HD785-5 Shop Manual PDF

SEBM013912
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.
© 2002 1
All Rights Reserved 00-1
Printed in Japan 10-02(02) B
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
2
The affected pages are indicated by the use of the
Revision Revision Mark
Revision Indication
Revision Action required
Revision
following
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numberIt is Mark
requested
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tions be taken to these pages according to the table c Page to be newly added Add
below.
b Page to be replaced Replace
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Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
b 00-1 B 10-4 b 10-39 B 10-73 10-115

00-2 2 10-5 b 10-40 B 10-74 10-116
b 00-2-1 B 10-6 c 10-40-1 B 10-75 10-117
b 00-2-2 B 10-7 1 c 10-40-2 B 10-76 10-118
b 00-2-3 B 10-7-1 1 10-41 10-77 10-119
b 00-2-4 B 10-8 10-42 1 10-78 10-120
b 00-2-5 B 10-9 10-42-1 1 10-80 10-121 5
b 00-2-6 B 10-10 b 10-42-2 B 10-81 10-122
00-3 10-12 0 b 10-43 B 10-82 10-123
00-4 10-13 0 10-44 10-83 10-124
00-5 10-14 10-45 1 10-84 1 b 10-125 B
00-6 10-15 10-45-1 1 10-84-1 1 10-126
00-7 10-16 10-46 10-85 10-127
00-8 10-17 10-47 10-86 10-128
00-9 10-18 10-48 10-87 10-129
00-10 10-19 0 10-49 10-88 10-130
00-11 10-20 10-50 10-89 10-131
00-12 10-21 10-51 10-90 10-132
00-13 10-22 10-52 10-91 10-133
00-14 10-23 10-53 10-92 10-134
00-15 10-24 10-54 10-93 10-135
00-16 10-25 10-56 10-94 10-136
00-17 10-26 10-57 10-95 10-137
00-18 10-27 10-58 10-96 10-138
00-19 10-28 10-59 10-97 10-139
00-20 10-29 1 10-60 10-98 10-140
00-21 10-29-1 1 10-61 10-99 10-141
00-22 10-29-2 1 10-62 10-100 10-142
b 10-30 B 10-63 10-101 10-143
01-1 c 10-30-1 B 10-64 10-102 10-144
01-2 5 c 10-30-2 B 10-65 10-103 10-145
01-2-1 5 ( 10-31) 10-66 10-104 10-146
01-3 1 b 10-32 10-67 10-105 10-147
01-4 1 10-33 10-68 10-106 10-148
01-5 1 10-34 10-69 10-108 10-149
01-6 1 10-35 10-70 10-109 10-150
01-7 1 10-36 10-70-1 6 10-110 10-151
b 10-37 B 10-70-2 6 10-111 10-152
10-1 1 b 10-37-1 B 10-71 10-112 10-153
10-2 1 c 10-37-2 B 10-71-1 6 10-113 10-154
b 10-3 B 10-38 10-72 10-114 10-155
HD785-5 00-2-1
B
10-156 10-211 20-2 1 20-132 1 20-222 6

10-157 10-212 20-3 0 20-133 1 20-223 6
10-158 10-213 20-3-1 0 20-134 1 20-224 1
10-159 10-214 20-4 1 20-135 1 20-226 1
10-160 10-215 20-5 0 20-136 1 20-227 1
10-161 10-216 20-6 0 20-137 1 20-228 1
10-162 10-217 20-7 0 20-138 1 20-229 1
10-163 10-218 20-8 1 20-139 1 20-230 1
10-164 10-219 20-9 1 20-140 1 20-231 1
10-165 10-220 20-10 1 20-141 5 20-232 1
10-166 10-221 20-11 1 20-142 1 20-233 1
10-167 10-222 20-12 1 20-143 7 20-234 1
10-168 10-223 20-13 1 b 20-144 B 20-235 1
10-169 10-224 20-14 1 20-145 1 20-236 1
10-170 10-225 20-15 1 20-146 1 20-237 1
10-171 10-226 20-16 1 20-147 5 20-238 1
10-172 10-227 20-17 1 20-148 5 20-240 1
10-173 10-228 20-18 1 20-149 5 20-241 1
10-174 10-228-1 3 20-19 2 20-150 5 20-242 1
10-175 10-228-2 3 20-20 1 20-151 5 20-243 1
10-176 10-228-3 3 20-21 1 20-152 5 20-244 1
10-177 10-228-4 3 b 20-101 B 20-153 5 20-245 7
10-178 10-228-5 3 b 20-102 B 20-154 5 20-246 1
10-179 10-228-6 3 20-103 5 20-155 5 20-247 1
10-180 10-228-7 3 20-104 1 20-156 5 20-248 1
10-181 10-228-8 3 20-105 1 20-157 5 20-249 1
10-182 10-228-9 3 20-106 1 20-158 A 20-250 7
10-183 10-228-10 3 20-107 7 c 20-159 B 20-251 7
10-184 10-229 20-108 7 c 20-160 B 20-252 1
10-185 10-230 20-109 1 c 20-161 B 20-253 1
10-186 10-231 20-110 1 c 20-162 B 20-254 1
10-187 10-232 20-111 1 c 20-163 B 20-255 7
10-188 10-233 20-112 1 c 20-164 B b 20-256 B
10-189 10-234 20-113 1 20-201 8 20-257 7
10-190 10-235 20-114 1 20-202 1 b 20-258 B
10-192 10-236 20-115 5 20-203 1 20-258-1 7
10-193 10-237 20-115-2 5 20-204 1 20-259 1
10-194 10-238 20-116 5 20-205 1 20-260 1
10-195 10-240 20-117 1 20-206 1 20-261 1
10-196 10-241 20-118 1 20-207 A 20-262 1
10-197 10-242 20-119 1 20-208 A 20-263 1
10-198 10-243 20-120 1 20-209 1 20-264 1
10-199 10-244 20-121 1 20-210 1 20-265 1
10-200 10-245 20-122 7 20-211 1 20-266 7
10-201 b 10-247 B b 20-123 B 20-212 1 20-267 7
10-202 10-248 8 c 20-123-1 B 20-213 1 b 20-268 B
10-203 10-249 8 b 20-124 1 20-214 7 20-269 7
10-204 10-250 8 20-125 1 20-215 7 20-270 5
10-205 10-251 8 20-126 5 20-216 7 20-271 1
10-206 10-252 A 20-127 5 20-217 7 20-272 1
10-207 10-253 A 20-128 1 20-218 7 20-273 1
10-208 10-254 A 20-129 1 20-219 7 20-274 1
10-209 20-130 5 20-220 6 20-275 1
10-210 20-1 1 20-131 5 20-221 6 20-276 1
00-2-2 HD785-5
B
20-277 1 20-403 1 20-533 1 20-604 1 20-808 1

20-278 1 20-404 1 20-534 1 20-605 1 20-809 1
20-301 1 20-405 1 20-535 1 20-606 1 20-810 1
20-302 7 20-406 1 20-536 1 20-607 1 20-811 1
20-303 1 20-407 1 20-537 1 20-608 1 20-812 1
20-304 7 20-408 1 20-538 1 20-609 1 20-813 1
20-305 1 20-409 1 20-539 1 20-610 1 20-814 1
20-306 1 20-410 1 20-540 1 20-611 1 20-815 1
20-307 1 20-412 1 20-541 1 20-612 1 20-816 1
20-308 1 20-413 1 20-542 1 20-613 1 20-817 1
20-309 1 20-414 1 20-543 1 20-614 1 20-818 1
20-310 1 20-415 1 20-544 1 20-615 1 20-819 1
20-311 1 20-416 1 20-545 1 20-616 1 20-820 1
20-312 1 20-417 1 20-546 1 20-617 1 20-821 1
20-313 1 20-418 1 20-547 1 20-618 1 20-822 1
20-314 1 20-419 1 20-548 1 20-619 1 20-823 1
20-315 1 20-420 1 20-549 1 20-620 1 20-824 1
20-316 1 20-421 1 20-550 1 20-701 1 20-825 1
20-317 1 20-422 1 20-551 1 20-702 1 20-826 1
20-318 1 20-423 1 20-552 1 20-704 1 20-827 1
20-319 1 20-424 1 20-553 1 20-705 1 20-828 1
20-320 1 20-425 1 20-554 1 20-706 1 20-829 1
20-321 1 20-426 1 20-555 1 20-707 1 20-830 1
20-322 1 20-501 1 20-556 1 20-708 1 20-831 1
20-323 1 20-502 1 20-557 1 20-710 1 20-832 1
20-324 1 b 20-503 B 20-558 1 20-711 1 20-901 1
20-325 1 20-504 1 20-559 1 20-712 1 20-902 1
20-326 1 20-506 1 20-560 1 20-713 1 b 20-903 B
20-327 1 20-507 1 20-561 1 20-714 1 b 20-904 B
20-328 1 20-508 1 20-562 1 20-715 1 c 20-905 B
20-329 1 20-509 1 20-563 1 20-716 1 20-906 1
20-330 1 20-510 1 20-564 1 20-717 1 20-907 1
20-331 1 20-511 1 20-565 1 20-718 1 20-908 1
20-332 1 20-512 1 20-566 1 20-719 1 20-909 1
20-333 1 20-513 1 20-567 1 20-720 1 20-910 1
20-334 1 20-514 1 20-568 1 20-721 1 20-911 1
20-335 1 20-515 1 20-569 1 20-722 1 20-912 1
20-336 1 20-516 1 20-570 1 20-723 1 20-913 1
20-337 1 20-517 1 20-571 1 20-724 1 20-914 1
20-338 1 20-518 1 20-572 1 20-725 1 20-915 1
20-339 1 20-519 1 20-573 1 20-726 1 20-916 1
20-340 1 20-520 1 20-574 1 20-727 1 20-917 1
20-341 1 20-521 1 20-575 1 20-728 1 20-918 1
20-342 1 20-522 1 20-576 1 20-729 1 20-919 1
20-343 1 20-523 1 20-577 1 20-730 1 20-920 1
20-344 1 20-524 1 20-578 1 20-731 1 20-921 1
20-345 1 20-525 1 20-579 1 20-732 1 20-922 1
20-346 1 b 20-526 B 20-580 1 20-733 1 20-923 1
20-347 1 20-527 1 20-581 1 20-801 1 20-924 1
20-348 1 20-528 1 20-582 1 20-802 1 20-925 1
20-349 1 20-529 1 b 20-583 B 20-803 1 20-926 1
20-350 1 20-530 1 20-601 1 20-804 1 20-927 1
20-401 1 20-531 1 20-602 1 20-806 1 20-928 1
20-402 1 20-532 1 20-603 1 20-807 1 20-929 1
HD785-5 00-2-3
B
20-930 1 20-1107 1 20-1161 1 20-1245 1 20-1404 8

20-931 1 20-1108 1 20-1162 1 20-1251 4 20-1405 8
20-932 1 20-1109 1 20-1163 1 20-1252 4 20-1406 8
20-933 1 20-1110 1 20-1164 1 20-1253 4 20-1407 8
20-934 1 20-1111 1 20-1165 1 20-1254 4 20-1408 8
20-935 1 20-1112 1 20-1166 1 b 20-1255 B 20-1409 8
20-936 1 20-1113 1 20-1167 1 b 20-1256 B 20-1410 8
20-937 1 20-1114 1 20-1168 1 b 20-1257 B 20-1411 8
20-938 1 20-1115 1 20-1169 1 20-1258 4 20-1412 8
20-939 1 20-1116 1 20-1170 1 20-1259 4 20-1413 8
20-940 1 20-1117 1 20-1171 1 20-1260 4 20-1414 8
20-941 1 20-1118 1 20-1201 1 20-1261 4 20-1415 8
20-942 1 20-1119 1 20-1202 1 20-1262 4 20-1416 8
20-943 1 20-1120 1 20-1204 1 20-1263 4 20-1417 8
20-944 1 20-1121 1 20-1205 1 20-1264 4 20-1418 8
20-945 1 20-1122 1 20-1206 1 20-1265 4 20-1419 8
20-946 1 20-1123 1 20-1207 1 20-1266 4 20-1420 8
20-947 1 20-1124 1 20-1208 1 20-1267 4 20-1421 8
20-948 1 20-1125 1 20-1209 1 20-1268 4 20-1422 8
20-949 1 20-1126 1 20-1210 1 20-1269 4 20-1423 8
20-950 1 20-1127 1 20-1211 1 20-1270 4 20-1424 8
20-951 1 20-1128 1 20-1212 1 20-1271 4 20-1425 8
20-952 1 20-1129 1 20-1213 1 20-1272 4 20-1426 8
20-953 1 20-1130 1 20-1214 1 20-1273 4 20-1427 8
20-954 1 20-1131 1 20-1215 1 20-1274 4 20-1428 8
20-955 1 20-1132 1 20-1216 1 20-1275 4 20-1429 8
20-956 1 20-1133 1 20-1217 1 20-1276 4 20-1430 8
20-1001 1 20-1134 1 20-1218 1 20-1277 4 20-1431 8
20-1002 1 20-1135 1 20-1219 1 20-1278 4 20-1432 8
20-1003 1 20-1136 1 20-1220 1 20-1279 4 20-1433 8
20-1004 1 20-1137 1 20-1221 1 20-1280 4 20-1434 8
20-1005 1 20-1138 1 20-1222 1 20-1281 4 20-1435 8
20-1006 1 20-1139 1 20-1223 1 20-1282 4 20-1436 8
20-1007 1 20-1140 1 20-1224 1 20-1283 4 20-1437 8
20-1008 1 20-1141 1 20-1225 1 20-1301 5 20-1438 8
20-1009 1 20-1142 1 20-1226 1 20-1302 5 20-1439 8
20-1010 1 20-1143 1 20-1227 1 20-1303 5
20-1011 1 20-1144 1 20-1228 1 20-1304 5 30-1 2
20-1012 1 20-1145 1 20-1229 1 20-1305 5 b 30-2 B
20-1013 1 20-1146 1 20-1230 1 20-1306 5 30-3 2
20-1014 1 20-1147 1 20-1231 1 20-1307 5 30-4 A
20-1015 1 20-1148 1 20-1232 1 20-1308 5 30-5 2
20-1016 1 20-1149 1 20-1233 1 20-1309 5 30-6 2
20-1017 1 20-1150 1 20-1234 1 20-1310 5 30-7 7
20-1018 1 20-1151 1 20-1235 1 20-1311 5 30-8 2
20-1019 1 20-1152 1 20-1236 1 20-1312 5 30-9 2
20-1020 1 20-1153 1 20-1237 1 20-1313 5 30-10 2
20-1021 1 20-1154 1 20-1238 1 20-1314 5 30-11 2
20-1101 1 20-1155 1 20-1239 1 20-1315 5 30-12 2
20-1102 1 20-1156 1 20-1240 1 20-1316 5 30-13 2
20-1103 1 20-1157 1 20-1241 1 20-1317 5 30-14 2
20-1104 1 20-1158 1 20-1242 1 20-1401 8 30-15 2
20-1105 1 20-1159 1 20-1243 1 20-1402 8 30-16 2
20-1106 1 20-1160 1 20-1244 1 20-1403 8 30-17 2
00-2-4 HD785-5
B
30-18 2 30-72 2 30-126 2 30-176 2 40-6

30-19 2 30-73 2 30-127 2 30-177 2 40-7
30-20 2 30-74 2 30-128 2 30-178 2 40-8
30-21 2 30-75 2 b 30-129 B 30-179 2 40-9
30-22 2 30-76 2 b 30-130 B 30-180 2 40-10
30-23 2 30-77 2 30-131 2 30-181 2 40-11
30-24 2 30-78 2 30-132 2 30-182 2 b 40-12 B
30-25 2 30-79 2 b 30-133 B 30-183 2 b 40-13 B
30-26 2 30-80 2 b 30-133-1 B 30-184 2 c 40-13-1 B
30-27 2 30-81 2 b 30-133-2 B 30-185 2 b 40-14 1
30-28 2 30-82 2 b 30-134 B 30-186 2 40-14-1 1
30-29 2 30-83 2 30-135 2 30-187 2 40-15
30-30 2 30-84 2 30-136 2 30-188 2 40-16
30-31 2 30-85 2 30-137 7 30-189 2 b 40-17 B
30-32 2 30-86 2 b 30-138 B 30-190 2 b 40-17-1 B
30-33 2 30-87 2 30-139 2 30-191 2 c 40-17-2 B
30-34 2 30-88 2 30-140 2 30-192 2 c 40-17-3 B
30-35 2 30-89 2 30-141 2 30-193 2 c 40-17-4 B
30-36 2 30-90 2 30-142 2 30-194 2 40-18
30-37 2 30-91 2 30-143 2 30-195 2 b 40-19 B
30-38 2 30-92 2 30-144 2 30-196 2 b 40-20 B
30-39 2 30-93 2 b 30-145 B 30-197 2 c 40-20-1 B
30-40 2 30-94 0 30-146 2 30-198 2 c 40-20-2 B
30-41 2 30-95 2 30-147 2 30-199 2 40-21
30-42 2 30-96 2 30-148 2 30-200 2 40-22
30-43 2 30-97 2 30-149 2 30-201 2 40-23
30-44 2 30-98 2 b 30-150 B 30-202 2 40-24
30-45 2 30-99 2 c 30-150-1 B 30-203 2 40-25 1
30-46 2 30-100 2 c 30-150-2 B 30-204 2 40-26
30-47 2 30-101 2 ( 30-151) 30-205 2 40-27
30-48 2 30-102 2 b 30-152 2 30-206 2 40-28
30-49 2 30-103 2 30-153 2 30-208 2 40-29
30-50 2 30-104 2 30-154 2 30-209 2 40-30
30-51 2 30-105 2 b 30-155 B 30-210 2 40-31
30-52 0 30-106 2 30-156 2 30-211 2 40-32
30-53 2 30-107 2 30-157 2 30-212 2 40-33
30-54 2 30-108 2 30-158 2 30-213 2
30-55 0 30-109 2 30-159 2 30-214 2 90-1 1
30-56 0 30-110 2 b 30-160 B 30-215 2 b 90-3 B
30-57 0 30-111 2 30-161 2 30-216 2 b 90-5 B
30-58 2 30-112 2 30-162 2 30-217 2 90-7 6
30-59 2 30-113 2 30-163 2 30-218 2 b 90-9 B
30-60 2 30-114 2 30-164 2 30-219 2 b 90-11 B
30-61 0 30-115 2 30-165 2 30-220 2 b 90-13 B
30-62 2 30-116 2 30-166 2 30-221 2 90-15
30-63 2 30-117 2 30-167 2 30-222 2 90-17
30-64 0 30-118 2 30-168 2 30-223 2 90-19
30-65 2 30-119 2 30-169 2 30-224 2 90-21
30-66 2 30-120 2 30-170 2 90-23
30-67 2 30-121 2 30-171 2 b 40-1 B 90-25
30-68 2 30-122 2 30-172 2 40-2 90-27
30-69 2 30-123 2 30-173 2 40-3 90-29
30-70 2 30-124 2 30-174 2 40-4 0 90-31
30-71 2 30-125 2 30-175 2 40-5 90-33
HD785-5 00-2-5
B
90-35 90-351 9
90-37
90-39
90-201 1
90-203 1
90-205 1
90-301 9
90-302 9
90-303 9
90-304 9
90-305 9
90-306 9
90-307 9
90-308 9
90-309 9
90-310 9
90-311 9
90-312 9
90-313 9
90-314 9
90-315 9
90-316 9
90-317 9
90-318 9
90-319 9
90-320 9
90-321 9
90-323 9
90-324 9
90-326 9
90-327 9
90-328 9
90-329 9
90-330 9
90-331 9
90-332 9
90-333 9
90-334 9
90-335 9
90-336 9
90-337 9
90-338 9
90-339 9
90-340 9
90-341 9
90-342 9
90-343 9
90-344 9
90-345 9
90-346 9
90-347 9
90-348 9
90-349 9
90-350 9
00-2-6 HD785-5
B
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 ¤ 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
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) 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
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
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.
¤ Safety
Special safety precautions
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.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
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
¤ 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
4
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
• 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
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(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.
When hoisting a load with two or more ropes,
Rope diameter Allowable load 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 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
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
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
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 tan k. Fo r d e tails , se e TES TIN G AN D
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, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube 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 met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• 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,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
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.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
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
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
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.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
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.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 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 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 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 Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 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 20.7
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 – - 12UNF 30.3
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) (mm 2)
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-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
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 water 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
B
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
1. Carrier SPECIFICATIONS
2. Planet gear shaft Type: Planetary gear, splash-type lubrication
3. Planet 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. Tube
12. Wheel hub
13. Drive shaft
10-37-1 HD785-5
B
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 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
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
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 water 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 Cooling water 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
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
STRUCTURE AND FUNCTION ASR-II SYSTEM (OP)
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
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
TESTING AND ADJUSTING
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
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
B
TOOLS FOR TESTING, ADJUSTING AND
TESTING AND ADJUSTING TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Measurement item Symbol Part No. Part Name Remarks
799-203-8001 Multi-tachometer
L:60 – 2,000rpm
Digital display H:60 –19,999rpm
Engine speed A 6215-81-3500 Thermometer drive
6210-81-4111 Gear box —

Water, 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 790-261-1203 Digital hydraulic tester Pressure gauge 49.0MPa{500 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
(boost pressure) V 799-201-2202 Boost gauge KIT –760 – 1,500 mHg
Fuel injection timing Dial gauge as commercially
adjustment R 795-471-1200 Gauge assembly available
799-201-9000 Handy smoke checker Discoloration 0 – 70%
Exhaust color G (with standard color)
Commercially (Discoloration % × 1/10
available Smoke meter •
=• Bosch index)
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
B
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
B
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 idling, then stop the engine.
HD785-5 20-157
5
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 idling 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 idling(Low) Auto Economy N ON ON Hold
2 2:00 3:00 120 sec. Low idling(High) Auto Economy N OFF OFF Hold Note 1
Low idling
3 4:00 5:00 60 sec. (Economy mode) Auto Economy N ON ON Hold
High idling
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 idling
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 idling
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 idling before shifting to position D (to prevent the machine from start-
ing suddenly).
20-160 HD785-5
B
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 idling Low
2 Low idling High
3 Low idling Economy mode
4 High idling Economy mode
5 Torque converter stall Economy mode
6 High idling Power mode
7 Torque converter stall Power mode
8 High idling Power mode
20-162 HD785-5
B
TESTING AND ADJUSTING Pm-CLINIC SERVICE
Pm-CLINIC SERVICE
HD785-5 20-163
B
TESTING AND ADJUSTING Pm-CLINIC SERVICE
20-164 HD785-5
B
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 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)
Transmission controller
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 water 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
7
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) Idling varidation signal 2 ON/OFF ON : GND (at accelater pedal OFF)
6) Idling 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 water 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 —
Suspension controller
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
B
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
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 connector connection b0C1 04 ON FLASHES E. ↔ C.1 E.C ↔ C.1 C.1
73 Short circuit with ground in BCV solenoid system b0C4 02 ON FLASHES E. ↔ C.4 E.C ↔ C.4 C.4
74 Disconnection in BCV solenoid system b0C6 02 ON FLASHES E. ↔ C.6 E.C ↔ C.6 C.6
75 Short circuit in BCV solenoid system b0C8 02 ON FLASHES E. ↔ C.8 E.C ↔ C.8 C.8
76 Transmission filter clogging warning b0d1 01 OFF FLASHES(ª) E. ↔ d.1 E.C ↔ d.1 d.1
HD785-5 20-267
7
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)
77 Torque converter oil temperature overheat warning b0d2 05 OFF FLASHES E. ↔ d.2 E.C ↔ d.2 d.2
78 Engine water temperature overheat warning (✩) b0d3 05 OFF FLASHES E. ↔ d.3 E.C ↔ d.3 d.3
79 Tilt warning b0d5 07 OFF FLASHES E. ↔ d.5 E.C ↔ d.5 d.5
80 Radiator water level drop warning b0d6 01 OFF FLASHES E. ↔ d.6 E.C ↔ d.6 d.6
81 Abnormality in charging circuit system b0d7 01 ON FLASHES(ª) E. ↔ d.7 E.C ↔ d.7 d.7
82 Engine overrun prevention brake actuated b0d8 03 OFF FLASHES E. ↔ d.8 E.C ↔ d.8 d.8
83 Engine overshoot b0d9 02 ON FLASHES E. ↔ d.9 E.C ↔ d.9 d.9
84 Drop in battery direct power source voltage b0dA 04 ON FLASHES E. ↔ d.A E.C ↔ d.A d.A
85 Drop in main power source voltage b0db 04 ON FLASHES E. ↔ d.b E.C ↔ d.b d.b
86 Steering oil temperature overheat warning b0E5 05 OFF FLASHES E. ↔ E.5 E.C ↔ E.5 E.5
87 Drop in air pressure b0E9 05 OFF FLASHES E. ↔ E.9 E.C ↔ E.9 E.9
88 Retarder overheat warning b0F3 05 OFF FLASHES E. ↔ F.3 E.C ↔ F.3 F.3
89 Drop in engine oil pressure b0F5 04 OFF OFF E. ↔ F.5 E.C ↔ F.5 F.5
90 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 water temperature overheat warning C023 05 OFF OFF E. ↔ 2.3 2.3
20-268 HD785-5
B
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 cooling water 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 water 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 water 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
B
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
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE
TROUBLESHOOTING AND PROBLEMS ON MACHINE
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
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 water 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
1
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE
TROUBLESHOOTING AND PROBLEMS 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
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 water temperature Abnormal rise in engine water temperature.

E. ↔ d.3  overheat warning
E.C↔d.3  fl When engine water
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
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.
20-526 HD785-5
B
TESTING AND ADJUSTING A-21
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?
Defective controller Replace
• 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?
Defective controller Replace
• 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 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. SPEED CODE JUDGMENT TABLE

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
B
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
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
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 REAR BRAKE CHAMBER
Removal .................................................... 30-130 Removal and Installation ......................... 30-172
Installation ................................................ 30-131 Disassembly ............................................. 30-173
FRONT BRAKE CALIPER Assembly .................................................. 30-177
Removal and Installation ......................... 30-132 FRONT BRAKE CHAMBER
Disassembly ............................................. 30-133 Disassembly ............................................. 30-180
Assembly ............................................... 30-133-1 Assembly .................................................. 30-182
FRONT BRAKE CALIPER PAD SLACK ADJUSTER
Removal and Installation ......................... 30-134 Removal and Installation ......................... 30-184
FRONT WHEEL HUB Disassembly and Assembly .................... 30-185
Disassembly ............................................. 30-135 BRAKE COOLING PUMP
Assembly .................................................. 30-137 Removal and Installation ......................... 30-186
FINAL DRIVE CARRIER STEERING, HOIST PUMP
Disassembly and Assembly .................... 30-141 TORQUE CONVERTER, TRANSMISSION PUMP
FINAL DRIVE Removal and Installation ......................... 30-188
Disassembly ............................................. 30-142 EMERGENCY STEERING MOTOR PUMP
REAR BRAKE STEERING VALVE
REAR WHEEL BRAKE Disassembly ............................................. 30-191
Disassembly ............................................. 30-147 Assembly .................................................. 30-195
Assembly .................................................. 30-148 BRAKE CONTROL VALVE (BCV)
PARKING BRAKE PAD Removal and Installation ......................... 30-202
Removal .................................................... 30-150 DEMAND VALVE
Installation ............................................. 30-150-1 Removal and Installation ......................... 30-203
PARKING BRAKE CALIPER Disassembly and Assembly .................... 30-204
Removal and Installation ...................... 30-150-2 RELIEF VALVE
Disassembly and Assembly .................... 30-152 Disassembly and Assembly .................... 30-205
FRONT SUSPENSION CYLINDER HOIST VALVE
Disassembly ............................................. 30-154 Disassembly and Assembly .................... 30-208
Assembly .................................................. 30-155 STEERING CYLINDER
VARIABLE DAMPING SELECTOR VALVE Removal and Installation ......................... 30-210
Assembly .................................................. 30-157 Assembly .................................................. 30-213
REAR SUSPENSION CYLINDER HOIST CYLINDER
Assembly .................................................. 30-160 Assembly .................................................. 30-218
AIR GOVERNOR BODY
Removal and Installation ......................... 30-161 Removal .................................................... 30-219
Disassembly and Assembly .................... 30-162 Installation ................................................ 30-220
BRAKE VALVE CONTROLLER
Disassembly ............................................. 30-164 AIR CONDITIONER COMPRESSOR
PARKING BRAKE CHAMBER RECEIVER TANK
Disassembly ............................................. 30-169 AIR CONDITIONER CONDENSER
30-2 HD785-5
B
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 FRONT BRAKE CALIPER
• 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 Be sure to install short torque pin (5) of torque
pins (4) and (5) at the plate end.
fl Install so that clearance d between disc (16)
and torque pin (3) is 1.5 – 3.0 mm.
fl Assemble the other pistons in the same way.
5. Install caliper assembly.

For details, see INSTALLATION OF FRONT CALI-
PER ASSEMBLY.
HD785-5 30-133-2
B
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER
ASSEMBLY OF FRONT
SUSPENSION CYLINDER
ASSEMBLY
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.
3. Cylinder rod assembly

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: 10 ¬ (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.
5) Install flange (8), retainer (7), and plate (6) to
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
B
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER
DISASSEMBLY OF REAR
SUSPENSION CYLINDER
ASSEMBLY
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
2
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER
ASSEMBLY OF REAR
SUSPENSION CYLINDER
ASSEMBLY
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
1) Press fit bushing to retainer (8) with tool Q2.
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}
5. Intake valve and oil level valve

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
B
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 FRONT AXLE

Unit: mm
No. Check item Criteria Remedy
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
Standard size Repair limit

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

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SEBM013912

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 B 10-4 b 10-39 B 10-73 10-115

10-156 10-211 20-2 1 20-132 1 20-222 6

20-277 1 20-403 1 20-533 1 20-604 1 20-808 1

20-930 1 20-1107 1 20-1161 1 20-1245 1 20-1404 8

30-18 2 30-72 2 30-126 2 30-176 2 40-6

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

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ 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

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

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,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15