left side behind
the operator seat) in the operator cab and
install the wiring harness for download-
ing.
3) Connect an end of the wiring harness for
downloading to the PC.
4) Turn on the power of the PC and turn the
key switch of the machine to “ON.” Make
sure that the monitor controller has
started and then start downloading with
the PC.
(To confirm operation of the VHMS con-
troller means to make sure that the VHMS
controller is operating and that figures are
integrated one after another on the screen
after the LED rotates.)
5) When “complete” appears on the PC for
downloading, the downloading has com-
pleted.
6) Turn the key switch on the machine to
“OFF” and turn off the power of the PC,
and then disconnect the wiring harness.
Put the cap on the download connector
as it was.
HD785-5 20-1547
(13)
7-1-3. Kinds of Collection Data Files

1) Index File
Record of common information such as ma-
chine model, serial number, SMR, etc.
2) Trend Analysis
Record of maximum or minimum values of
blow-by value, exhaust gas temperature, etc.
every 20 hours.
3) Snapshot
Record of data in specified time before and
after error occurrence.
4) Load Map
Record of frequency of engine speed and in-
jection amount taken on axes in relevant area.
5) Cycle Interval
Record of cumulative frequency of engine
speed change.
6) Running Area
Record of operation distribution in each 4-di-
vided area of engine performance chart.
7) Running Direction
Record of frequency of operation locus in each
4-divided area of engine performance chart.
8) Faulty History
Time series record of occurred errors.
9) T/M Shift Map
Record of speed change data of the transmis-
sion.
10) T/M Fill Time
Record of transmission clutch connection time
data.
11) PLMII Data
Record of payload meter data
12) Eng ON/OFF History
Record of actual operation data of engine.
20-1548 HD785-5
(13)
7-1-4. Check of Data

For the checking method of data, refer to the “Op-
eration and Maintenance Manual of Analysis
Tool.”
• Make sure that each file is saved and does
not contain abnormal data.
• Compare the Quick PM data with the PM Clinic
data to make sure that they do not contain
abnormal values.
<Check of Quick PM Data>
• Engine speed (Hi, torque converter stall)
• Blow-by pressure (Hi, torque converter stall)
• Exhaust gas temperature (Torque converter
stall)
• Engine oil pressure (Li, Hi, torque converter
stall)
• Engine oil pressure (No PM data ... Reference
value)
HD785-5 20-1549
(13)
TROUBLESHOOTING INSPECTION AND MAINTENANCE
8. INSPECTION AND MAINTENANCE

8-1. INSPECTION TIMING : INSPECTION (3) Replace the sensor with a new one.
AND MAINTENANCE TIMING OF 2) Breather
MACHINE Inspect the breather, and if it is soiled,
clean it.
Try to inspect the system when the machine
(1) Wipe dust and dirt around the
is repaired.
breather. Then, loosen the clamp and
remove the hose and the breather in
8-2. INSPECTION ITEM this order.
★ When any abnormality is found in inspec- (2) Rinse the breather body (including the
tion or check, take proper corrective ac- inner element) in light oil or cleaning
tions. oil.
• At the time of check before starting (Us- (3) After the cleaning, blow oil inside the
ers are requested to check the following:) element completely with compressed
1) Check if sensors are mounted cor- air, dry and set it in the breather body.
rectly. (Check if they are mounted (4) Inspect the hose and the tube. If their
loosely, are damaged and are soiled.) insides are soiled with deteriorated oil
• Blow-by gas sensor (slush), clean them in the same way
• Engine oil temperature sensor or replace them with new ones.
• Exhaust gas temperature sensor
• Communication antenna • When required
2) Check if wiring harness, cables and 1) When download data values are abnor-
connectors are disconnected or dam- mal, inspect each sensor.
aged.
3) Check if oil or gas is leaking from sen- 8-3. CORRECTIVE ACTION
sor mounted portions.
When any abnormality is found, make proper
repair, replacement or re-mounting (addi-
• At the time of maintenance every 1,000 hours
tional tightening) as the occasion demands.
1) Communication Antenna
• Check if the antenna mounting portion
is loose or plays.
• Check if the antenna body is damaged,
loose or plays.
• If the antenna is abnormal, replace it
with a new one.
• At the time of Maintenance every 2,000 hours

1) Blow-by Gas Sensor
When inspecting the engine breather,
check if the inside of the blow-by gas sen-
sor is soiled.
(1) Wipe soil on the sensor outside and
install the sensor.
(2) When the sensor vent hole (inside) is
soiled with deteriorated oil (slush) or
is apt to be clogged, execute the fol-
lowing:
★ Check the trend value of measure-
ment data. → When the value
tends to decrease, the sensor is
supposed to be out of order.
★ When the sensor output voltage
is not in the range from 0.3 to 0.7V
at the time of “Key Switch ON” or
“Engine Stop,” the sensor is out
of order.
20-1550 HD785-5
(13)
TROUBLESHOOTING REPLACEMENT OF PARTS
9. REPLACEMENT OF PARTS
Initialization of VHMS System
When installing the system for the first time, or when replacing the VHMS controller or any compo-
nent (transmission, engine, etc.), you are requested to initialize the system.
• For the initialization,
1) PC (Personal Computer),
2) Download software (799-608-3210) and
3) Cable (799-608-3220)
are necessary.
• A person, who accomplished the necessary education, shall execute the initialization under the
guidance of a responsible person. Otherwise, contact Komatsu Ltd.
<Precautions at the time of Replacing VHMS and

ORB Controller>
9-1 WHEN THE VHMS CONTROLLER IS

REPLACED
1) It is necessary to initialize the VHMS con-
troller.
• Follow the instruction of a responsible
person or contact Komatsu Ltd.
9-2 WHEN COMMUNICATION CON-

TROLLER IS REPLACED
In the following cases, important procedures
are necessary such as opening or closing sta-
tion of the communication controller. So,
follow instructions of the responsible person
or contact Komatsu Ltd.
A) When a controller already installed to the
machine is replaced with a different con-
troller.
B) When a controller already installed to the
machine is reinstalled to another machine.
C) When a controller is disposed of.
D) When a machine to which a controller has
been installed is transferred or sold.
E) When a machine to which a controller has
been installed is disposed of ? ?.
HD785-5 20-1551
(13)
TROUBLESHOOTING PROCEDURE FOR INITIAL SETUP OF VHMS
PROCEDURE FOR INITIAL SETUP OF VHMS

(Applicable machine models: HD785/985-5)
Timing Operation step Explanation
Before starting • Prepare the necessary tools and check sheet. 799-608-3220 Download cable
operation 799-608-3211 Setup program (VHMS technical analysis tool box)
Portable PC (Install VHMS technical analysis tool box beforehand)
Starting switch OFF Check the serial No. first from the following nameplates Position of VHMS nameplate
Check machine and component and enter the serial No. on the check sheet.
nameplates • Machine • Engine • Transmission
• VHMS controller
Connect the cable (799-608-3220) to the VHMS

controller download connector of the VHMS controller installed to the rear left in the cab.
Connect PC and VHMS controller Connect the other end to the RS232C terminal of the
portable personal computer.
Starting switch ON Check the 7-segment display window of the VHMS controller to see that the operation is normal.
Check that VHMS controller works * With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes
Do not start properly in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.
engine yet
Start up the personal computer and click the VHMS initial setup tool icon.
Start VHMS initial set-up tool For details of the method of installing the VHMS initial setup program, Note: This program will not
(VHMS technical tool box) see the separate program operation instructions. start if the VHMS controller
and PC are not connected.
(automatic updating of definition data) If the definition data for the connected machines is not in the "VHMS analysis tool" of the personal
computer, it is downloaded automatically from the VHMS controller and the "VHMS analysis tool"
will be updated.
Click the YES button to update the definition data.
After starting up, first input the ID (Service ID).

Initial set-up of VHMS controller Select "Data Clear and Set up".
The ID is the part No. for the VHMS

controller (Exclude hyphens and set the
first figure from the right to 0.). It differs
according to the machine model.
-1 Setting up machine data 1) Setting calendar

– – Set the present time and date.
This sets the basic data for the machine 2) Confirming machine model and setting
in the VHMS controller. serial No.
– – After checking the machine model,
set the machine serial No.
If one or more figures from the left of the
machine serial No. are 0s, do not
enter 0s for those positions.
3) Setting engine Serial No.
4) Setting transmission Serial No.
– – Set the transmission Serial No. in
engine Serial No. 2.
-2 Setting up payload meter 1) Click the tag of the PLM and set the start time and unit (B) for data collection.
– – In the example on the right, the start time
(Machine with PLM II function) is set at 11 PM and the interval at 2 days,
and the results of these data are set to
be transmitted by satellite.
After completing the setup, check that the
payload meter time display is the same as
the VHMS setting.
Finally, click OK.

(Cont'd) Click Apply to register the setting.
20-1552 HD785-5
(14)
TROUBLESHOOTING PROCEDURE FOR INITIAL SETUP OF VHMS
Starting switch OFF 1) Check the 7-segment display in the VHMS controller inspection window.
Save settings – – The display continues for several seconds after the starting switch is turned OFF. Check that
When the starting switch is turned OFF, the saving-to-memory display goes out completely.
the saving of data to the VHMS controller
is completed.
Starting switch ON
Check VHMS functions Check the 7-segment display window of the VHMS controller to see that the operation is normal.
In the following steps the function of * With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes in a
the VHMS system is checked. rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.
Start engine [Outline of procedure]

Perform quick PM clinic 1) Warm up the engine, then carry out the quick PM.
Follow the procedure given in the shop 2) Carry out low/high idle and torque converter stall during the next 7
manual to perform the quick PM clinic. minutes 30 seconds. Be extremely careful about safety when
carrying out the torque converter stall.
Starting switch OFF 1) Check the 7-segment display in the VHMS controller inspection window.
Save to VHMS memory – – The display continues for several seconds after the starting
When the starting switch is turned OFF, switch is turned OFF. Check that the saving-to-memory
the saving of data to the VHMS controller display goes out completely.
is completed.
Starting switch ON Check that the VHMS controller and portable personal
Download computer are connected by a cable.
Start the VHMS technical analysis tool box from the PC screen.
Download all files.
For details, see the instruction manual for the
technical analysis tool box.
Check downloaded data After completing the download operation, use the View function to check the VHMS data.
• Check that the settings are correctly displayed.
(Data, time, service meter, machine serial No., etc.)
• Check that the quick PM data from the Snapshot operation in Step has been saved.
Starting switch OFF

Save to VHMS memory
When the starting switch is turned OFF, the
saving of data to the VHMS controller is
completed.
After returning to 1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
office Completing operation to set up power for the VHMS is turned OFF), if the all system is normal.
VHMS and contacting Komatsu 2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
This completes the initial setup of the VHMS.

The setup of the database (Web server) is carried out by Komatsu, so after you have
completed the operation, inform Komatsu as follows.
1) Send the check sheet by fax.
2) Send the downloaded VHMS data by Notes or E-mail to the following address.
Welcome to WebCARE. VHMS, WebCARE Support Center

Use WebCARE to check the data. (Service Business Development Group Customer Support Division Komatsu Head Office)
https://webcare.komatsu.co.jp Tel: 03-5561-2765
Fax: 03-5561-4766
E-mail: [email protected]
HD785-5 20-1553
(15)
TROUBLESHOOTING PROCEDURE FOR OPENING ORBCOMM SERVICE
PROCEDURE FOR OPENING ORBCOMM SERVICE

(Applicable machine models: HD798/985-5 Dump Truck)
★ Make a communications contract with Orbcomm before performing this work.
(Send the Orbcomm terminal opening request packed together with the instruction manual for communica-
tions contract. (2 to 3 weeks prior to the operation))
799-608-3220 Download cable

Before starting • Prepare the necessary tools and check sheet. 799-608-3211 Setup program (VHMS technical analysis tool box)
operation • Contact Komatsu before starting the setup Portable PC (Install VHMS technical analysis tool box beforehand)
operation. (Contact at least 3 days before)
Check the serial No. first from the following nameplates

Position of VHMS nameplate
Check of ORBCOMM controller and enter the serial No. on the check sheet.
• Machine • Engine • Transmission
• VHMS controller
Starting switch OFF Connect the cable (799-608-3220) to the VHMS controller download connector of the VHMS
Connect PC and VHMS controller controller installed to the rear left in the cab.
Connect the other end to the RS232C terminal of the portable personal computer.
Starting switch ON
Check the 7-segment display window of the VHMS controller to check that the
Do not start Check that VHMS controller works operation is normal.
engine yet properly * If the LEDs operate normally, when the starting switch is turned ON, the 7 segments flash
in rotating movement, and then display the hexadecimal count-up.
For details, see the shop manual.
Note: This program will not
Start up the personal computer and click the VHMS start if the VHMS controller
Start VHMS initial setup tool initial setup tool icon on the desktop. and PC are not connected.
(VHMS technical tool box) For details of the method of installing the VHMS initial
setupprogram, see the separate program operation instructions.
If the definition data for the connected machines is not in the technical analysis tool box on
the personal computer, download it automatically from the VHMS controller and update the te
chnical analysis tool box.
Click the YES button to update the definition data.
After starting up, first input the ID (Service ID).

Initial setup of VHMS controller Select "Data Clear and Set up".
The ID is the part No. (Exclude hyphens
and set the first figure from the right to
0.) for the VHMS controller. It differs
according to the machine model.
-1 Setting up communications 1) Selecting data to send

This sets up the selection of VHMS – – There are 3 types of data that can be sent. With this operation is possible to set
data to be sent by satellite communications acceptance /refusal of satellite communications and the frequency of change.
and the frequency of communications. – – Decide the data to change, then click on
Edit to change it.
*
*1: The default for the

* (The setting of the machine data number of items in the
and PLM is already completed) Fault History is 8.
For details, see the
instruction manual for the
setup tool.
2) Setting up GCC code Territory

GCC code
– – Click Edit and select 130 (if Japan) for the (country)
GCC code. 1 USA
120 ITALY
121 MALAYSIA
Finally, click Apply to register the setting. 122 KOREA
123 BRAZIL
(Cont'd) 130 JAPAN
20-1554 HD785-5
(15)
Starting switch OFF Save to VHMS memory Check the 7-segment display in the VHMS controller inspection window.
When the starting key is turned OFF, the • The display continues for several seconds after the starting switch is turned OFF.
saving of data to the VHMS controller is Check that the saving-to-memory display goes out completely.
completed. 1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
power for the VHMS is turned OFF), if the all system is normal.
2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
Starting switch ON Check that VHMS controller works Check the 7-segment display window of the VHMS controller to see that the operation is normal.
properly * With normal operation of the LEDs, when the starting switch is turned ON, the 7-segment flashes
in a rotating movement, then displays the hexadecimal count-up. For details, see the shop manual.
When checking that the operation of the Orbcomm controller is normal, wait for 3 minutes after
Check the satellite communication.
starting the VHMS, then check the condition of the decimal point on the VHMS monitor (7-segment).
• OFF : ORBCOMM controller cannot communicate with ORBCOMM terminal.
• ON : Communication with ORBCOMM terminal is OK.
Terminal does not have communication data.
• Quick flash : Communication with ORBCOMM terminal is OK.
Terminal has communication data and has captured satellite.
• Slow flash : Communication with ORBCOMM terminal is OK.
Terminal has communication data and has not captured satellite.
Starting switch OFF Saving of contents of setting Check the 7-segment display in the VHMS controller inspection window.
Turn the starting switch OFF to save the • The display continues for several seconds after the starting switch is turned OFF. Check that
data in the VHMS controller. the saving-to-memory display goes out completely.
After returning to office

Completing operation to set up VHMS This completes the setup for Orbcomm.
and contacting Komatsu The setup of the reception inside of the satellite communications is carried out by Komatsu,
so after you have completed the operation, inform Komatsu as follows.
1) Send the check sheet by fax.
2) Send the downloaded VHMS data by Notes or E-mail to the following address.
Welcome to WebCARE VHMS, WebCARE Support Center

Use WebCARE to check the data (Service Business Development Group Customer Support Division Komatsu Head Office)
https://wcare.komatsu.co.jp Tel: 03-5561-2765
Fax: 03-5561-4766
HD785-5 20-1555
(14)
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS INITIAL SET-UP CHECK SHEET sheet
(For HD785/985-5 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Orbcomm controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotating, hexadecimal count-up display)
Is selection of mode for setup tool

Start VHMS initial setup tool yes no
"Data Clear and Set up"?
Initial setup of VHMS controller

-1 Set machine data Is model name same as name of machine? yes no
Has machine serial No. been input correctly? yes no
This sets the basic data for the machine in Has engine serial No. been input correctly? yes no
the VHMS controller. Has date been set to today's date? yes no
Has time been set to correct time? yes no
-2 Set up payload meter Input set values for PLM data collection
Time of starting data collection
(For PLM ΙΙ or machine with PLM function) Data collection interval (days) day
Is PLM time same as VHMS
controller? (±1 min)
Save settings Is 7-segment LED OFF? yes no
Check VHMS functions Do LEDs work properly? yes no
Perform quick PM clinic Was switch held for 5 sec? yes no
Save to VHMS memory Is 7-segment LED OFF? yes no
Download Do LEDs work properly? yes no
Have all files been downloaded? yes no

Check downloaded data Time of download (use wristwatch) Hrs
[Check data]
Is there any MFAO error in Fault History? yes no
In Fault History, do set values for SMR
yes no
and time match?
Are there any data missing in Snapshot? yes no
Are there any data in Transmission Shift Change Map? yes no
Point of Contact VHMS, WebCARE Support Center

(Service Business Development Group Customer Support Division Komatsu Head Office)
Tel: 03-5561-2765
Fax: 03-5561-4766
20-1556 HD785-5
(14)
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS OPENING ORBCOMM SERVICE CHECK SHEET sheet
(For HD785/985-5 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No
nameplates Service meter.
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Orbcomm controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, hexadecimal count-up display)
(Check operation of Orbcomm)
Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up"?
Initial setup of VHMS controller
–1 Set up communications Input set value of short Fault History

Condition of communications On Off
This sets up the selection of VHMS Number of items (default value: 10) items
data to be sent by satellite communications Input set value of short Trend Analysis
and the frequency of communications. Condition of communications On Off
Interval (default value: 20 hrs) Hrs
Input set value of short Payload data
Condition of communications On Off
Time of start of data collection
Data collection interval (day) day
Is GCC code set to 130 (if Japan) yes no
Check that VHMS controller works properly. Is operation normal?

(After display of rotation, hexadecimal numbers are yes no
counted up.)
Check the satellite communication. Is decimal point of VHMS (7-segment LED on right side)
yes no
flashing at short or long intervals?
Point of Contact VHMS, WebCARE Support Center

(Service Business Development Group Customer Support Division Komatsu Head Office)
Tel: 03-5561-2765
Fax: 03-5561-4766
HD785-5 20-1557
(14)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ..................... 30- 3 BRAKE COOLER

PRECAUTIONS WHEN CARRYING OUT Removal and Installation ........................... 30-38
OPERATION ................................................. 30- 4 OUTPUT SHAFT
SPECIAL TOOL LIST ...................................... 30- 6 Removal and Installation ........................... 30-39
STARTING MOTOR Disassembly ............................................... 30-41
Removal and Installation ............................ 30- 9 Assembly .................................................... 30-42
ALTERNATOR TORQUE CONVERTER, TRANSMISSION
Removal and Installation ........................... 30-10 Removal ...................................................... 30-44
ENGINE OIL COOLER Installation .................................................. 30-46
Removal and Installation ........................... 30-11 PROCEDURE FOR CENTERING THE ENGINE
LEFT BANK FUEL INJECTION PUMP ASSEMBLY AND TORQUE CONVERTER,
Removal and Installation ........................... 30-12 TRANSMISSION ASSEMBLY .................... 30-47
RIGHT BANK FUEL INJECTION TORQUE CONVERTER, CONTROL VALVE
PUMP(WITHOUT GOVERNOR) Removal and Installation ........................... 30-48
Removal and Installation ........................... 30-13 Disassembly and Assembly ...................... 30-49
AIR COMPRESSOR TORQUE CONVERTER AND TRANSMISSION
Removal and Installation ........................... 30-14 Disconnection ............................................. 30-50
WATER PUMP Connection .................................................. 30-51
Removal and Installation ........................... 30-15 TORQUE CONVERTER, PTO
AFTERCOOLER CORE Disassembly ............................................... 30-52
Removal ...................................................... 30-16 Assembly .................................................... 30-58
Installation .................................................. 30-17 TRANSMISSION
TURBOCHARGER Disassembly ............................................... 30-64
Removal and Installation ........................... 30-18 Assembly .................................................... 30-78
NOZZLE HOLDER ECMV
Removal and Installation ........................... 30-19 Disassembly and Assembly ...................... 30-95
CYLINDER HEAD DIFFERENTIAL
Removal ...................................................... 30-20 (For standard differential)
Installation .................................................. 30-21 Removal ...................................................... 30-97
EXHAUST BRAKE Installation .................................................. 30-98
Removal and Installation ........................... 30-23 Disassembly ............................................... 30-99
ENGINE Assembly .................................................. 30-103
Removal ...................................................... 30-24 DIFFERENTIAL
Installation .................................................. 30-28 (With differential lock)
ENGINE FRONT SEAL Removal .................................................... 30-112
Removal and Installation ........................... 30-29 Installation ................................................ 30-113
ENGINE REAR SEAL Disassembly ............................................. 30-114
Removal and Installation ........................... 30-32 Assembly .................................................. 30-119
RADIATOR, TORQUE CONVERTER COOLER FRONT WHEEL
Removal ...................................................... 30-36 Removal and Installation ......................... 30-129
Installation .................................................. 30-37
HD785-5 30-1
2
REAR WHEEL PARKING BRAKE CHAMBER
Removal .................................................... 30-130 Removal and Installation ......................... 30-168
Installation ................................................ 30-131 Disassembly ............................................. 30-169
FRONT BRAKE CALIPER Assembly .................................................. 30-170
Removal and Installation ......................... 30-132 REAR BRAKE CHAMBER
Disassembly ............................................. 30-133 Removal and Installation ......................... 30-172
Assembly ............................................... 30-133-1 Disassembly ............................................. 30-173
FRONT BRAKE CALIPER PAD Assembly .................................................. 30-177
Removal and Installation ......................... 30-134 FRONT BRAKE CHAMBER
FRONT WHEEL HUB Disassembly ............................................. 30-180
Disassembly ............................................. 30-135 Assembly .................................................. 30-182
Assembly .................................................. 30-137 SLACK ADJUSTER
FINAL DRIVE CARRIER Removal and Installation ......................... 30-184
Removal and Installation ......................... 30-140 Disassembly and Assembly .................... 30-185
Disassembly and Assembly .................... 30-141 AIR DRIER (DESICCANT TYPE)
FINAL DRIVE Removal and Installation ...................... 30-185-1
Disassembly ............................................. 30-142 Disassembly and Assembly ................. 30-185-2
Assembly .................................................. 30-144 BRAKE COOLING PUMP
REAR BRAKE Removal and Installation ......................... 30-186
Removal and Installation ......................... 30-146 STEERING, HOIST PUMP
REAR WHEEL BRAKE Removal and Installation ......................... 30-187
Disassembly ............................................. 30-147 TORQUE CONVERTER, TRANSMISSION PUMP
Assembly .................................................. 30-148 Removal and Installation ......................... 30-188
PARKING BRAKE PAD EMERGENCY STEERING MOTOR PUMP
Removal .................................................... 30-150 Removal and Installation ......................... 30-189
Installation ............................................. 30-150-1 STEERING VALVE
PARKING BRAKE CALIPER Removal and Installation ......................... 30-190
Removal and Installation ...................... 30-150-2 Disassembly ............................................. 30-191
Disassembly and Assembly .................... 30-152 Assembly .................................................. 30-195
FRONT SUSPENSION CYLINDER BRAKE CONTROL VALVE (BCV)
Removal and Installation ......................... 30-153 Removal and Installation ......................... 30-202
Disassembly (Standard cylinder) ............ 30-154 DEMAND VALVE
Assembly (Standard cylinder) ................. 30-155 Removal and Installation ......................... 30-203
Disassembly Disassembly and Assembly .................... 30-204
(Cylinder with buffer ring) .................... 30-155-1 RELIEF VALVE
Assembly Disassembly and Assembly .................... 30-205
(Cylinder with buffer ring) .................... 30-155-2 HOIST VALVE
KING PIN Removal and Installation ......................... 30-206
Removal and Installation ...................... 30-155-4 Disassembly and Assembly .................... 30-208
VARIABLE DAMPING SELECTOR VALVE STEERING CYLINDER
Disassembly ............................................. 30-156 Removal and Installation ......................... 30-210
Assembly .................................................. 30-157 Disassembly ............................................. 30-211
REAR SUSPENSION CYLINDER Assembly .................................................. 30-213
Removal and Installation ......................... 30-158 HOIST CYLINDER
Disassembly (Standard cylinder) ............ 30-159 Removal and Installation ......................... 30-216
Assembly (Standard cylinder) ................ 30-160 Disassembly ............................................. 30-217
Disassembly
Assembly .................................................. 30-218
(Cylinder with buffer ring) .................... 30-160-1
Assembly BODY
(Cylinder with buffer ring) .................... 30-160-2 Removal .................................................... 30-219
AIR GOVERNOR Installation ................................................ 30-220
Removal and Installation ......................... 30-161 CONTROLLER
Disassembly and Assembly .................... 30-162 Removal and Installation ......................... 30-221
BRAKE VALVE AIR CONDITIONER COMPRESSOR
Removal and Installation ......................... 30-163 Removal and Installation ......................... 30-222
Disassembly ............................................. 30-164 RECEIVER TANK
Assembly .................................................. 30-166 Removal and Installation ......................... 30-223
AIR CONDITIONER CONDENSER
Removal and Installation ......................... 30-224
30-2 HD785-5
(16)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF cccc ASSEMBLY ............... Title of operation
...................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ..................................................... Step in operation
fl .................................................................. Technique or important point to remember
when removing XXXX (1).
2. t t t t (2): ............................................... 1 Indicates that a technique is listed for use
during installation
3. assembly (3)
6 .................................................................... Quantity of oil or water drained
INSTALLATION OF cccc ASSEMBLY .... . Title of operation

• Carry out installation in the reverse order to removal.
1 ............................................................. Technique used during installation
fl .................................................................. Technique or important point to remember when
installing t t t t (2).
• Adding water, oil ................................. Step in operation
fl ............................................................ Point to remember when adding water or oil
-.........................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
HD785-5 30-3
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 L
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34 DEW00401
30-4 HD785-5
A
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nece- New/ Ske-

Component Symbol Part No. Part Name ssity Q’ty model
re-
tch Nature of work, remarks
790-502-1003 Cylinder repair stand 1
1
790-101-1102 Pump 1
Removal, installation of
2 790-102-3802 Wrench assembly 1 cylinder round head
3 Socket (Width Removal, installation of nylon
790-302-1340 across flat: 80mm) 1 nut (steering)
4 790-720-1000 Expander 1
5 796-720-1660 Ring 1 Installation of piston ring
6 07281-01159 Clamp 1
790-201-1811 Push tool 1
Press fitting of coil bushing
790-101-5021 Grip 1 Kit No. 790-201-1700
7
01010-50816 Bolt 1
790-201-1620 Plate 1 Press fitting of dust seal
Disassembly, assembly 792-630-1300 Push tool 1

of hoist cylinder U Press fitting of No. 1 coil
8 790-101-5421 Grip 1 bushing (hoist cylinder)
01010-51240 Bolt 1
790-445-4210 Push tool 1
Press fitting of No. 2 coil
9 790-101-5421 Grip 1 bushing (hoist cylinder)
01010-51240 Bolt 1
790-445-4220 Push tool 1
Press fitting of No. 1 dust
10 790-101-5421 Grip 1 seal (hoist cylinder)
01010-51240 Bolt
790-445-4230 Push tool 1

Press fitting of No. 2 dust
11 790-101-5421 Grip 1 seal (hoist cylinder)
01010-51240 Bolt 1
790-720-1000 Expander 1
Installation of piston, wear
12 796-720-1690 Ring 1 ring (hoist cylinder)
07281-01919 Clamp 1
Removal, installation of
dump body V 1 790-441-1320 Hook 4
799-703-1200 Service tool kit 1
Vacuum pump
799-703-1100 (100V) 1
Collection, re-use of Vacuum pump Collection, charging with air
new freon gas X 1 799-703-1110 (220V) conditioner gas
Vacuum pump
790-703-1120 (240V)
799-703-1400 Gas leak tester 1
30-8 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE
REMOVAL OF EXHAUST
BRAKE ASSEMBLY
¤ Disconnect the cable from the negative (–)
terminal of the battery.
1. Open engine food.
2. Disconnect air hose (1).
3. Remove exhaust tube clamp (2).
4. Disconnect U-bolt (3).
5. Disconnect exhaust tube (4) from exhaust

brake.
6. Remove clamp (5), then remove exhaust brake

assembly (6).
INSTALLATION OF EXHAUST
BRAKE ASSEMBLY
• Carry out installation in the reverse order to
removal.
HD785-5 30-23
(13)
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
¤ Stop the machine on level ground, and put
blocks under the wheels.
¤ Raise the dump body and lock with the safety
pin.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
fl Close the fuel supply valve.
1. Radiator assembly
Remove radiator assembly.
For details, see REMOVAL OF RADIATOR ASSEM-
BLY.
2. Wiring
1) Disconnect alternator wiring (1) (red).
2) Disconnect air compressor wiring connectors
(2) (CN17, 18, 19).
3) Disconnect electrical intake air heater relay

wiring (3) (left bank) and (4) (right bank).
4) Disconnect engine coolant temperature sen-

sor connector (5).
5) Disconnect 2 starting motor wires (6).
6) Disconnect 2 starting motor wiring connec-
tors (7).
30-24 HD785-5
(15)
12. Air piping

1) Disconnect discharge hose (22).
2) Disconnect unload hose (23).
13. Drive shaft (input end)

1) Remove guard (24).
2) Disconnect drive shaft (25). 1
14. Engine assembly

1) Remove mount bolts (front end) (26). 2
2) Remove mount bolts (rear end) (27).
3) Lift off engine assembly (28). 3
0 Engine assembly : 3,300 kg
HD785-5 30-27
(15)
INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
• Install the radiator assembly.
For details, see INSTALLATION OF RADIATOR
ASSEMBLY.
8 Drive shaft (front) mounting bolt:

Thread tightener (LT-2)
3 Drive shaft (front) mounting bolt:

156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
3 Engine mounting bolt:

926.8 ± 103.0 Nm {94.5 ± 10.5 kgm}
3
fl When installing the engine assembly, assemble
cushions (29) and (30).
fl Carry out centering.

For details, see PROCEDURE FOR CENTERING
ENGINE ASSEMBLY AND TORQUE CONVERTER,
TRANSMISSION ASSEMBLY.
• Refilling with coolant

Add water up to the radiator water filler port. Then
run the engine to circulate the water through the
system and check the water level in the reserve
tank again.
• Refilling with oil

Refill oil to the specified level and run the engine
to circulate the oil through the system. Then check
the oil level again.
30-28 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY RADIATOR, TORQUE CONVERTER OIL COOLER
3. Remove fan net (6).
4. Disconnect thermostat outlet hoses (7) and (8).
5. Disconnect aeration hose (9).
6. Disconnect bypass hose (10).
7. Disconnect radiator outlet hose (11).
8. Disconnect radiator bypass hose (12).
9. Disconnect torque converter oil cooler hoses (13)

and (14).
10. Remove radiator top mount (15).
11. Remove radiator bottom mount (16).
12. Lift off radiator and torque converter cooler as-

sembly (17).
0 Radiator, torque converter cooler assem-

bly : 410 kg
INSTALLATION OF RADIATOR,
TORQUE CONVERTER COOLER
ASSEMBLY
moval.
• Refilling with coolant

Add coolant to the specified level, and run the
engine to circulate the coolant through the sys-
tem. Then check the coolant level in the reserve
tank again.
1
Sling and install the mount bolts.
2
Check the number and thickness of the shims.
3
Sling and install the mount bolts.
HD785-5 30-37
(15)
DISASSEMBLY AND ASSEMBLY BRAKE COOLER
REMOVAL OF BRAKE COOLER

ASSEMBLY
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Drain coolant and brake oil.
= Coolant : 174 ¬
= Brake cooling oil : 143 ¬
2. Remove underguard (1).
3. Disconnect coolant outlet joint hose (2).
4. Disconnect coolant inlet joint hose (3).
5. Disconnect brake oil inlet hose (4).

fl Disconnect the outlet hose on the opposite
side.
6. Remove brake cooler assembly (5).
0 Brake cooler assembly : 170 kg
INSTALLATION OF BRAKE
COOLER ASSEMBLY
moval.
• Refilling with oil, coolant
- Engine coolant : 174 ¬
- Brake cooling oil : 143 ¬

fl Add brake cooling oil to the brake oil tank,
and engine coolant, and check the levels. Run
the engine to circulate the oil and coolant
through the system, then stop the engine and
check the brake oil and coolant levels again.
30-38 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, PTO
ASSEMBLY OF TORQUE
CONVERTER, PTO ASSEMBLY
1. Shaft
1) Set torque converter housing in tool C2.
2) Install shaft (16).
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
3) Install seal ring (15).
2. Pump assembly
1) Assemble pump assembly as follows.
i) Install bearing (19) to guide (18).
fl Check the common number of the
bearing, and the direction of installa-
tion for the A and B marks.
ii) Install pump (20).
iii) Fit retainer (21), and tighten bolts.
2) Install inner race (22) to shaft (16).

fl Align the match mark of the bearing in-
stalled to the pump assembly, then install.
3) Install pump assembly (14).
fl Fix seal ring (15) with grease, so that the
protrusion from the shaft is uniform.
4) Install remaining inner race (22).
5) Install nut (12).
8 Nut thread: Thread tightener (LT-2)
3 Bearing nut:
196.1 – 245.2 Nm {20.0 – 25.0 kgm}
3 Stator nut:
441.3 – 490.4 Nm {45.0 – 50.0 kgm}
30-58 HD785-5
(15)
3. Stator
1) Assemble the following parts to the stator.
i) Install snap ring (24) to outer race (23).
ii) Install one-way clutch (25) to outer race
(23).
fl Be careful not to damage the sprag.
fl Install the one-way clutch so that the

arrow showing the direction of free
rotation points clockwise (right) as
seen from the lip of the outer race.
Do not remove the sprag.
iii) Install outer race and one-way clutch as-

sembly (26) to stator (11).
8 Mounting bolt:
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
iv) Expand fit bushing (27).

fl Fix ball (28) with grease, then align the
position and install.
fl Be careful not to damage the contact
surface of the bushing.
HD785-5 30-59
(15)
ASSEMBLY OF PTO ASSEMBLY
1. Using push tool, press fit bearing (15) in case (16).

fl After assembling, drop approx. 6 cc of engine
oil on the bearing, and rotate the bearing sev-
eral times.
2. Assemble oil seal (14) and O-ring to oil cage (13),

then install to case (16).
8 O-ring: Grease (G2-LI)
8 Press fitting surface of oil seal:

Gasket sealant (LG-5)
8 Lip surface of oil seal: Grease (G2-LI)
3. Assembly of pump drive gear cage assembly

fl When assembling the bearing, check the
manufacturing No. of the inner race and outer
race, and the match marks (A and A, B and
B).
fl After assembling, drop approx. 6 cc of engine
oil on the bearing, and rotate the bearing sev-
eral times.
1) Using push tool, press fit outer race (11) and
(10) in cover (12).
2) Using push tool, press fit bearing (9) in gear
(7), then assemble in cover (12).
3) Assemble bearing (8), and tighten nuts (1)
temporarily.
8 Nut: Thread tightener (LT-2)
4) Assemble plate (6), and install snap ring (5).
4. Install pump drive gear cage assemblies (4), (3),

and (2) to case.
5. Using tool C3, tighten nuts (1).
3 Nut: 353.0 ± 39.2 Nm {36.0 ± 4.0 kgm}
HD785-5 30-63
(15)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iv) Assemble seal ring (25) to piston.

v) Assemble piston (3) in housing (4), then
install cylinder (2).
8 Mounting bolt:
3 Mounting bolt:
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
2) Using eyebolts, raise housing assembly (1),

align outside teeth of piston with inside teeth
of drum, and install housing assembly.
8 Mounting bolt:
3 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
HD785-5 30-83
(15)
ASSEMBLY OF TRANSMISSION
ASSEMBLY
1. Output shaft assembly

1) Press fit bearing (65) in cage (60).
2) Fit seal ring and install plate (66).
8 Mounting bolt:
3 Mounting bolt:
58.8 – 73.6 Nm {6.0 – 7.5 kgm}
fl Align the seal ring with the outside of the
plate, and center the outside circumfer-
ence, then fix with grease.
3) Assemble output shaft assembly as follows.

i) Press fit bearing (67) to output shaft (64).
ii) Install bearing (68) to cage (63).

iii) Install oil seal (69) to cage (63).
8 Lip surface of oil seal:

Grease (G2-LI)
iv) Set output shaft (64) on press, then push

inner race of bearing, and install cage (63).
HD785-5 30-85
(15)
v) Install collar (62) to output shaft (64).

vi) Install worm (61) to output shaft (64).
4) Fit O-ring and install output shaft assembly

(59) to cage (60).
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2. No. 7 clutch ring gear

1) Turn over cage, and set on block.
2) Install ring gear (58) to cage.
3. Guide pin
Install guide pin (57).
30-86 HD785-5
(15)
14. No. 4 clutch sun gear, plate, spring

1) Fit seal ring and install sun gear (29), then in-
stall snap ring (28).
2) Fit spring (27) and install plate (26).
15. Tie bolts

Install tie bolts (25).
9 Tie bolt: For details,

98.1 – 122.6 Nm {10.0 – 12.5 kgm}
fl Push in the tie bolts by hand to the end face
of the tap hole.
fl Do not use an impact wrench until the bolt
has mated with the tap thread.
16. No. 3 clutch ring gear

Install ring gear (24).
9 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
17. No. 3 clutch drum

Install drum (20).
18. No. 3 clutch disc, plate, spring

Install disc (21), plate (22), and spring (23).
19. No. 3 clutch housing assembly

1) For details of assembling piston, see Item 6
of Assembly of No. 2 clutch assembly.
2) Push drum (20) up from No. 4 clutch plate.
3) Using eyebolts, raise housing assembly (19),
align outside teeth of piston with drum, then
install housing assembly.
8 Mounting bolt:
9 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
30-90 HD785-5
(15)
20. Checking operation of piston

Using tool D1, check operation of No. 4, 5, 6, and
7 clutch pistons.
fl Air pressure: 3 – 6 kg/cm2
fl Standard piston stroke
Piston No. Stroke (mm)

No. 4 4.2
No. 5 6.6
No. 6 6.8
No. 7 6.8
fl If the movement is not smooth, pour in en-

gine oil and check again.
21. Transmission case

1) Assemble the following parts to transmission
case.
i) Fit seal ring to outer groove of collar (18),
then align with dowel pin of transmission
case, and install.
8 Seal ring: Grease (G2-LI)

ii) Install cage (16).
iii) Install bearings (17) to both ends.
2) Install O-ring to transmission case end.
3) Secure eyebolts with nut, then raise and in-

stall transmission case (14).
22. No. 2 clutch assembly

Using eyebolts, install No. 2 clutch assembly (13).
HD785-5 30-91
(15)
3) Fit gasket, set mounting surface of oil pan (11)

horizontally, then raise transmission assem-
bly (10) and install.
8 Oil pan: Gasket sealant (LG-1)
26. Sleeve
1) Set transmission assembly (10) in position
with oil pan facing down.
2) Fit O-ring and install sleeve (9).
27. ECMV assembly

1) Fit O-ring and install ECMV assembly (7).
3 ECMV assembly mounting bolt:

27.5 – 34.3 Nm {2.8 – 3.5 kgm}
2) Install oil filter (8).
3) Install wiring.
4) Install cover (6).
HD785-5 30-93
(15)
DISASSEMBLY AND ASSEMBLY ECMV
ASSEMBLY OF ECMV ASSEMBLY
fl If the pressure valve has been disassembled or 3. Checking ECMV pressure

any parts have been replaced, always check the Check ECMV pressure.
hydraulic pressure. For details, see TESTING AND ADJUSTING
fl Clean all parts, and check for dirt or damage. Coat checking ECMV pressure.
the sliding surfaces of all parts with engine oil
before installing. 4. Adjusting ECMV pressure
• If the results of the check show that the
1. Pressure check valve ECMV pressure is not within the stan-
1) Assemble valve (14) in body (1). dard pressure, adjust the pressure with
fl Push with a finger from both ends of the shim (12).
body to check that the valve moves
smoothly. Amount of adjustment with 1 shim (thick-
2) Fit O-ring to solenoid valve (15) and install to ness: 0.2 mm): Approx. 0.19 kg/cm2
body.
fl To INCREASE pressure, INCREASE
9 Mounting bolt: shim thickness.
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm} To DECREASE pressure, DECREASE
3) Assemble piston (13) in valve (14). shim thickness.
fl Check that the piston moves smoothly. fl Install the shim securely, and be care-
4) Assemble shim (12) and spring (11) in valve ful not to drop it inside the valve.
(14), then fit O-ring and install to body. fl After adjusting the shim thickness,
• Standard number of shims: 3 check the pressure again.
• Standard shim thickness: 0.6 mm
(Thickness of each shim: 0.2 mm)
fl When using all of valve body (1), spring (11),
piston (13), valve (14), and solenoid valve (15)
again, assemble the same thickness of shim
as before disassembly. If any of the above
parts have been replaced, assemble the stan-
dard number of shims.
fl When replacing solenoid valve (15), remove
plate (2), and check that spring (11) is as-
sembled securely.
2. Flow detector valve

1) Assemble valve (5) in body.
fl Push with a finger from both ends of the
body to check that the valve moves
smoothly.
2) Assemble spring (6), then fit O-ring to body
and install fill switch (9), and bracket (10).
9 Mounting bolt:
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
3) Assemble spring (4), then fit O-ring to plug
(3) and install to body.
4) Install plate (2) to body.
9 Mounting bolt:
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
5) Install connectors (7) and (8) to bracket.
30-96 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL OF DIFFERENTIAL
ASSEMBLY
(For standard differential)
1. Drain oil.
= Final drive case, differential gear case :

194 ¬
2. Parking brake, spring cylinder

Remove parking brake spring cylinder.
3. Slack adjuster assembly

Remove slack adjuster assembly.
4. Disconnect hoses (1) and (2).
5. Remove bracket (3).

fl Loosen the U-bolt, and turn over the valve as-
sembly bracket on the cross member.
6. Remove cover (4).
7. Pull out shaft (5).

fl Fit eyebolts and pull out with bar.
8. Remove guard (6).
10. Disconnect drive shaft assembly (8). 1
0 Drive shaft assembly : 120 kg
11. Lift off differential assembly (9). 2

fl Fit a shackle to the mounting surface of the
differential, fit a lever block to the pinion end,
then raise and adjust the height while lifting
off.
fl Be careful not to damage the housing seal
surface.
0 Differential assembly : 1,250 kg
HD785-5 30-97
(15)
INSTALLATION OF
DIFFERENTIAL ASSEMBLY
moval.
8 Drive shaft mounting bolt:

9 Drive shaft mounting bolt:

156.9 – 196.1 Nm {16.0 – 20.0 kgm}
8 Differential assembly mounting bolt:

9 Differential assembly mounting bolt:

823.8 – 1029.7 Nm {84.0 – 105.0 kgm}

fl Add oil to the specified level, then check the
oil level again.
- Final drive case : 64 ¬ × 2
- Differential gear case : 130 ¬
30-98 HD785-5
2
• Disassembly of pinion, cage assembly

1) Remove cage (13) together with bearing in-
ner (14) from pinion gear (15).
2) Remove spacer (16), then remove bearing in-
ner (17).
3) Remove holder (18), then remove center bear-

ing inner race (19) from pinion gear (15).
4) Remove bearing outer races (20) and (21) from
cage (13).
fl The bearing is an adjustment-free bear-
ing, so check the matching numbers, and
keep as a set in a safe place.
7. Differential gear assembly

1) Remove lock (22).
2) Using tool H4, loosen left and right side bear-
ing adjustment nuts (23) until they can be
turned by hand.
3) Loosen mounting bolts (24), and remove cap

(25).
4) Lift off differential gear assembly (26).
5) Remove left and right side bearing adjustment
nuts (23).
30-100 HD785-5
(15)
10) Remove side gear (41).

11) Remove thrust washer (42).
12) Remove bevel gear (44) from case (43).

13) Remove bearing (45) from case.
8. Bearing
Remove snap ring (46), then remove bearing (47)
from differential case (48).
30-102 HD785-5
(15)
ASSEMBLY OF DIFFERENTIAL
ASSEMLY
1. Bearing
1) Set differential case in tool H1.
2) Using push tool, press fit bearing (47) in dif-
ferential case (48), then install snap ring (46).
2. Pinion cage assembly

• Assembly of pinion cage assembly
1) Using push tool, press fit outer races (20) and
(21) in cage (13).
fl Check that there is no clearance between
the outer races and the cage.
2) Press fit center bearing inner race (19) in pin-

ion gear (15), then install holder (18).
fl Shrinkage fit: Heat to 100°C
8 Mounting bolt:
3 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
3) Press fit bearing inner race (17), and install

spacer (16).
the end face of the pinion gear and the
inner race.
HD785-5 30-103
(15)
4) Set cage (13) to pinion gear (15), and install

bearing (14).
5) Coat bearing rollers and tread surface of in-
side and outside races well with engine oil
(SAE30).
• Installation of pinion, cage assembly

Fit O-ring, and assemble shim, then install
pinion and cage assembly (12) to differential
case.
fl Assemble the same number and thickness
of shims that was removed during disas-
sembly.
3 Mounting bolt: For details,

490.4 – 608.0 Nm {50.0 – 62.0 kgm}
3. Support
1) Install oil seal (49) and O-ring to support (11).
4. Coupling
Install coupling (10), then install O-ring and holder
(9), and tighten mounting bolt (8).
fl When doing this, rotate the bearing 20 – 30
times and tighten bolt (8) gradually.
fl If bolt (8) is tightened without rotating the
bearing, the bearing may be damaged.
8 Mounting bolt:
3 Mounting bolt:
1961.4 – 2451.8 Nm {200.0 – 250.0 kgm}
fl After tightening, rotate the bearing again 20
– 30 times to check that it rotates smoothly
and check that bolt (8) is tightened to the
specified torque.
30-104 HD785-5
(15)
5. Use one of the following methods to check that

the setting of the bearing is normal.
fl(1) Fit spring balance (2) in the tap hole of the
coupling, and measure the starting torque
in the tangential direction.
(Do this before installing the bevel gear end.)
Starting torque: Max. 5.1 kg
fl(2) Measure the end play of the bearing.
End play in axial direction: 0.01 – 0.17 mm
Method of measuring
i) Rotate bearing 20 – 30 times, set dial
gauge as shown in diagram, and align 0
mark.
ii) With coupling portion raised (lifting load:
approx. 300 kg), rotate coupling 20 – 30
times, and check that reading of dial
gauge is stable.
iii) Reading of dial gauge obtained in Step ii)
= end play in the axial direction.

• Assembly of differential gear assembly
1) Install bevel gear (44) in differential gear case
(43).
8 Mounting bolt:
3 Mounting bolt: For details,

921.9 – 1029.7 Nm {94.0 – 105.0 kgm}
2) Install side bearing (45).
the end face of the case and the bearing.
3) Turn over case, then align with dowel pin and
install thrust washer (42).
fl Check that the head of the dowel pin is
0.5␣ +0.2
␣ ␣ 0␣ ␣ ␣ ␣ mm lower than the surface of the
washer.
4) Install side gear (41).
HD785-5 30-105
(15)
5) Pinion gear
ing, so check the matching numbers of the
bearing, collar, and outer race, and keep
as a set in a safe place.
i) Using push tool, press fit outer races (40)
and (39) in pinion gear.
ii) Using push tool, press fit bearing (38) to
shaft (35).
iii) Set pinion gear to shaft, then assemble

collar (37), and using push tool, install
bearing (36).
iv) Hold pinion gear assembly (32) with press,
and using tool H5, tighten ring nut (34).
8 Ring nut: Thread tightener (LT-2)
3 Ring nut:
578.6 – 745.3 Nm {59.0 – 76.0 kgm}
6) Assemble pinion gear assembly (32) to cross

shaft (33), then raise and install to case.
fl Align the notched portion of the pinion
gear shaft with the dowel pin of the case,
and install.
fl Move the pinion gear, and check that the
gear assembly rotates easily.
7) Install side gear (31).
8) Align with dowel pin, and install thrust washer

(30).
0.5 +0.2
␣ 0␣ ␣ ␣ ␣ mm lower than the surface of the
washer.
30-106 HD785-5
(15)
10) Fit case (32) and tighten mounting bolts (31).
8 Mounting bolt:
3 Mounting bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
• Installation of differential assembly

1) Tighten side bearing adjustment nuts (23)
temporarily, and place differential gear case
assembly (26) temporarily.
2) Fit cap (25) and tighten mounting bolts (24).
8 Mounting bolt:
3 Mounting bolt:
1520.0 – 1912.3 Nm {155.0 – 195.0 kgm}
fl Align the match mark of the cap.
fl Rotate the bevel gear 20 – 30 turns to settle
the bearing, then tighten.
3) Adjusting preload of bearing
i) Install measurement adapters H2 to both
ends of cap (23).
ii) Measure dimension between adapters
with depth micrometer H3.
fl When measuring, hold the microme-
ter securely with one hand, and put
the probe in contact parallel to the
measurement adapter.
iii) Add 0.4 ± 0.15 mm to measured dimen-
sion, and set scale of micrometer.
fl The added dimension becomes the
amount of deflection of the case be-
tween before giving preload and af-
ter giving preload.
4) Tighten adjustment nuts (23) from both ends,
and continue to tighten with tool H4, paying
careful attention to the groove that the lock
enters.
fl When doing this, to settle the bearing
properly, rotate the bevel gear and tap the
bearing cap and bevel gear with a copper
hammer.
HD785-5 30-107
(15)
8. Lock
Install left and right locks (22).
9. Caliper assembly
1) Install disc plate (7).
8 Mounting bolt:
3 Mounting bolt:
490.4 – 608.0 Nm {50.0 – 62.0 kgm}
2) Fit plate (4) on one side temporarily.

3) Fit pad (5) and install caliper (6).
4) Fit plate on other side and tighten fully.
fl Make a clearance of 0.1 mm between the
plate and the caliper.
8 Mounting bolt:
3 Mounting bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
10. Parking brake chamber assembly

1) Install parking brake chamber (3), and con-
nect forked portion of rod and lever of slack
adjuster (1) with pin (2).
fl Pump air into the parking brake chamber
and retract the rod.
30-110 HD785-5
(15)
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
(With differential lock)
1. Bearing
1) Set differential case in tool H1.
2) Using push tool, press fit bearing (47) in dif-
ferential case (48), then install snap ring (46).
2. Pinion cage assembly

• Assembly of pinion cage assembly
1) Using push tool, press fit outer races (20) and
(21) in cage (13).
the outer races and the case.
2) Press fit center bearing inner race (19) in pin-

ion gear (15), then install holder (18).
8 Mounting bolt:
3 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
3) Press fit bearing inner race (17), and install

spacer (16).
the end face of the pinion gear and the
inner race.
HD785-5 30-119
(15)
4) Set cage (13) to pinion gear (15), and install

bearing (14).
5) Coat bearing rollers and tread surface of in-
side and outside races well with engine oil
(SAE30).
• Installation of pinion, cage assembly

Fit O-ring, and assemble shim, then install
pinion and cage assembly (12) to differential
case.
fl Assemble the same number and thickness
of shims that was removed during disas-
sembly.
9 Mounting bolt:
490.4 – 608.0 Nm {50.0 – 62.0 kgm}
3. Support
1) Install oil seal (49) and O-ring to support (11).
4. Coupling
Install coupling (10), then install O-ring and holder
(9), and tighten mounting bolt (8).
fl When doing this, rotate the bearing 20 – 30
times and tighten bolt (8) gradually.
fl If bolt (8) is tightened without rotating the
bearing, the bearing may be damaged.
8 Mounting bolt:
3 Mounting bolt:
1961.4 – 2451.8 Nm {200.0 – 250.0 kgm}
fl After tightening, rotate the bearing again 20
– 30 times to check that it rotates smoothly
and check that bolt (8) is tightened to the
specified torque.
30-120 HD785-5
(15)
5. Use one of the following methods to check that

the setting of the bearing is normal.
fl(1) Fit spring balance (2) in the tap hole (ø396)
of the coupling, and measure the starting
torque in the tangential direction.
(Do this before installing the bevel gear end.)
Standard torque: Max. 5.1 kg
fl(2) Measure the end play of the bearing.
End play in axial direction: 0.01 – 0.17 mm
Method of measuring
i) Rotate bearing 20 – 30 times, set dial
gauge as shown in diagram, and align 0
mark.
ii) With coupling portion raised (lifting load:
approx. 300 kg), rotate coupling 20 – 30
times, and check that reading of dial
gauge is stable.
iii) Reading of dial gauge obtained in Step ii)
= end play in the axial direction.

• Assembly of differential gear assembly
1) Install bevel gear (44) in differential gear case
(43).
8 Mounting bolt:
3 Mounting bolt:
921.9 – 1029.7 Nm {94.0 – 105.0 kgm}
HD785-5 30-121
(15)
3) Pinion gear
ing, so check the matching numbers of the
bearing, collar, and outer race.
i) Using push tool, press fit outer races (40)
and (39) in pinion gear.
ii) Using push tool, press fit bearing (38) to
shaft (35).
iii) Set pinion gear to shaft, then assemble

collar (37), and using push tool, install
collar (37) and bearing (36).
iv) Hold pinion gear assembly (32) with press,
and using tool H5, tighten ring nut (34).
8 Ring nut: Thread tightener (LT-2)
9 Mounting bolt:
578.6 – 745.3 Nm {59.0 – 76.0 kgm}
4) Assemble pinion gear assembly (32) together

with cross shaft (33).
• Align groove of washer (64) with dowel
pin (65) of case, and install.
fl If the groove of the washer is not fit-
ted completely on the dowel pin, the
cross shaft will not fit properly, and
the pinion gear will not rotate
smoothly. Check these two points
carefully.
5) Install washer (41) to case (43).

0.5 +0.2
␣ 0␣ ␣ ␣ mm lower than the surface of the
washer.
6) Install differential side gear (42).
7) Case
i) Install case (43).
fl Align match mark on mating case (46),
and install.
ii) Tighten with bolts (63).
8 Mounting bolt:
9 Mounting bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
30-122 HD785-5
(15)
8) Differential side gear, gear

i) Turn over case, and set on block (height:
approx. 200 mm).
ii) Install differential side gear (31).
iii) Install gear (62).
9) Pins, discs, plates, springs
i) Install 6 pins (60) to case (61).
ii) Assemble plates (57), discs (58), and
springs (59).
fl Coat the face of the discs and plates
with SAE30.
fl Assemble in the following order:
plate, disc, plate, disc, ..., plate.
10) Piston, seal

i) Install seal (68) to piston(35).
ii) Install seal (67) to case (29).
fl Be careful to install the seal facing in
the correct direction.
iii) Install piston (35) in case (29).
11) Case
i) Align with dowel pin (70), install washer
(30) to case (29).
fl Check that the head of the surface of
the dowel pin is 0.5 ␣+0.2
␣ 0␣ ␣ ␣ mm lower than
the surface of the washer.
ii) Align case (29) with position of pin (60),
and install.
iii) Tighten 18 bolts (28).
8 Mounting bolt:
3 Mounting bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
12) Seal, sleeve

i) Install 2 seals (69) to case (29).
ii) Install sleeve (54), taking care not to dam-
age seals (69).
fl Use a block of thickness 10 – 15 mm
to support the sleeve.
13) Bearing
Shrink fit bearing (27) to case (29).
Shrink fitting temperature: 100°C for approx.
30 minutes
the end face of the case and bearing.
HD785-5 30-123
(15)
7. Installation of differential assembly

1) Tighten side bearing adjustment nuts (23)
temporarily, and place differential gear case
assembly (26) temporarily.
2) Fit cap (25) and tighten mounting bolts (24).
fl When installing cap (25), align position of

drill hole in cap (25) with pin (71) mounted
to sleeve (54), and install.
fl Coat outside circumference of pin with liq-
uid adhesive LG-5.
8 Mounting bolt:
3 Mounting bolt:
1520.1 – 1912.4 Nm {155.0 – 195.0 kgm}
fl Align the match mark of the cap.
fl Rotate the bevel gear 20 – 30 turns to settle
the bearing, then tighten.
3) Adjusting preload of bearing

i) Install measurement adapters H2 to both
ends of cap (23).
ii) Measure dimension between adapters
with depth micrometer H3.
fl When measuring, hold the microme-
ter securely with one hand, and put
the probe in contact parallel to the
measurement adapter.
iii) Add 0.4 ± 0.15 mm to measured dimen-
sion, and set scale of micrometer.
fl The added dimension becomes he
amount of deflection of the case be-
tween before giving preload and af-
ter giving preload.
30-124 HD785-5
(15)
4) Tighten adjustment nuts (23) from both ends,

and continue to tighten with tool H4, paying
careful attention to the groove that the lock
enters.
fl When doing this, to settle the bearing
properly, rotate the bevel gear and tap the
bearing cap and bevel gear with a copper
hammer.
fl Precautions when adjusting preload

If the increase in deflection caused by
overtightening of the adjustment nut ex-
ceeds the standard amount, return the
adjustment nuts to the condition before
adjusting. When doing this, rotate the
bevel gear and tap the bearing cap and
bevel gear with a plastic hammer, check
that there is no clearance at portion (b),
and adjust again.
8. Adjusting tooth contact, backlash

Adjust backlash and tooth contact at the same
time.
1) Adjust backlash as follows.
i) Move bevel gear with adjustment nut (23).
When adjusting the bevel gear, do not
change the preload of the bearing. Always
turn the adjustment nuts at both ends the
same amount in the same direction.
ii) Put a dial gauge at right angles in contact
with the reverse face of the tooth at the
outside of the bevel gear. Turn the adjust-
ment nut and adjust the backlash.
fl Backlash: 0.41 – 0.56 mm
fl Adjust at 3 – 4 places. Keep the pinion
gear locked when measuring.
2) Adjust tooth contact as follows.
i) Adjust the in and out movement of the
bevel pinion by changing the shims be-
tween the differential case and bearing
cage.
ii) Adjust tooth contact
For details, see 3) Adjusting tooth contact.
HD785-5 30-125
(15)
9. Lock
Install left and right locks (22).
10. Differential lock piping

Install differential piping (53).
fl Blow in air, and check action of piston.
Air pressure: 4 – 8 kg/cm2
11. Caliper assembly

1) Install disc plate (7).
8 Mounting bolt:
9 Mounting bolt:
490.4 – 608.0 Nm {50.0 – 62.0 kgm}
2) Fit plate (4) on one side temporarily.

3) Fit pad (5) and install caliper (6).
4) Fit plate on other side and tighten fully.
fl Make a clearance of 0.1 mm between the
plate and the caliper.
8 Mounting bolt:
3 Mounting bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
5) Fit springs (51) and brackets (52).
HD785-5 30-127
(15)
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL OF FRONT WHEEL

ASSEMBLY
blocks on both sides of the rear wheels.
¤ Put a hydraulic jack (294 kN {30 ton}) under the
suspension cylinder, and jack up the front wheel
assembly.
1. Remove 16 wheel clamp nuts (1). 1
2. Remove front wheel assembly (2). 2
0 Front wheel assembly: 1,850 kg

fl Use a forklift truck (5 ton) to remove front
wheel assembly.
fl When removing, be careful not to damage the
air valve of the inside wheel assembly.
¤ After removing the wheel assembly, stand it in
a safe place and use blocks to prevent it from
falling over.
INSTALLATION OF FRONT
WHEEL ASSEMBLY
fl If any stud bolt is broken, replace all of the stud
bolts.
fl When the tire is removed and installed, if any stud
bolt is loosened, be sure to remove it and then
tighten it again.
2 Stud bolt: Adhesive (LT-2)
3 Tightening torque of stud bolt: Min. 439
Nm {44.8 kgm}, Target: 588 Nm {60 kgm}
moval.
1
fl Follow the order (1 to 8) for tightening the
wheel clamp nuts and install uniformly.
fl Tighten fully after lowering the machine to the
ground. 2
fl Align the notched groove of the wheel
9 Wheel clamp nut:
hub and the position of the air valve.
When coating thread with LM-G:
fl Be careful not to damage air valve.
1,520.1 – 1,912.4 Nm {155 – 195 kgm}
• Turn front wheel assembly, then check
When not coating thread with LM-G:
that runout is within 5 mm.
1,961.4 – 2,451.8 Nm {200 – 250 kgm}
• After installing front wheel assembly,
fl when the thread is coated with LM-G (molyb- run 5 – 6 km to settle each contacting
denum disulphide lubricant), the tightening parts.
torque is different, so check the torque value Then check that hub nuts are tightened
carefully before tightening. to the specified tightening torque.
HD785-5 30-129
(16)
DISASSEMBLY AND ASSEMBLY REAR WHEEL
REMOVAL OF REAR WHEEL

ASSEMBLY
blocks on both sides of the front wheels.
¤ Put a hydraulic jack [1] (490 kN {50 ton}) under
the rear axle, and jack up the rear wheel assem-
bly.
1. Remove air valve lock plate (1).
3. Remove wedge ring (3). 2
4. Remove outside wheel assembly (4). 3
0 Wheel assembly: 1,850 kg

fl Using a forklift truck (5 ton), remove the wheel
assembly together with the wedge ring (3).
fl Be careful not to break the air valve of the in-
side wheel assembly, then remove it.
¤ After removing the wheel assembly, stand

it in a safe place and use blocks to prevent it
from falling over.
5. Remove spacer (5).

fl Use a forklift truck (49 kN {5 ton}).
0 Spacer: 107 kg
7. Remove inside wheel assembly (7). 5
0 Wheel assembly: 1,850 kg
fl Use a forklift truck (49 kN {5 ton}).

fl Be careful not to break the air valve of the in-
side wheel assembly, then remove it.
¤ After removing the wheel assembly, stand it in

a safe place and use blocks to prevent it from
falling over.
30-130 HD785-5
(16)
DISASSEMBLY AND ASSEMBLY REAR WHEEL
INSTALLATION OF REAR
WHEEL ASSEMBLY
fl If any stud bolt is broken, replace all of the stud
bolts.
fl When the tire is removed and installed, if any stud
bolt is loosened, be sure to remove it and then
tighten it again.
2 Stud bolt: Adhesive (LT-2)
3 Tightening torque of stud bolt: Min. 439
Nm {44.8 kgm}, Target: 588 Nm {60 kgm}
moval.
14
fl Tighten wheel clamp nuts uniformly in the
correct order (1 to 13) of tightening.
fl Tighten fully after lowering the machine to the
ground.
3 Clamp nut:
When coating thread with LM-G:
1,520.1 – 1,912.4 Nm {155 – 195 kgm}
When not coating thread with LM-G:
1,961.4 – 2,451.8 Nm {200 – 250 kgm}
fl When the thread is coated with LM-G (mo-
lybdenum disulphide lubricant), the tighten-
ing torque is different, so check the torque
value carefully before tightening.
2
fl Install the wedge ring so that the protrusion
of the wedge ring from the cover surface is
uniform around the whole circumference of
the ring.
35
fl Align the notched groove in the wheel hub
with the wheel rim stopper.
fl When installing, be careful not to damage the
air valve.
• Rotate the wheel and check that the runout is

within 5 mm.
• After installing the rear wheel assembly, travel
approx. 5 – 6 km to settle all contacting portions,
then always check that the torque is the specified
tightening torque.
HD785-5 30-131
(16)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER
REMOVAL OF FRONT BRAKE

CALIPER ASSEMBLY
1. Front wheel assembly
fl Remove front wheel assembly.
For details, see REMOVAL OF FRONT WHEEL
ASSEMBLY.
2. Disconnect tube (1).

fl Disconnect 2 tubes on each side.
3. Remove caliper assemblies (2). 1

fl Leave 2 or 3 of the 16 mounting bolts in posi-
tion, then use a forklift truck or other equip-
ment as support, remove the remaining
mounting bolts, and remove caliper assem-
bly (2).
4 Caliper assembly (2): 75 kg
BRAKE CALIPER ASSEMBLY
moval.
8 Mounting bolt: Thread tightener (LT-2)
9 Mounting bolt:
926.8 ± 98.1 Nm {94.5 ± 10 kgm}
fl Bleed the air from the front brake.
Adjusting brake and bleeding air.
30-132 HD785-5
(16)
DISASSEMBLY OF FRONT
BRAKE CALIPER ASSEMBLY
1. Loosen pin fixing bolts (1) and (2), remove torque
pins (3), (4), and (5), then remove pads (6).
2. Remove plate (7), then remove plug (8), backup

ring (9), and seal (10).
3. Remove dust seal (11), then remove piston (12).
4. Remove ring (13) and backup ring (14).

fl Disassemble the other pistons in the same
way.
HD785-5 30-133
(13)
ASSEMBLY OF FRONT BRAKE

CALIPER ASSEMBLY
1. Install backup ring (13), seal (14), and dust seal
(11) in groove of torque plate (15) securely.
2. Install piston (12).

fl Fit the lip of the dust seal in the groove of the
piston.
3. Fit seal (10), backup ring (9), and plug (8), and
install plate (7).
4. Fit pads (6), and install torque pins (5), (4), and
(3), then tighten with pin fixing bolts (2) and (1).
8 Pin: Grease (G2-LI)
3 Pin fixing bolt:

51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
30-133-1 HD785-5
(13)
• Lock bolts (1) and (2) are different from the

normal bolts: the tip (portion a) cuts into the
surface of the pin. (Creates plastic deforma-
tion.)
fl When tightening, even when resistance
is felt, it is necessary to tighten further in
order to cut into the surface. For this rea-
son, if the tightening is less than the speci-
fied tightening torque, the bolt will not cut
in sufficiently and it will not hold in posi-
tion properly.
b : Cut-in point
c : Cut-in mark
fl While tightening the pin fixing bolt, move the
torque pin in the axial direction and check that
the bolt is fitted in the groove of the torque
pin.
fl Be sure to install short torque pin (5) of torque
pins (4) and (5) at the plate end.
fl Assemble the other pistons in the same way.
5. Install caliper assembly.

For details, see INSTALLATION OF FRONT CALI-
PER ASSEMBLY.
fl Install so that clearance d between disc (16)
and torque pin (3) is 1.5 – 3.0 mm.
HD785-5 30-133-2
(13)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER PAD
REMOVAL OF FRONT BRAKE

CALIPER PAD
1. Front wheel assembly
fl For details, see REMOVAL OF FRONT WHEEL
ASSEMBLY.
2. Pull out torque pin (1). 1

fl Loosen bolt (2), and pull torque pin (1) until
the pads can be removed.
3. Remove pads (3).

1) Install a vinyl hose to bleeder screw (4) so that
the brake oil can be drained out.
2) Loosen the bleeder screw, and return piston
(5) to the bottom of the cylinder with a bar.
BRAKE CALIPER PAD
moval.
9 Pin fixing bolt:

51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
fl For the precautions for installing the pin fix-
ing bolt, see ASSEMBLY OF FRONT BRAKE
CALIPER ASSEMBLY.
fl Bleed air from front brake circuit after seeing
“AIR BLEEDING FOR BRAKE CIRCUIT” of
TESTING AND ADJUSTING.
30-134 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB
WHEEL HUB ASSEMBLY
1. Front caliper assembly
For details, see REMOVAL OF FRONT CALIPER AS-
SEMBLY.
2. Cover
Remove cover (1).
3. Wheel hub assembly

1) Support wheel hub assembly (2) with forklift
truck.
2) Remove retainer (3).
fl Check the number and thickness of the
shims, and keep in a safe place.
3) Lever wheel hub assembly (2) lightly from

rear, and push out together with bearing (4).
4) Remove bearing (4), then remove wheel hub
assembly (2).
3 Wheel hub assembly: 700 kg
5) Disassemble wheel hub assembly as follows.

i) Remove mounting bolts, then remove
brake disc (5).
ii) Remove oil seal (6).
iii) Remove outer race (7).
iv) Remove outer race (8).
HD785-5 30-135
(15)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
DISASSEMBLY OF FINAL DRIVE

CARRIER ASSEMBLY
1. Remove 4 bolts (1) and 6 bolts (2), then remove
plate (3).
2. Using a press, pull out shaft (4).
3. Pull out pinion gear assembly (5), and remove 2

bearings (6) and spacer (7).
4. Remove outer race (8) and spacer (9).

fl The bearing is an adjustment-free bearing, so
5. Remove snap ring (10).
6. Remove spacer (11) from carrier.
ASSEMBLY OF FINAL DRIVE

CARRIER ASSEMBLY
1. Install spacer (11) to carrier.
2. Install snap ring (10).
3. Fit spacer (9), and press fit outer race (8).
4. Set spacer (7) and bearing (6) in position, then

raise pinion gear and assemble, and install bear-
ing (6) from top.
5. Push pinion gear assembly (5) into carrier.
6. Fit plate (3) with bolt (1) temporarily, then install

2 guide bolts to shaft (4), and press fit.
fl Expand fit the shaft, or press fit with a press.
7. Tighten bolts (2) to specified torque, and after

rotating pinion gear 5 – 6 turns, tighten 6 bolts (2)
and 4 bolts (1) to specified torque again.
3 Plate mounting bolt:

245.2 – 308.9 Nm {25.0 – 31.5 kgm}
2 Plate mounting bolt:

HD785-5 30-141
(15)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Rear wheel assembly
For details, see REMOVAL OF REAR WHEEL AS-
SEMBLY.
2. Carrier assembly
For details, see REMOVAL OF CARRIER ASSEM-
BLY.
3. Retainer, shim
1) Using tool J1, secure inner gear (1) and outer
gear (2).
fl To install the tool, remove bolt (3) from
the outer gear, and use the three tool
mounting tap holes in the inner gear.
fl To prevent damage to the floating seal,
always remove before removing retainer
(4).
2) Remove mounting bolts, then remove retainer
(4) and shim.
fl Check the number and thickness of the
shims, and keep in a safe place.
4. Ring gear assembly

1) Lift off ring gear assembly (5).
0 Ring gear assembly: 90 kg
2) Disassemble ring gear assembly as follows.

i) Remove mounting bolts (6), then remove
holder (7).
ii) Remove inner hub (9) from ring gear (8).
30-142 HD785-5
(15)
5. Rear wheel hub assembly

1) Sling wheel hub assembly (10) or support with
forklift, then remove nut (11).
2) Pull out wheel hub assembly (10) partly, re-

move bearing (12), then remove wheel assem-
bly.
fl The bearing comes out easily, so be ex-
tremely careful not to let it drop.
0 Rear wheel hub assembly: 2,000 kg
3) Remove outer races (13) and (14) from wheel

hub assembly (10).
6. Bearing
Remove bearing (15).
HD785-5 30-143
(15)
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Bearing
Install bearing (15).
2. Wheel hub assembly

1) Using push tool J2, press fit outer races (13)
and (14) in wheel hub (10).
2) Fit O-ring, then raise rear wheel hub assem-
bly (10), and set to inner gear.
3) Install bearing (12), and tighten nut (11).
8 Nut thread: Thread tightener (LT-2)
9 Nut:
490.4 – 608.0 Nm {50.0 ± 62.0 kgm}
Torques and Standard Values Table
fl Do not remove tool J1 until the retainer
has been completely secured.
3. Ring gear assembly

1) Assemble ring gear assembly as follows.
i) Set inner hub (9) to ring gear (8).
ii) Fit holder (7), and tighten mounting bolts
(6).
8 Bolt thread:
2) Raise ring gear assembly (5) and install.
30-144 HD785-5
(15)
4. Shim, retainer
1) Adjust preload of bearing as follows.
i) With no shim assembled, install retainer
(4) temporarily with 3 bolts.
ii) Remove tool J1 from 3 places, and tighten
nuts.
iii) Rotate wheel hub 5 – 6 times and tighten
3 bolts uniformly to a tightening torque.
9 Mounting bolt:
122.6 – 132.4 Nm {12.5 – 13.5 kgm} 
 Serial No.: HD785-5: 4001 – 4209 
 
 HD985-5: 1021 – 1051
147 ± 4.9 Nm {15 ± 0.5 kgm} 
 Serial No.: HD785-5: 4210 and up 
 
 HD985-5: 1052 and up
fl If the bolts are tightened without ro-
tating the wheel hub, the bearing will
not settle, and the correct preload can-
not be given.
iv) Using depth micrometer 1, measure di-
mension c between end face of shaft and
retainer.
fl Measure at two places and take the
average.
v) Remove retainer, and measure thickness
a of retainer. Select a shim thickness (b =
c – a) + 0.3 mm.
fl Set the shim thickness at intervals of
0.05 mm and round up fractions.
2) Insert shim, then fit retainer (4) and tighten
mounting bolts.
fl Rotate the wheel hub 5 – 6 times and
tighten the bolts uniformly until the tight-
ening torque is constant.
8 Bolt thread:
3 Bolt:
823.8 – 1029.7 Nm {84.0 – 105.0 kgm}
fl After tightening the bolts, rotate the wheel
hub, and check that there is no abnormal-
ity in rotation.
5. Carrier assembly
For details, see INSTALLATION OF CARRIER AS-
SEMBLY.
6. Rear wheel assembly

For details, see INSTALLATION OF REAR WHEEL
ASSEMBLY.
HD785-5 30-145
(15)
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER
REMOVAL OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
1. Disassemble front wheel hub assembly.
For details, see DISASSEMBLY OF FRON WHEEL
HUB ASSEMBLY.
2. Loosen valve (1).

Loosen the valve and release the nitrogen gas.
fl After releasing the nitrogen gas, tighten the
valve.
3. Disconnect brake hoses (2). 2
4. Disconnect grease tubes (3).
5. Remove elbow (4).
6. Pull out pins (5) and (6).
7. Remove tie rod (7) from lever.
8. Move lever and remove steering cylinder rod (8).
9. Remove bolt (9).

fl When removing the bolts marked , rotate
the knuckle arm approx. 40° towards the chas-
sis, then remove the bolts marked ␣ ␣ . When
doing this, return the knuckle arm to its origi-
nal position, then put a jack under the king
pin and jack up to remove.
10. Remove cylinder rod pin (10).

fl Sling suspension assembly using a forklift
truck.
11. Remove suspension cylinder assembly (11).

fl Disconnect the suspension assembly from the
knuckle arm.
0 Suspension assembly : 460 kg
SUSPENSION CYLINDER
ASSEMBLY
•Carry out installation in the reverse order to re-
moval.
1
9 Valve : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
¤ Before steering the machine for the first time

after installing the front suspension cylinder, be
sure to charge the suspension cylinder with ni-
trogen gas and adjust it. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
front suspension cylinder.
HD785-5 30-153
(15)
SUSPENSION CYLINDER
ASSEMBLY (STANDARD
CYLINDER)
• Using a block, stand the cylinder assembly up-
right.
1. Cover
Remove cover.
2. Intake valve, oil level valve

Remove intake valve (1) and oil level valve (2).
3. Cylinder rod assembly

1) Remove flange mounting bolts (3) and air
bleed plug (4).
2) Raise cylinder rod assembly (5) with plate (6),
retainer (7) and flange (8) still installed.
fl Raise to position where cylinder rod as-
sembly contacts step of stopper (9).
3) Install tool Q1 to cylinder.
4) Raise cylinder assembly until it rises approx.
50 mm from floor, then hit from top of tool
Q1 with a plastic hammer so that stopper
passes from step in cylinder.
5) Remove tool Q1, then remove cylinder rod
assembly.
4. Flange
1) Remove plate (6), retainer (7), flange (8), and
stopper (9) from rod assembly (5).
2) Remove dust seal (10) and bushing (11) from
retainer (7).
3) Remove packing (12) and bushing (13) from
flange (8).
5. Wear ring
Remove wear ring (14) from cylinder rod (5).
30-154 HD785-5
(13)
ASSEMBLY OF FRONT
SUSPENSION CYLINDER
ASSEMBLY (STANDARD
CYLINDER)
1. Wear ring
Install wear ring (14) to cylinder rod (5).
2. Flange
1) Using tool Q2, press fit bushing (13) in flange
(8) and install U-packing (12).
2) Using a plastic hammer, press fit bushing (11)
to retainer (7) and install dust seal (10).
fl Be careful not to deform the bushing
when installing it.
fl Do not use a hydraulic press since it can
break the bushing.

1) Install stopper (9) to cylinder rod (5).
2) Install flange (8), retainer (7), and plate (6) to
cylinder rod.
3) Using block, stand cylinder upright.
fl Fill inside of cylinder with engine oil.
- Cylinder: Approx 19.5 ¬ (EO10-CD)
4) Raise cylinder rod assembly (5), and assemble

in cylinder.
fl When assembling the rod assembly in the
cylinder, if the rod assembly is inserted
too far, the oil will spurt out, so stop at a
position where the oil does not spurt out.
fl After installing the suspension com-
pletely, adjust the oil and gas levels. For
details, see TESTING AND ADJUSTING
OF SUSPENSION CYLINDER.
cylinder with bolts (3).
6) Install air bleed valve (4).
9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
4. Oil level valve, intake valve

Install oil level valve (2) and intake valve (1).
9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
5. Cover
Install cover.
HD785-5 30-155
(15)
SUSPENSION CYLINDER
ASSEMBLY (CYLINDER WITH
BUFFER RING)
• Using a block, stand the cylinder assembly up-
right.
1. Cover
Remove cover.
2. Intake valve, oil level valve

Remove intake valve (1) and oil level valve (2).

1) Remove flange mounting bolts (3) and air
bleed plug (4).
2) Raise cylinder rod assembly (5) with plate (6),
retainer (7) and flange (8) still installed.
fl Raise to position where cylinder rod as-
sembly contacts step of stopper (9).
3) Install tool Q1 to cylinder.
4) Raise cylinder assembly until it rises approx.
50 mm from floor, then hit from top of tool
Q1 with a plastic hammer so that stopper
passes from step in cylinder.
5) Remove tool Q1, then remove cylinder rod
assembly.
4. Flange
1) Remove plate (6), retainer (7), spacer (18),
flange (8), and stopper (9) from rod assembly
(5).
2) Remove dust seal (10) and bushing (11) from
retainer (7).
3) Remove packing (12), buffer ring (15) and
bushing (13) from flange (8).
5. Wear ring
Remove wear ring (14) from cylinder rod (5).
30-155-1 HD785-5
(13)
ASSEMBLY OF FRONT
SUSPENSION CYLINDER
BUFFER RING)
1. Wear ring
Install wear ring (14) to cylinder rod (5).
2. Flange
1) Using tool Q2, press fit bushing (13) to flange
(8), and then install U-packing (12) and buffer
ring (15).
¤ Buffer ring (15) is made of 2 parts. When
installing it, set the round corner of part
[2] (Black) inside part [1] (Blue).
2) Using a plastic hammer, press fit bushing (11)
to retainer (7) and install dust seal (10).
fl Be careful not to deform the bushing
when installing it.
fl Do not use a hydraulic press since it can
break the bushing.

1) Install stopper (9) to cylinder rod (5).
cylinder rod.
3) Using block, stand cylinder upright.
fl Fill inside of cylinder with engine oil.
- Cylinder: Approx 19.5 ¬ (EO10-CD)
4) Raise cylinder rod assembly (5), and assemble

in cylinder.
fl When assembling the rod assembly in the
cylinder, if the rod assembly is inserted
too far, the oil will spurt out, so stop at a
position where the oil does not spurt out.
fl After installing the suspension com-
pletely, adjust the oil and gas levels. For
details, see TESTING AND ADJUSTING
OF SUSPENSION CYLINDER.
HD785-5 30-155-2
(13)
5) Install flange (8), and spacer (18), retainer (7),

and plate (6) to cylinder with bolts (3).
9 Parts B and C in figure at right (COH12366)
: Gasket sealant (LG-6)
6) Install air bleed valve (4).
9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
4. Oil level valve, intake valve

Install oil level valve (2) and intake valve (1).
9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
5. Cover
Install cover.
30-155-3 HD785-5
(13)
DISASSEMBLY AND ASSEMBLY KING PIN
REMOVAL OF KING PIN

1. Front suspension assembly
Remove the front suspension cylinder assembly.
For details, see Removal of front suspension cyl-
inder assembly.
2. Straighten lock plates (1) and remove bolts (2) and

holder (3). 12
3. Remove knuckle arm (4) from arm (5).
0 Knuckle arm assembly: 200 kg
4. Remove bolt (6) and bearing (7). 3
INSTALLATION OF KING PIN

moval.
1
8 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
25 – 31.5 kgm (Target: 28.5 kgm)
fl Apply adhesive (LT-2) to bolts (2). Install the
lock plates and tighten the bolts to the speci-
fied torque. At this time, tighten the bolts in
order at least 3 times until they are tightened
to the specified torque evenly. Check the tight-
ening torque with a torque wrench, and then
bend the lock plates.
2
fl Bend each lock plate securely so that it will
be fitted to a side of the bolt head.
3
8 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
10 – 12.5 kgm (Target: 11.5 kgm)
HD785-5 30-155-4
(15)
DISASSEMBLY AND ASSEMBLY VARIABLE DAMPING SELECTOR VALVE
DISASSEMBLY OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY
¤ Release the nitrogen gas. 2) Disassemble retainer assembly.

Remove dust seal (10) from retainer (9),
then using push tool, remove bushing (11).
Adjusting suspension cylinder (releasing ni-
3) Remove flange assembly (12).
trogen gas from suspension cylinder).
4) Disassemble flange assembly.
• Remove the air cylinder assembly. Remove U-packing (14), O-ring (15), and
ring (16) from flange (13).
5) Remove shaft assembly (17).
2. Remove lever (2), then remove key (3). 6) Disassemble shaft assembly.
Using push tool, remove bearing (19) from
shaft (18).
4. Remove tube (5).
7. Remove orifice plate assembly (20) from valve
¤ The oil inside the cylinder will come out body (7).
from the tube, so prepare a container to
catch it. 8. Disassemble orifice plate assembly.
1) Remove bolt (21), then remove plates (22),
= Front suspension cylinder: (23), (24), (25), and (26).
2) Remove pin (27) from plate (25).
17 ¬ (each)
9. Remove tube assembly (28).
5. Remove valve body assembly (6).
10. Disassemble tube assembly.
6. Disassemble valve body assembly. Remove O-ring (30), ring (31), and O-ring (30)
1) Remove retainer assembly (8) from valva from tube (29).
body (7).
30-156 HD785-5
(13)
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER
DISASSEMBLY OF REAR
SUSPENSION CYLINDER
ASSEMBLY (STANDARD
CYLINDER)
1. Cover
Hanging the cylinder assembly, loosen band (1)
and remove the button, then remove cover (2).
2. Intake valve and oil level valve

1) Remove the protector, then remove intake
valve (4).
2) Drain oil from the cylinder.

Place the cylinder assembly on its end, upside
down.
1) Remove flange mounting bolt (5), then re-
move plate (6).
2) Slowly hang cylinder rod assembly (7) with a
crane to remove it from cylinder (10), without
removing retainer (8) and flange (9).
4. Flange
1) Remove retainer (8) and flange (9) from rod
assembly (7).
2) Remove U-packing (11), backup ring, and O-
ring (12) from flange (9).
3) Remove the bushing from flange (9).
4) Remove seal (13) and bushing from retainer
(8).
5. Wear ring
Remove wear ring (14) from rod (15).
HD785-5 30-159
(13)
ASSEMBLY OF REAR
SUSPENSION CYLINDER
ASSEMBLY (STANDARD
CYLINDER)
1. Wear ring
Install wear ring (14) to rode (15).
2. Flange
1) Press fit bushing to retainer (8) with tool Q2.
2) Install U-packing and O-ring (12) to flange (9).
3) Install backup ring and O-ring (12) to flange
(9).
3. Retainer
2) Install seal (13) to retainer (8).

1) Erect cylinder (10) by using a block.
2) Hang cylinder rod assembly (7) and install it
to cylinder (10).
3) Install plate (6), retainer (8), and flange (9) to-
gether with mounting bolts (15).
3 Mounting bolt:
66.2 ± 7.4 Nm {6.8 ± 0.7 kgm}

Turn the cylinder assembly in reverse.
1) Hang cylinder (10) until dimension becomes
specified one.
2) Supply oil through oil level port with an oil
pump until bubbles do not come out from the
intake port any more.
3) After filling the oil, install intake valve (4) and
oil level (3).
3 Intake valve and oil level valve:

44.1 ± 5 Nm {4.5 ± 0.5 kgm}
6. Cover
1) Install cover (2) and tighten band (1).
2) Install the protector of the intake valve and
oil level valve.
30-160 HD785-5
(15)
DISASSEMBLY OF REAR
SUSPENSION CYLINDER
BUFFER RING)
1. Cover
Hanging the cylinder assembly, loosen band (1)
and remove the button, then remove cover (2).

1) Remove the protector, then remove intake
valve (4).
2) Drain oil from the cylinder.

Place the cylinder assembly on its end, upside
down.
1) Remove flange mounting bolt (5), then re-
move plate (6).
2) Slowly hang cylinder rod assembly (7) with a
crane to remove it from cylinder (10), without
removing retainer (8) and flange (9).
4. Flange
1) Remove retainer (8) and flange (9) from rod
assembly (7).
2) Remove U-packing (11), and buffer ring (16),
backup ring, and O-ring (12) from flange (9).
3) Remove the bushing from flange (9).
4) Remove seal (13) and bushing (17) from re-
tainer (8).
5. Wear ring
Remove wear ring (14) from rod (15).
HD785-5 30-160-1
(13)
ASSEMBLY OF REAR
SUSPENSION CYLINDER
BUFFER RING)
1. Wear ring
Install wear ring (14) to rode (15).
2. Flange
1) Press fit bushing to flange (9), bushing (17)
with tool Q2.
2) Install U-packing (11) and buffer ring (16) to
flange (9).
¤ Buffer ring (16) is made of 2 parts. When
installing it, set the round corner of part
[2] (Black) inside part [1] (Blue).
3) Install backup ring and O-ring (12) to flange
(9).
3. Retainer
2) Install seal (13) to retainer (8).

1) Erect cylinder (10) by using a block.
2) Hang cylinder rod assembly (7) and install it
to cylinder (10).
3) Install plate (6), retainer (8), and flange (9) to-
gether with mounting bolts (15).
3 Mounting bolt:
66.2 ± 7.4 Nm {6.8 ± 0.7 kgm}

Turn the cylinder assembly in reverse.
1) Hang cylinder (10) until dimension becomes
specified one.
2) Supply oil through oil level port with an oil
pump until bubbles do not come out from the
intake port any more.
3) After filling the oil, install intake valve (4) and
oil level (3).
3 Intake valve and oil level valve:

44.1 ± 5 Nm {4.5 ± 0.5 kgm}
6. Cover
1) Install cover (2) and tighten band (1).
2) Install the protector of the intake valve and
oil level valve.
30-160-2 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY REAR BRAKE CHAMBER
2) Turn over body, assemble packing (18), seat

(17), and packing (16) and insert ring (15), then
secure with snap ring (14).
fl Assemble so that the seal lip is facing the
outside.
fl Check that the snap ring is fitted securely
in the groove.
8 Packing : Engine oil
3. Piston assembly
Insert air cylinder (22) in piston assembly (25).
fl Coat the inside circumference of the air cylin-
der well with grease.
fl When inserting the piston, insert it at an angle
of approx. 30°. When it is inserted about 1/3,
set the air cylinder on its side and push in fully.
fl Check that the piston assembly moves
smoothly.
4. Body assembly
Insert spring (23) in mounting portion of air cyl-
inder, assemble O-ring (31) to body assem-
bly (13), then install to air cylinder.
fl Push the body by hand and tighten the mount-
ing bolts on opposite sides in turn to install.
9 Mounting bolt :
43.12 ± 5.88 Nm {4.4 ± 0.6 kgm}
5. Assembly of piston
1) Insert valve (10), spring (9), and seat (8) in pis-
ton (11), and secure with snap ring (7).
fl Be careful to insert the spring facing in
the correct direction.
fl Check that the snap ring is fitted securely
in the groove.
30-178 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CHAMBER
ASSEMBLY OF FRONT BRAKE CHAMBER ASSEMBLY
• Precautions when assembling

1) Coat the outside diameter of air piston rod
(4), the cup groove, cup (14) and air cylinder
(9), and the inside diameter (sliding part) with
a suitable amount of lithium grease.
2) Coat the outside diameter of oil piston (7), the
cup groove, cup (10), the inside diameter of
oil cylinder (2), and the inside diameter (cup
groove) of cover (14), and 2 cups (18) with a
suitable amount of brake oil.
1. Cover assembly
1) Install plug (23).
8 Plug: Adhesive (LT-2A)
9 Plug: 19.6 ± 2.0 Nm {2.0 ± 0.2 kgm}
2) Install filter (21) and ring (22).
3) Assemble bushing (20), secondary cup (18),
spacer (19), secondary cup, cup supporter
(17), stop ring (16) in order.
30-182 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CHAMBER
2. Air cylinder assembly

1) Assemble packing (15) to piston and rod com-
plete (3).
2) Assemble spring (13), piston and rod com-
plete assembly (3), O-ring, and air cylinder (9)
to cover assembly (14), then tighten bolts (12).
fl Using 2 – 3 fully threaded bolts 1 with a
length below the head of approx. 150 mm,
compress spring (13) uniformly and screw
in.
8 Mounting bolt:
9 Mounting bolt:
65.7 ± 7.4 Nm {6.7 ± 0.75 kgm}
3. Oil piston assembly

1) Supply compressed air at 0.1 – 0.2 MPa {1 – 2
kg/cm2 } to air cylinder, and extend rod (4) of
piston and rod complate (3) fully.
2) Assemble backup ring (11) and seal (10) to
oil-piston (7).
3) After moving ring (5) towards air chamber

end, secure bushing guide (8) and oil piston
(7) to oil piston with mounting pin (6), then
install ring (5) to ring groove.
4) Exhaust compressed air from air cylinder.
4. Oil cylinder
Install oil cylinder (2) with bolts (1).
9 Mounting bolt:
37.8 ± 3.4 Nm {3.85 ± 0.35 kgm}
5. Checking
1) Bleed air from oil cylinder.
2) Check that at least 17.6 MPa {180 kg/cm2} of
oil pressure is generated in the oil cylinder
when 0.8 MPa {8 kg/cm2} of air pressure is
applied to air cylinder.
3) Check that there is no leakage of air or oil.
HD785-5 30-183
(15)
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
¤ Stop the machine on level ground and put blocks
under the wheels.
pin.
¤ Open the drain valve of the rear air tank and re-
lease the pressure inside the tank.
1. Disconnect hose (1) coming from brake chamber.
2. Disconnect hose (2) going to left and right rear

brakes.
3. Remove slack adjuster assembly (3).
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY
moval.
fl Bleed the air from the brake circuit.
Bleeding air from brake circuit.
30-184 HD785-5
2
DISASSEMBLY AND ASSEMBLY AIR DRIER (DESICCANT TYPE)
REMOVAL AND INSTALLATION

OF AIR DRIER (DESICCANT TYPE)
(IF EQUIPPED)
¤ Stop the engine, apply the parking brake, and

put chocks under the tires.
REMOVAL
1. Open the drain valve of the air tank to release the
air in the brake piping.
2. Remove the thermostat wiring of air drier (5) from

rear of the operator’s cab.
3. Remove air hoses (1) – (4).
4. Remove air drier (5).
fl Remove the air drier on the right side similarly.
INSTALLATION
moval.
30-185-1 HD785-5
(16)
DISASSEMBLY AND ASSEMBLY

OF AIR DRIER (DESICCANT TYPE)
(IF EQUIPPED)
fl When disassembling the air drier, prepare the fol-

lowing repair kit for replacement.
Repair kit
234-44-42150
No. Part name Q’ty
3 O-ring 1
4 O-ring 1
6 O-ring 1
7 Valve 1
11 O-ring 1
14 Oil filter 1
15 Gasket ring 1
16 Gasket ring 1
19 O-ring 1
21 Filter 2
22 Desiccant 1
24 O-ring 1
27 Check valve 1
30 O-ring 1
34 O-ring 1
fl Prepare NABCO Grease Pack, part No. 454-990-

30090 (about 10 g) in advance.
fl Prepare 3 M6 x 80 screws and a pair of tweezers.
HD785-5 30-185-2
(16)
Component parts of desiccant-type air drier

No. Part No. Part name Q’ty
234-44-42100 Air drier assembly
1 ✩ • Body 1
2–9 234-44-42110 • Valve body assembly (1)
2 ✩ • • Valve body 1
3 ✩ • • O-ring (kit) 1
4 ✩ • • O-ring (kit) 1
5 ✩ • • Piston 1
6 ✩ • • O-ring (kit) 1
7 ✩ • • Valve (kit) 1
8 ✩ • • Valve spring 1
9 ✩ • • Bolt and washer 1
10 ✩ • Exhaust body 1
11 ✩ • O-ring (kit) 1
12 ✩ • Retaining ring 1
13 – 29 234-44-42120 • Cartridge (1)
13 ✩ • • Case 1
14 ✩ • • Oil filter (kit) 1
15 ✩ • • Gasket ring (kit) 1
16 ✩ • • Gasket ring (kit) 1
17 ✩ • • Filter plate (1) 1
18 ✩ • • Bolt 1
19 ✩ • • O-ring (kit) 1
20 ✩ • • Spacer 1
21 ✩ • • Filter (kit) 2
22 ✩ • • Desiccant (kit) 1
23 ✩ • • Filter plate (2) 1
24 ✩ • • O-ring (kit) 1
25 ✩ • • Set spring 1
26 ✩ • • Case cover 1
27 ✩ • • Check valve (kit) 1
28 ✩ • • Bolt 6
29 ✩ • • Nut and washer 7
30 ✩ • O-ring (kit) 1
31 ✩ • Bolt and washer 4
32 ✩ • Purge chamber 1
33 ✩ • Plug 1
34 ✩ • O-ring (kit) 1
35 ✩ • Stopper ring 1
36 ✩ • Bolt and washer 2
37 ✩ • Stopper plate (1) 1
38 ✩ • Stopper plate (2) 1
39 – 43 234-44-42130 • Thermostat assembly (1)
39 ✩ • • Thermostat 1
40 ✩ • • Heater boot 2
41 ✩ • • Terminal 2
42 ✩ • • Terminal cover 1
43 ✩ • • Terminal 1
44 234-44-42140 • Heater 2
45 ✩ • Gasket 2
46 ✩ • Screw 2
47 ✩ • Cord clamp 1
48 ✩ • Rolling screw 1
49 ✩ • Bracket 2
50 ✩ • Bolt 2
51 ✩ • Nut and washer 2
52 ✩ • Terminal and cord 1
53 ✩ • Rolling screw 1
54 ✩ • Nut 1
234-44-42150 Repair kit containing 1 set of above parts
✩ : These parts are not supplied loose and do not
have Komatsu part Nos.
30-185-3 HD785-5
(16)
fl The No. in ( ) after each part name is the No. of

that part in the above component parts table.
DISASSEMBLY
• Disassembly of air drier cartridge
1. Disconnect ground wire (52) from bolt (50) of
bracket (49) and then loosen bolts (36) having 10-
mm width across flats to remove stopper plates
(37) and (38).
2. Remove stopper ring (35) from purge chamber

(32) with a flat-head screwdriver.
fl Insert a flat-head screwdriver [1] in the cut of
purge chamber (32) and hitch stopper ring
(35), and you can remove the stopper ring (35)
easily.
3. Pull body (1) out of purge chamber (32).
HD785-5 30-185-4
(16)
4. Remove 4 bolts (31) with a cross-head screwdriver

[2] and remove cartridge assembly (60) from body
(1).
5. Remove 3 of 6 nuts (29) alternately. (Use a 10-

mm spanner.)
6. Install 3 M6 x 80 bolts [3] to the holes from which

the bolts were removed.
¤ Spring (25) is compressed about 40 mm
when installed. Be sure to hold it tempo-
rarily with M6 full thread bolts having stems
of about 80 mm long and nuts. If you do not
hold it, it may shoot case cover (26) with its
spring force (approx. 725 N {74 kg}), and that
is dangerous.
7. Remove left 3 nuts (29).
8. Loosen the 3 nuts of bolts [3] gradually in order

until spring (25) expands fully, and then remove
cover (26) and spring (25).
30-185-5 HD785-5
(16)
9. Take out filter plate (23), filter (21), desiccant (22),

and filter (21) in order from above.
HD785-5 30-185-6
(16)
10. Put case (13) upside down and insert 12-mm

socket [4] in the head of bolt (18) at the center
and grip its knob with vise [5].
11. Remove nut and washer (29) from above case (13)
with a 10-mm ring wrench or socket wrench [6].
12. Remove filter plate (17), gasket ring (16) and (15),
oil filter assembly (14), spacer (20), and O-ring (19)
in order.
30-185-7 HD785-5
(16)
• Component parts of cartridge

From left of upper line: Case (13), desiccant (22), and
filter
From left of middle line: Case cover (26), set spring

(25), O-ring (24), and filter plate (23)
From left of lower line: Filter plate (17), gasket ring

(16), check valve (27), and oil filter assembly (14)
Upper line of right lower part: Spacer (20), gasket ring

(15), and O-ring
Middle line of right lower part: Nut and washer (29)
and bolt (18)
Lower line of right lower part: Nut, washer, and bolt
• Disassembly of body
1. Direct heater (44) installed to body (1) up, remove
retaining ring (12) with C-snap ring pliers (for hole)
[7], and remove exhaust body (10) and ring (11).
(See the sectional view.)
¤ When removing retaining ring (12), hold it
securely with C-snap ring pliers (for hole) so
that it will not jump out toward your face.
HD785-5 30-185-8
(16)
2. Hold the head of bolt (9) with pliers and pull out
valve body assembly (61).
3. Put a 10-mm hexagonal wrench in hexagonal hole

H of piston (5) in valve body assembly (61) to fix
the piston and loosen bolt (9) which is tightening
valve assembly (7).
¤ While holding valve assembly (7), loosen the
bolt (9) gradually. If you do not hold the valve
assembly (7), valve spring (8) may shoot it
toward your face with its spring force (Set
load: Approx. 49 N {5 kg}), and that is dan-
gerous.
4. Take piston (5), valve spring (8), and valve assem-

bly (7) out of valve body (2).
5. Remove O-rings (3), (4) and (6).
30-185-9 HD785-5
(16)
• Component parts of body

Left upper line: Retaining ring (12), exhaust body (10)
Left lower line: O-ring (11), valve body assembly (61)
Right: Body (1)
• Component parts of valve body assembly

Left upper line: Piston (5), valve spring (8), valve body
(2), valve assembly (7), bolt and washer (9)
Left lower line: O-rings (3), (4) and (6)
ASSEMBLY
fl Clean all the disassembled parts, except the rub-
ber parts and desiccant, with clear cleaning oil.
Wipe off sticking matter from them and dry them.
If a part has a flaw or it is worn, replace it with
new one.
fl When reusing the rubber parts, wipe them thor-
oughly with cloth.
fl Replace the desiccant with new one.
¤ If you touch the desiccant with the bare hand
or put it in your mouth, it will heat and burn
you. Never do it.
¤ • Be sure to use the regular desiccant.
• Do not use a desiccant other than the ones
we specify. (If you do so, the desiccant
may become powder and flow out. As a
result, the brake piping may be clogged
with desiccant and the brake may not work
normally, and that is dangerous.)
• Different types of desiccant are used for
different models, even if they are made by
the same manufacturer. Take care not to
mistake one for another.
HD785-5 30-185-10
(16)
• Assembly of cartridge
1. Put O-ring (19) in the groove of spacer (20) and
cover it with gasket ring (15).
2. While pressing spacer (20), O-ring (19), and gas-

ket ring (15) against the hollow part of oil filter
assembly (14), set filter plate (17) and gasket ring
(16) to the opposite side and insert bolt (18) from
the filter plate (17) side. (Install bolt (18) in next
step 3. Use it to position the other parts in this
step.)
fl When setting filter plate (17), direct its pro-
jected center side toward the oil filter (14).
30-185-11 HD785-5
(16)
3. Insert bolt (18) in the hole at the center of case

(13) and fix the assembly made in step 2 to the
opposite side with nut and washer (29).
3 Nut (29): 3.9 – 6.9 Nm {40 – 70 kgcm}
4. Push in filter (21) into the bottom of case (13) with

the softer side up, and then put desiccant (22) in
case (13).
fl The refill capacity of desiccant (22) is about
1.1 kg. Put all of 1 bag of the repair kit in des-
iccant (22).
¤ If the quantity of the supplied desiccant is
less than the specification, it may become
powder and flow out. As a result, the brake
piping may be clogged with desiccant and
the brake may not work normally. Accord-
ingly, be sure to supply the specified quan-
tity of the desiccant.
HD785-5 30-185-12
(16)
5. While turning case (13), hit its periphery lightly

with a plastic hammer to settle the desiccant.
6. Place the second filter (21) with the softer side

down.
7. Place filter plate (23) and tap the desiccant.

¤ If the desiccant is not tapped, it may become
powder and flow out. As a result, the brake
piping may be clogged with desiccant and
the brake may not work normally. Accord-
ingly, be sure to tap the desiccant according
to the following procedure.
• Method of tapping
1. Place 2 – 3 pieces of soft cloth [8] on a surface
which you will tap the case against so that
the bottom of the case will not be damaged
when you tap.
2. Holding filter plate (23) with both hands, raise
whole case (13) to a height of about 100 mm.
3. Tap whole case (13) lightly. Do not release
case (13) but lower your hands and case (13)
together.
4. Repeat steps 1 – 3 about 30 times. Stop tap-
ping after filter plate (23) lowers about 4 – 6
mm from the initial position.
30-185-13 HD785-5
(16)
8. Install O-ring (24) and check valve (27) to case

cover (26).
fl Apply grease to the projection at the center
of check valve (27) so that you can set check
valve (27) easily.
2 Projection at center of check valve (27):
Grease (NABCO Grease)
fl Part No. of NABCO Grease Pack:
454-990-30090 (Approx. 10 g)
9. Place set spring (25) on filter plate (containing the

desiccant) (23).
HD785-5 30-185-14
(16)
10. Place case cover (26) on the top, press it with

puller [9] from above, and fix them with bolts (28)
and nuts and washers (29).
9 Nut (29): 3.9 – 6.9 Nm {40 – 70 kgcm}
¤ When the above parts are set, the spring load
is about 725 N {74 kg}. Take care.
• Assembly of body
fl Replace O-rings (3), (4) and (6) with new one.
1. Coat O-ring (6) with grease and fit it to piston (5).
2 O-ring (6): Grease (NABCO Grease)
(Part No. of NABCO Grease Pack: 454-990-30090,
Weight of grease: Approx. 10 g)
2. Apply grease (see above) to the O-ring sliding part

of valve body (2) and guide of piston (5) and put
valve spring (8) in valve body (2).
3. While pushing in piston (5) having O-ring (6) from

the valve spring (8) side, fix valve assembly (7)
on the opposite side with bolt and washer (9).
9 Bolt (9): 3.9 – 6.9 Nm {40 – 70 kgcm}
30-185-15 HD785-5
(16)
4. Put valve body assembly (61), O-ring (11), and ex-

haust body (10) in body (1) in order, and then fit
retaining ring (12) to the groove of body (1).
fl When putting valve body assembly (61) in the
body (1), take care that O-ring (3) will not be
caught in the cut of the body.
• Assembly of body
1. Coat O-rings (34) and (30) with grease and fit them
to the grooves of body (1).
2 O-rings (34), (30): Grease (NABCO Grease)
HD785-5 30-185-16
(16)
2. Insert cartridge assembly (60) in the guide of body

(1).
3. Using with a cross-head screwdriver [2], tighten

bolts (31).
3 Bolt (31): 3.9 – 6.9 Nm {40 – 70 kgcm}
4. Push body (1) in purge chamber (32) and fit stop-

per ring (35) to the groove of purge chamber (32).
fl Pry stopper ring (35) into the groove by ap-
plying a flat-head screwdriver [1] outward.
5. Tighten stopper plates (37) and (38) with bolts and

washers (36).
30-185-17 HD785-5
(16)
6. Fix one end (the crimp terminal of the smaller

mounting hole) of terminal and code assembly
(52) with screw (53).
3 Screw (53): 2.0 – 3.9 Nm {20 – 40 kgcm}
7. Insert the other end of terminal and code assem-

bly (52) in the threaded part of bolt (50) of bracket
(49) and fix it.
3 Bolt (50): 4.9 – 8.8 Nm {50 – 90 kgcm}
• Inspection after installing to machine

1. Start the engine. After the air pressure reaches
the maximum level, check that air is discharged
from the exhaust port of the air drier when the
load state changes to the unload state.
Much air is discharged first. After about 3 sec-
onds, however, the discharge rate is so lowered
that you cannot hear the discharge sound.
2. After the air pressure lowers to the minimum level

and the unload state changes to the load state,
check the leakage through the exhaust port of the
air drier.
The leakage must not exceed 20 cc/min. (The di-
ameter of a soap water bubble must not exceed
15 mm in 6 seconds.)
3. Check each pipe joint for leakage.
4. Check that the thermostat and heater are wired

normally.
HD785-5 30-185-18
(16)
DISASSEMBLY AND ASSEMBLY BRAKE COOLING PUMP
REMOVAL OF BRAKE COOLING

PUMP ASSEMBLY
pin.
0 Cover : 90 kg
2. Disconnect suction tubes (2) and (3).
3. Disconnect hoses (4) and (5) going to left and right

rear brakes.
4. Remove mounting bolts, then remove brake cool-

ing pump assembly (6).
0 Brake cooling pump assembly : 55 kg
INSTALLATION OF BRAKE
COOLING PUMP ASSEMBLY
moval.

fl Add oil to the specified level, then check the
oil level again.
30-186 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY DEMAND VALVE
DISASSEMBLY AND ASSEMBLY OF DEMAND VALVE
DISASSEMBLY OF DEMAND VALVE ASSEMBLY OF DEMAND VALVE

ASSEMBLY ASSEMBLY
1. Remove cover (2) from demand valve assem- 1. Fit backup ring and O-ring and install relief
bly (1), then remove spring (3). valve assembly (12).
fl The spring is under an installed load of 35
kg, so remove slowly with a long bolt. 2. Fit backup ring and O-ring and assemble ori-
fice (11), then secure with plate (10).
2. Remove plate (4), screw in bolts into end face
thread of plug (5), and pull out seat, then re- 3. Assemble demand spool (9), then fit O-ring
move spring (6) and poppet (7). and tighten plug (8).
3. Remove plug (8), and pull out demand spool 4. Assemble poppet (7) and spring (6), then fit
(9). backup ring and O-ring and install plug (5),
then secure with plate (4).
4. Remove plate (10), screw in bolts into end face
thread of orifice (11), and remove orifice. 5. Assemble spring (3), then fit O-ring and install
cover (2).
5. Remove relief valve assembly (12).
30-204 HD785-5
(15)
DISASSEMBLY AND ASSEMBLY HOIST VALVE
DISASSEMBLY OF HOIST VALVE ASSEMBLY OF HOIST VALVE

ASSEMBLY ASSEMBLY
1. Remove main relief valve assembly (1). 1. Insert valve (38) and spring (37) in valve body
(39), then fit O-ring and assemble seat (36),
2. Loosen nut (2), and remove screw (3), then re- and install plate (35).
move retainer (4), spring (5), and poppet (6).
8 Mating surface of plate:
3. Loosen nut (7), and remove holder (8) and seat Adhesive (Loctite)
(9).
2. Press fit bearing (32), oil seal (30), and dust
seal (29) in case (33).
4. Remove snap ring (10), then remove retainer
(11), valve (12), and spring (13) from sleeve 8 Bearing, oil seal, dust seal:
(14).
Grease (G2-LI)
5. Remove tube (15). 3. Insert shaft (31), assemble key (27) and lever
(26), then align position of notch in spool (34)
6. Remove case (16), and bolts (17), then remove with lever (26), and secure with bolt (25).
detent (18), collar (19), retainer (20), spring (21),
4. Install plate (28) and cover (24).
and retainer (22).
8 Mating surface of plate and cover:
7. Remove valve control case assembly (23).
Adhesive (Loctite)
8. Remove cover (24), then loosen bolt (25), move 5. Insert spool (34), and install valve control case
lever (26), and remove key (27). assembly (23).
9. Remove plate (28), then remove dust seal (29), 8 Mating surface of case:
oil seal (30), shaft (31), and bearing (32) from Adhesive (Loctite)
case (33), and pull out spool (34).
6. Assemble retainer (22), spring (21), retainer
(20), collar (19), and detent (18), then tighten
10. Remove plate (35), and seat (36), then remove
bolts (17).
spring (37) and valve (38) from valve body (39).
9 Bolt: 14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}
7. Fit O-ring and install case (16).
8 Mating surface of case:

Adhesive (Loctite)
8. Install tube (15).
9. Assemble spring (13), valve (12), and retainer
(11) in sleeve (14), then fit snap ring (10) and
install seal (9), holder (8), and nut (7).
9 Nut:
107.9 ± 14.7 Nm {11.0 ± 1.5 kgm}
10. Install poppet (6), spring (5), retainer (4), screw
(3), and nut (2).
9 Nut: 19.6 ± 2.9 Nm {2.0 ± 0.3 kgm}

11. Install main relief valve assembly (1).
9 Main relief valve:

152.0 ± 24.5 Nm {15.5 ± 2.5 kgm}
HD785-5 30-209
(15)
40 MAINTENANCE STANDARD
Output shaft .................................................. 40- 2

Torque converter valve ................................ 40- 3
Torque converter .......................................... 40- 4
Transmission ................................................. 40- 6
ECMV
(Electronic Control Modulation Valve) ...... 40-11
Front axle ...................................................... 40-12
Front axle (with ABS/ASR)(If equipped) ... 40-13-1
Rear axle support (HD785-5) ....................... 40-14
Rear axle support (HD985-5) .................... 40-14-1
Differential .................................................... 40-15
Final drive (HD785-5) .................................... 40-17
Final drive (HD985-5) ................................. 40-17-3
Front brake .................................................... 40-18
Rear brake ..................................................... 40-19
Rear brake (with ABS/ASR)(If equipped) ... 40-20-1
Parking brake ................................................ 40-21
Steering linkage ............................................ 40-22
Front suspension cylinder ........................... 40-24
Rear suspension cylinder ............................ 40-25
Parking brake chamber ................................ 40-26
Slack adjuster ............................................... 40-27
Hydraulic pump (SAR-160)
(for torque converter and transmission)... 40-28
Hydraulic pump
(SAR4-180+180: for steering,
work equipment)
(SAR4-285+285: for brake cooling) ............ 40-29
Demand valve ............................................... 40-30
Cross-over relief valve ................................. 40-30
Hoist valve .................................................... 40-31
Steering cylinder .......................................... 40-32
Hoist cylinder ................................................ 40-33
HD785-5 40-1
B
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between torque size Shaft Hole clearance limit
1 converter spool and body
– 0.035 +0.016 0.035 –
32 0 0.061 0.067
– 0.045
Clearance between main – 0.035 +0.016 0.035 –

2 relief spool and body 32 0.067
– 0.045 0 0.061
Clearance between lockup – 0.035 +0.016 0.035 –

3 clutch spool and body 32 0.067
– 0.045 0 0.061
Standard size Repair limit
Free length Installed Installed Free length Installed

Main relief valve spring length load load Replace
4
1,210 N 1,090 N
118 94.5 {123.8 kg} 116.6 {111.4 kg}
Torque converter relief 295 N 266 N

5 valve spring 144.1 95 {30.1 kg} 142.4 {27.1 kg}
136 N 123 N
6 Lockup valve spring 108.1 89.7 {13.9 kg} 106.8 {12.5 kg}
Poppet spring (torque 34.3 N 31.4 N

7 converter relief, main relief) 26 17.6 {3.5 kg} 25.7 {3.2 kg}
20.6 N 18.6 N
8 Lockup valve poppet spring 30 16 {2.1 kg} 29.6 {1.9 kg}
HD785-5 40-3
(15)
MAINTENANCE STANDARD FRONT AXLE

Unit: mm
Standard size Tolerance Repair limit

1 Wear of sliding surface 0
of oil seal 330 Depth of wear: 0.1
– 0.140
Wear of outside part of 220 0 219.801

2 shaft to fit bearing – 0.029
Repair or
Wear of outside part of 180 0 179.830 replace
3 shaft to fit bearing – 0.025
Wear of inside part of 340 – 0.070 339.960

4 wheel hub to fit bearing – 0.127
Wear of inside part of 280 – 0.060 279.965

5 wheel hub to fit bearing – 0.112
HD785-5 40-13
B
MAINTENANCE STANDARD FINAL DRIVE
HD785-5 Serial No.: 4210 – 4253
Unit: mm
Standard backlash Repair limit

1 Backlash between planet
gear and sun gear 0.26 – 0.58 1.2
Replace
Backlash between planet
2 gear and ring gear 0.30 – 0.78 1.0
Repair limit: 1.5 TIR Repair or

3 Curvature of drive shaft replace

4 Thickness of spacer Replace
51 ± 0.1 49
5 Outside diameter of tube 320 +0.002 319.754

to fit bearing – 0.034
6 Outside diameter of tube 300 0.000 299.778

Repair or
replace
7 Inside diameter of wheel 480 – 0.045 479.955
hub to fit bearing – 0.108
8 Inside diameter of wheel 460 – 0.045 459.955

hub to fit bearing – 0.108
40-17-1 HD785-5
B
Unit: mm

Replace
Repair limit: 1.5 TIR Repair or

3 Curvature of drive shaft replace

51 ± 0.1 49
5 Outside diameter of tube 320 +0.002 319.754

Repair or
replace
6 Outside diameter of tube 300 0.000 299.778
HD785-5 40-17-2
B
Unit: mm

Replace
Repair or
3 Curvature of drive shaft Repair limit: 1.5 TIR replace
51 ± 0.1 49
Outside diameter of tube +0.002

5 320 – 0.034 319.754
to fit bearing
Outside diameter of tube 0.000

6 300 – 0.032 299.778
to fit bearing Repair or
replace
Inside diameter of wheel – 0.045
7 480 – 0.108 479.955
hub to fit bearing
Inside diameter of wheel – 0.045

8 460 – 0.108 459.955
hub to fit bearing
HD785-5 40-17-4
B
MAINTENANCE STANDARD REAR BRAKE
Unit: mm

Backlash between outer
1 gear and plate 0.21 – 0.64 2.2
Backlash between inner

2 gear and disc 0.21 – 0.64 2.2

3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6

Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit

6 Distortion of disc wear
surface Max. 0.45 0.7
Distortion of plate and Max. 0.50 0.7

7 damper wear surface
Assembly thickness of plate
8 and disc 123.9 115.0

Contact surface of retainer Repair or
9 oil seal 0 replace
ø 580 Depth of wear: 0.3
– 0.175
40-20 HD785-5
B
MAINTENANCE STANDARD REAR BRAKE
WITH ABS/ASR (IF EQUIPPED)

Unit: mm

Backlash between outer
1 gear and plate 0.21 – 0.64 2.2
Backlash between inner

2 gear and disc 0.21 – 0.64 2.2

3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6

Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit

6 Distortion of disc wear
surface Max. 0.45 0.7
Distortion of plate and Max. 0.50 0.7

7 damper wear surface
Assembly thickness of plate
8 and disc 123.9 115.0

Contact surface of retainer Repair or
9 oil seal 0 replace
ø 580 Depth of wear: 0.3
– 0.175
40-20-2 HD785-5
B
90 OTHERS
Electrical circuit diagram

Electrical circuit diagram for inside cab
(With mechanical governor) (1/3) ........................ 90- 3
(With electronic governor) (1/5) ........................... 90- 9
(With electronic governor) (2/5) ........................... 90-11
Electrical circuit diagram for outside cab (1/2) ... 90-19
Electrical circuit diagram for outside cab (2/2) ... 90-21
Electrical control system
Electrical circuit diagram ...................................... 90-23
Automatic shift control system
Electrical circuit diagram (1/2).............................. 90-25
Automatic suspension system
System circuit diagram (1/2) ................................ 90-29
System circuit diagram (2/2) ................................ 90-31
Payload meter (Printer type) (OP)
Payload meter II (Card type) (OP)
PMC system (OP)
ASR-II system (OP)
AIR circuit diagram ............................................... 90-43
Electrical circuit diagram
Engine control system ........................................ 90-201
Transmission control system
1. Electric govenor specification ...................... 90-203
2. Mechanical govenor specification ............... 90-205
4-4. Electrical circuit diagram .............................. 90-207
HD785-5 90-1
(13)
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (1/3)
HD785-5 90-3
(13)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (2/3)
HD785-5 90-5
(13)
ELECTRICAL CIRCUIT DIAGRAM a In case that local option is attached to the electrical circuit of the machine, spare fuse (in the fuse box FB1) of sutable capacity
should be used for safety.
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH MECHANICAL GOVERNOR) (3/3) a In this case, terminal of part number below should be provided.
Part number Part name
08021-00400 Terminal
HD785-5 90-7
(13)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (WITH ELECTRONIC GOVERNOR) (1/5)
HD785-5 90-9
(13)
HD785-5 90-11
(13)
HD785-5 90-13
(13)
HD785-5 90-15
(13)
HD785-5 90-17
(13)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/2)
HD785-5 90-19
(13)
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/2)
HD785-5 90-21
(13)
ELECTRICAL CONTROL SYSTEM
HD785-5 90-23
(13)
AUTOMATIC SHIFT CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM (1/2)
HD785-5 90-25
(13)
AUTOMATIC SHIFT CONTROL SYSTEM
HD785-5 90-27
(13)
AUTOMATIC SUSPENSION SYSTEM
SYSTEM CIRCUIT DIAGRAM (1/2)
HD785-5 90-29
(13)
AUTOMATIC SUSPENSION SYSTEM
SYSTEM CIRCUIT DIAGRAM (2/2)
HD785-5 90-31
(13)
PAYLOAD METER (PRINTER TYPE) (OP)
HD785-5 90-33
(13)
PAYLOAD METER II (CARD TYPE) (OP)
HD785-5 90-35
(13)
PMC SYSTEM (OP)
HD785-5 90-37
(13)
PMC SYSTEM (OP)
HD785-5 90-39
(13)
ASR-II SYSTEM (OP)
HD785-5 90-41
(13)
ASR-II SYSTEM (OP)
AIR CIRCUIT DIAGRAM
HD785-5 90-43
(13)
ENGINE CONTROL SYSTEM
HD785-5 90-201
(13)
TRANSMISSION CONTROL SYSTEM
1. Electric govenor specification
HD785-5 90-203
(13)
TRANSMISSION CONTROL SYSTEM
2. Mechanical govenor specification
HD785-5 90-205
(13)
4-4. ELECTRICAL CIRCUIT DIAGRAM
HD785-5 90-207
(14)

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SEBM013916

MACHINE MODEL SERIAL NUMBER

• HD785-5 and HD985-5 mount the SA12V140-1 engine.

01 GENERAL ............................................................................................................ 01-1

10 STRUCTURE AND FUNCTION ........................................................... 10-1

20 TESTING AND ADJUSTING ................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40 MAINTENANCE STANDARD ............................................................... 40-1

90 OTHERS ............................................................................................................... 90-1

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

b 00-1 (16) 10-4 (15) 10-40 (12) 10-73 10-113

10-154 10-209 20-1 (15) 20-131 (13) 20-219 (7)

30-188 (2) 40-16

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal