Shop Manual HD 785-7

SEN01274-15
DUMP TRUCK HD785 -7

SERIAL NUMBERS 7001 and up
SEN01276-15
DUMP TRUCK 1SHOP MANUAL
HD785-7
Machine model Serial number

HD785-7 7001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
HD785-7 1
SEN01276-15 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01274-15
00 Index and foreword SEN01275-15

Index SEN01276-15 q
Foreword and general information SEN01277-04
01 Specification SEN01278-04
Specification and technical data SEN01279-04 q
10 Structure, function and maintenance standard SEN01280-09

Engine and cooling system SEN01281-01
Power train, Part 1 SEN01282-03
Steering system SEN01284-01
Brake system SEN01285-04
Undercarriage and frame SEN01286-02
Hydraulic system SEN01287-03
Work equipment (Body) SEN04681-00
Cab and its attachments SEN01288-01
Electrical system, Part 1 SEN01289-01
20 Standard value table SEN01293-01

Standard service value table SEN01769-01
30 Testing and adjusting SEN01294-06

Testing and adjusting, Part 1 SEN01770-03 q
Testing and adjusting, Part 3 SEN01772-03
40 Troubleshooting SEN01295-05
Failure code table and fuse locations SEN01936-02
2 HD785-7
General information on troubleshooting SEN01937-03

Troubleshooting by failure code, Part 1 SEN01938-02 q
Troubleshooting by failure code, Part 3 SEN01940-02
Troubleshooting of electrical system (E-mode) SEN01948-04
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01949-01
Troubleshooting of engine (S-mode) SEN01950-01
50 Disassembly and assembly SEN01296-04

General information on disassembly and assembly SEN01951-03
Body SEN04645-00
Electrical system SEN04647-01
90 Diagrams and drawings SEN01297-07

Hydraulic diagrams and drawings SEN01298-03
Electrical diagrams and drawings SEN01299-07
HD785-7 3
Table of contents 1
00 Index and foreword
Index SEN01276-15
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01277-04

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN01279-04
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 7
Fuel, coolant and lubricants ........................................................................................................ 8
10 Structure, function and maintenance standard

Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler ...................... 2
Fuel system ................................................................................................................................. 4
Power train skeleton.................................................................................................................... 2
Output shaft................................................................................................................................. 4
Drive shaft ................................................................................................................................... 6
Torque converter and transmission hydraulic piping ................................................................... 8
Brake cooling oil control valve (BCV) .......................................................................................... 10
Torque converter ......................................................................................................................... 11
Torque converter valve ................................................................................................................ 19
Transmission ............................................................................................................................... 22
Transmission control valve .......................................................................................................... 50
ECMV .......................................................................................................................................... 52
Lubricating oil amount selector valve .......................................................................................... 59
Axle ............................................................................................................................................. 2
Differential ................................................................................................................................... 4
Final drive.................................................................................................................................... 5
Wheels ........................................................................................................................................ 6
Steering column........................................................................................................................... 2
Steering linkage........................................................................................................................... 3
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Secondary brake valve................................................................................................................ 7
Accumulator charge valve ........................................................................................................... 8
4 HD785-7
Accumulator ................................................................................................................................ 12
Slack adjuster.............................................................................................................................. 14
Brake, parking brake ................................................................................................................... 18
Parking brake solenoid................................................................................................................ 24
Retarder control valve ................................................................................................................. 25
Exhaust brake ............................................................................................................................. 26
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 4
Rear axle support........................................................................................................................ 12
Steering and hoist hydraulic piping ............................................................................................. 2
Steering, hoist filter (high pressure circuit) .................................................................................. 4
Dump body control ...................................................................................................................... 6
Hydraulic tank ............................................................................................................................. 8
Steering valve.............................................................................................................................. 9
Crossover relief valve.................................................................................................................. 13
Steering cylinder.......................................................................................................................... 14
Steering control valve.................................................................................................................. 15
Hoist valve................................................................................................................................... 24
Dump control valve (EPC valve) ................................................................................................. 30
Hydraulic pump ........................................................................................................................... 34
Work equipment (Body) SEN04681-00
Auto greasing system.................................................................................................................. 2
Hoist cylinder............................................................................................................................... 13
ROPS cab ................................................................................................................................... 2
Air conditioner ............................................................................................................................. 3
Rear view monitor ....................................................................................................................... 12
Controller related......................................................................................................................... 15
Machine monitor system ............................................................................................................. 2
Automatic shift control system .................................................................................................... 2
External power supply heater...................................................................................................... 22
Automatic emergency steering system ....................................................................................... 24
Automatic suspension system..................................................................................................... 28
Retarder control system .............................................................................................................. 31
Battery disconnector switch ........................................................................................................ 44
Dump control lever ...................................................................................................................... 48
VHMS controller related .............................................................................................................. 2
ABS/ASR system ........................................................................................................................ 28
Altitude setting function ............................................................................................................... 46
Sensors, switches ....................................................................................................................... 2
20 Standard value table

Standard service value table SEN01769-01
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 4
30 Testing and adjusting

HD785-7 5
Testing and adjusting tools list..................................................................................................... 3

Sketch of special tool .................................................................................................................. 8
Testing engine speed .................................................................................................................. 9
Testing air supply pressure (boost pressure) .............................................................................. 10
Testing exhaust temperature ....................................................................................................... 12
Testing exhaust gas color............................................................................................................ 14
Adjustment of valve clearance .................................................................................................... 16
Testing compression pressure..................................................................................................... 18
Testing blow-by pressure............................................................................................................. 20
Testing engine oil pressure.......................................................................................................... 21
Handling of fuel system devices.................................................................................................. 22
Releasing residual pressure from fuel system ............................................................................ 22
Testing fuel pressure ................................................................................................................... 23
Reduced cylinder mode operation............................................................................................... 24
No-injection cranking................................................................................................................... 24
Testing leakage-from pressure limiter and return rate from injector ............................................ 25
Bleeding air from fuel circuit (Standard spec.)............................................................................. 28
Bleeding air from fuel circuit (Extra low-grade fuel spec.) ........................................................... 30
Testing the fuel circuit for leakage ............................................................................................... 32
Replacement and adjustment of fan belt..................................................................................... 33
Testing and adjusting alternator belt tension ............................................................................... 34
Testing and adjusting air conditioner compressor belt ................................................................ 35
Testing torque converter stall speed............................................................................................ 3
Testing power train oil pressure................................................................................................... 5
Adjusting transmission speed sensor.......................................................................................... 13
Testing and adjusting brake oil pressure ..................................................................................... 14
Testing of accumulator nitrogen gas pressure and procedure for
charging accumulator with nitrogen gas .................................................................................. 17
Testing brake performance.......................................................................................................... 22
Bleeding air from brake circuit..................................................................................................... 24
Bleeding air from ASR circuit (if equipped) ................................................................................. 26
Testing wear of front brake disc................................................................................................... 27
Testing wear of rear brake disc ................................................................................................... 28
Method of releasing parking brake in an emergency .................................................................. 29
Testing and adjusting front suspension cylinder.......................................................................... 30
Testing and adjusting rear suspension cylinder........................................................................... 34
Testing and adjusting front suspension cylinder (Automatic suspension specification) .............. 38
Testing and adjusting hydraulic pressure in steering, hoist circuit............................................... 39
Testing and adjusting oil pressure in dump EPC circuit .............................................................. 42
Air bleeding from steering cylinder .............................................................................................. 43
Procedure for raising dump body in emergency.......................................................................... 44
Adjusting body positioner sensor ................................................................................................ 45
Handling of high voltage circuit of engine controller .................................................................... 47
Adjusting transmission controller................................................................................................. 47
Method for emergency escape at electrical system failure ......................................................... 48
Setting and adjusting of devices.................................................................................................. 2
Special functions of machine monitor (EMMS)............................................................................ 2
Opening ORBCOMM terminal..................................................................................................... 2
VHMS controller initial setting procedure .................................................................................... 4
Precautions for replacing VHMS controller ................................................................................. 29
Pm Clinic check sheet ................................................................................................................. 35
Initial setting of payload meter..................................................................................................... 39
Setting of payload meter built in VHMS....................................................................................... 40
6 HD785-7
40 Troubleshooting
Failure code table and fuse locations SEN01936-02
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 18
General information on troubleshooting SEN01937-03
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Contents of troubleshooting table................................................................................................ 6
Connection table for connector pin numbers .............................................................................. 8
T-branch box and T-branch adapter table ................................................................................... 44
Failure code [1500L0] Dual engagement .................................................................................... 3
Failure code [15B0NX] Transmission oil filter: Clogging ............................................................. 4
Failure code [15F0KM] R o F shifting abuse 1: Mistake in operation ........................................ 6
Failure code [15F0MB] R o F shifting abuse 2: Mistake in operation ........................................ 6
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting ................... 7
Failure code [15G0MW] R clutch: Slipping ................................................................................. 8
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting .................. 10
Failure code [15H0MW] Hi clutch: Slipping................................................................................. 12
Failure code [15J0MW] Lo clutch: Slipping ................................................................................. 14
Failure code [15K0MW] 1st clutch: Slipping................................................................................ 16
Failure code [15L0MW] 2nd clutch: Slipping............................................................................... 18
Failure code [15M0MW] 3rd clutch: Slipping............................................................................... 20
Failure code [15N0MW] 4th clutch: Slipping ............................................................................... 22
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF ....... 24
Failure code [15SBMA] R clutch solenoid: Malfunction .............................................................. 26
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF ...... 28
Failure code [15SCMA] Hi clutch solenoid: Malfunction ............................................................. 31
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF ..... 32
Failure code [15SDMA] Lo clutch solenoid: Malfunction ............................................................. 35
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF..... 36
Failure code [15SEMA] 1st clutch solenoid: Malfunction ............................................................ 39
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF.... 4
Failure code [15SFMA] 2nd clutch solenoid: Malfunction ........................................................... 7
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF .... 8
Failure code [15SGMA] 3rd clutch solenoid: Malfunction ........................................................... 11
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF .... 12
Failure code [15SHMA] 4th clutch solenoid: Malfunction............................................................ 15
Failure code [15SJMA] Lockup clutch solenoid: Malfunction ...................................................... 16
Failure code [2F00KM] Parking brake: Mistake in operation or setting....................................... 18
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front).......................................... 21
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) .......................................... 21
Failure code [989A00] Engine over run prevention command signal: Operating ........................ 22
Failure code [989D00] Rear section tipping over alarm: Alarm is activated................................ 22
Failure code [A570NX] Engine oil filter: Clogging ....................................................................... 24
Failure code [AA10NX] Air cleaner element: Clogging ............................................................... 26
Failure code [AB00L4] Alternator: Failure on battery charge circuit
(R terminal signal is present and engine is stopped)............................................................... 28
Failure code [AB00MA] Alternator: Malfunction .......................................................................... 30
Failure code [AB00MB] Alternator: Failure on battery charge circuit
(Absence of R terminal signal and detection error) ................................................................. 32
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure ... 34
Failure code [B@BAZK] Engine oil: Level too low ...................................................................... 36
Failure code [B@BCNS] Engine: Overheat ................................................................................ 38
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level ................................... 40
HD785-7 7
Failure code [B@BFZK] Lowering of fuel level............................................................................ 42

Failure code [B@C6NS] Brake cooling oil: Overheating (Front) ................................................. 43
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear).................................................. 44
Failure code [B@CENS] Overheating of torque converter oil ..................................................... 46
Failure code [B@GAZK] Battery electrolyte level: Lowering of level........................................... 47
Failure code [B@JANS] Steering oil: Overheat........................................................................... 48
Failure code [CA111] Engine controller (Left bank): Internal abnormality ................................... 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality ................................. 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank):
Abnormal speed sensor signal ................................................................................................ 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank):
Abnormal speed sensor signal ................................................................................................ 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected........................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 12
Failure code [CA131] Throttle sensor high error (At left bank only) ............................................ 14
Failure code [CA132] Throttle sensor low error (At left bank only).............................................. 17
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Failure code [CA144] Coolant temperature sensor too high:
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .............................................................................................................. 30
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only):
High voltage detection ............................................................................................................. 32
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source (2) too high (Left bank):
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ............... 44
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA263] Fuel temperature sensor too high (Left bank):
Failure code [CB263] Fuel temperature sensor too high (Right bank):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
8 HD785-7
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ............................................. 55
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ........................................... 56
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ...................................... 57
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection .................................... 58
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................. 59
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ........................................... 60
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ...................................... 61
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection .................................... 62
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (Left bank):
Disconnection, short circuit...................................................................................................... 4
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch........................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch ........................ 16
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit .................... 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality .......... 20
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
Failure code [CA431] Trouble in idle validation switch................................................................ 28
Failure code [CA432] Idle validation action error ........................................................................ 32
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence ..................................................................................... 35
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence ..................................................................................... 35
Failure code [CA451] Common rail pressure sensor too high (Left bank):
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection ............................................................................................ 40
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection ............................................................................................ 40
HD785-7 9
Failure code [CA553] Common rail pressure too high (1) (Left bank):
Excessively high pressure detected ........................................................................................ 41
Failure code [CB553] Common rail pressure too high (1) (Right bank):
Excessively high pressure detected ........................................................................................ 42
Failure code [CA554] In-range error in common rail pressure sensor (Left bank):
In-range error........................................................................................................................... 43
Failure code [CB554] In-range error in common rail pressure sensor (Right bank):
In-range error........................................................................................................................... 43
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left bank):
Loss of pressure feed detected ............................................................................................... 44
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right bank):
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal ............ 52
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal.......... 54
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only):
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only):
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank):
Abnormal phase....................................................................................................................... 59
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank):
Abnormal phase....................................................................................................................... 59
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data.................. 3
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data ............... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank):
Abnormal Bkup signal.............................................................................................................. 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank):
Bkup signal error...................................................................................................................... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank):
Communication error ............................................................................................................... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank):
Communication error ............................................................................................................... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error........................................................................................................................ 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error........................................................................................................................ 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 14
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error ....................... 26
Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 28
Failure code [CA2186] Throttle sensor power supply low error .................................................. 30
Failure code [CA2555] Intake heater relay voltage low error (Left bank) .................................... 32
Failure code [CA2556] Intake heater relay voltage high error (Left bank)................................... 34
10 HD785-7

Failure code [D180KA] Preheating relay output system: Disconnection ..................................... 3
Failure code [D180KB] Preheating relay output system: Grounding fault ................................... 4
Failure code [D180KY] Preheating relay output system: Hot short circuit .................................. 6
Failure code [D19HKB] Stop lamp relay output system: Short circuit ......................................... 8
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection....................... 10
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault .................... 12
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit .................... 14
Failure code [DAF9KM] Wrong connection of connector ............................................................ 16
Failure code [DAFRKR] CAN communication error (Machine monitor): Communication error... 17
Failure code [DAQ0KK] Transmission controller direct power supply:
Lowering of source voltage...................................................................................................... 18
Failure code [DAQ0KT] Transmission controller nonvolatile memory:
Abnormality in controller .......................................................................................................... 20
Failure code [DAQ2KK] Transmission controller solenoid power source:
Power source voltage too low.................................................................................................. 22
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection .................. 24
Failure code [DAQRKR] Abnormality in CAN communication (Transmission)............................ 25
Failure code [DAQRMA] Transmission controller option setting: Malfunction............................. 30
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller ........ 30
Failure code [DB12KK] Retarder controller solenoid power source:
Power source system trouble .................................................................................................. 31
Failure code [DB13KK] Retarder controller battery direct power source:
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 35
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled .... 36
Failure code [DB1RMA] Disagreement of option setting (Retarder controller)............................ 40
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled...... 41
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled ...... 47
Failure code [DBB0KK] (or VHMS_LED display: "n9" o "01")
VHMS controller: Low source voltage (input) .......................................................................... 54
Failure code [DBB0KQ] (or VHMS_LED display: "nF" o "11")
(VHMS controller: Disagreement of model selection signals) ................................................. 56
VHMS controller battery power supply: Low source voltage (input) ........................................ 68
Failure code [DBB5KP] (or VHMS_LED display: "n9" o "04")
(VHMS controller 5 V power supply output: Low output voltage) ............................................ 60
(VHMS controller 24 V power supply output: Low output voltage) .......................................... 62
(VHMS controller 12 V power supply output: Low output voltage) .......................................... 64
Failure code [DBBQKR] (or VHMS_LED display: "n8" o "02") VHMS controller
CAN communication: Defective communication (Abnormality in target component system) .. 65
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ....................................... 65
Failure code [DBC2KK] ABS controller solenoid power source:
Power source system trouble .................................................................................................. 66
Failure code [DBC3KK] ABS controller battery direct power source:
Failure code [DBC9KQ] Disagreement of model selection (ABS controller) ............................... 68
Failure code [DBCRKR] Abnormality in CAN communication (ABS) .......................................... 70
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................. 71
Failure code [DBG2KK] Solenoid power supply: Low voltage .................................................... 75
Failure code [DBG3KK] Battery direct power supply: Low voltage ............................................. 76
Failure code [DBG9KQ] Model selection signal: Abnormal......................................................... 78
Failure code [DDD7KX] Trouble in travel speed setting switch system:
Out of input signal range ......................................................................................................... 80
Failure code [DDD8KA] ARSC system switch system: Disconnection ....................................... 82
Failure code [DDD8KB] ARSC system switch system: Short circuit ........................................... 84
HD785-7 11
Failure code [DDD9KA] ABS system switch system: Disconnection .......................................... 86

Failure code [DDD9KB] ABS system switch system: Short circuit .............................................. 88
Failure code [DDDAKA] ASR system switch: Disconnection ...................................................... 90
Failure code [DDDAKB] ASR system switch: Short circuit.......................................................... 92
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault ................................. 94
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit ...... 96
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)........................................ 98
Failure code [DDTHKA] Hi clutch fill switch: Disconnection ........................................................ 100
Failure code [DDTJKA] Lo clutch fill switch: Disconnection ........................................................ 102
Failure code [DDTKKA] 1st clutch fill switch: Disconnection....................................................... 104
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection ...................................................... 106
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection...................................................... 108
Failure code [DDTNKA] R clutch fill switch: Disconnection......................................................... 110
Failure code [DDTPKA] 4th clutch fill switch: Disconnection....................................................... 112
Failure code [DF10KA] Gear shift lever: Disconnection .............................................................. 114
Failure code [DF10KB] Gear shift lever: Short circuit.................................................................. 116
Failure code [DGE5KX] or VHMS_LED display: "n4" o "01"
(Atmospheric temperature sensor: Out of input signal range) ................................................. 120
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range ........... 126
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system
(Disconnection and short circuit) ............................................................................................. 128
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system
(Ground fault)........................................................................................................................... 130
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system
(Disconnection and short circuit) ............................................................................................. 131
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system
(Ground fault)........................................................................................................................... 132
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range ................... 134
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range ..... 136
Failure code [DGT5KA] (or VHMS_LED display: "n3" o "12")
Left bank exhaust temperature sensor system (Front): Disconnection ................................... 3
Failure code [dGT5KA] (or VHMS_LED display: "n3" o "22")
Left bank exhaust temperature sensor system (Rear): Disconnection .................................... 6
Failure code [DGT5KB] (or VHMS_LED display: "n3" o "11")
Left bank exhaust temperature sensor system (Front): Short circuit ....................................... 9
Failure code [dGT5KB] (or VHMS_LED display: "n3" o "21")
Left bank exhaust temperature sensor system (Rear): Short circuit........................................ 12
Right bank exhaust temperature sensor system (Front): Disconnection ................................. 15
Right bank exhaust temperature sensor system (Rear): Disconnection.................................. 18
Right bank exhaust temperature sensor system (Front): Short circuit..................................... 21
Right bank exhaust temperature sensor system (Rear): Short circuit ..................................... 24
Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32")
(Blow-by pressure sensor: Short circuit).................................................................................. 27
Failure code [DHE5KY] (or VHMS_LED display: "n3" o "31")
(Blow-by pressure sensor: Short circuit with power supply line).............................................. 30
Failure code [DHP4KY] (or VHMS_LED display: "n5" o "44")
Suspension pressure sensor system: Short circuit (Right front).............................................. 32
Failure code [DHP4KZ] (or VHMS_LED display: "n5" o "43")
Suspension pressure sensor system: Disconnection or ground fault (Right front) .................. 34
Suspension pressure sensor system: Short circuit (Left front) ................................................ 36
Suspension pressure sensor system: Disconnection or ground fault (Left front) .................... 38
12 HD785-7
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) ........ 40
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble:
Out of input signal range (Right rear) ...................................................................................... 41
Suspension pressure sensor system: Short circuit (Right rear) .............................................. 44
Suspension pressure sensor system: Disconnection or ground fault (Right rear)................... 46
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)........... 48
Failure code [DHP7KX] Failure in suspension pressure sensor system:
Out of input signal range (Left rear)......................................................................................... 49
Suspension pressure sensor system: Short circuit (Left rear) ................................................. 52
Suspension pressure sensor system: Disconnection or ground fault (Left rear) ..................... 54
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range........... 56
Failure code [DHT5L6] Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal ................................................................ 58
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range ........ 60
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range ......... 62
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................. 64
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) .................... 66
Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Rear right)................... 68
Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Rear left)..................... 70
Failure code [DJF1KA] Fuel level sensor: Disconnection ........................................................... 72
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)......................... 74
Failure code [DK51L5] Trouble in retarder lever potentiometer and RVS ................................... 75
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ........... 78
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal... 80
Failure code [DK54KX] Body positioner sensor: Out of input signal range................................. 82
Failure code [DKD0L6] Failure in steering angle speed sensor.................................................. 84
Failure code [DKH0KX] Pitch angle sensor: Out of input signal range ....................................... 86
Failure code [DKH1KX] (or VHMS_LED display: "n4" o "33") Pitch angle sensor:
Abnormality.............................................................................................................................. 88
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection ......................... 90
Failure code [DLF1LC] Transmission input shaft speed sensor:
Disagreement of revolution speed signal ................................................................................ 92
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............. 94
Failure code [DLF2LC] Transmission intermediate shaft speed sensor:
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right)................................ 4
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) ........................................... 6
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left) .................................. 8
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................. 10
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right) .................................. 12
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right) ................................... 14
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) ............................................. 16
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right).................................. 16
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) .................................... 18
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left)................................................ 20
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) ............................................... 22
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left) .................................... 22
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection ....................... 24
Failure code [DLT3LC] Transmission output shaft speed sensor:
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection ....................... 28
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection ...................... 30
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit .... 32
HD785-7 13
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality:

Disconnection or grounding fault ............................................................................................. 34
Failure code [DV00KB] Buzzer output: Short circuit.................................................................... 36
Failure code [DW2AKA] Main pressure variable valve output: Disconnection ............................ 38
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault .................... 40
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short.......................... 42
Failure code [DW2AL1] Main pressure variable valve: Defective reset ...................................... 44
Failure code [DW2ALH] Main pressure variable valve: Malfunction ........................................... 46
Failure code [DW2BKA] Main oil level selector valve output: Disconnection .............................. 47
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault ...................... 48
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short............................ 50
Failure code [DW2BL1] Main oil level selector valve: Defective reset ........................................ 52
Failure code [DW2BLH] Main oil level selector valve: Malfunction ............................................. 54
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection ............ 55
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault .... 56
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short.......... 58
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset ...................... 60
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction ........................... 62
Failure code [DW35KZ] Failure in output system of auto suspension solenoid 1:
Disconnection or short circuit................................................................................................... 64
Failure code [DW71KZ] Exhaust brake output system trouble
(Disconection/Ground fault/Hot short) ..................................................................................... 68
Failure code [DW72KZ] Kick-out solenoid output system trouble:
Failure code [DW73KZ] Failure in hoist select valve output system:
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble:
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)........................... 76
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection ................................. 78
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault .................................... 80
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit..................................... 82
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate) ........................ 82
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system ........................................ 84
Failure code [DWNDMA] Defective ABS cut-off valve (Front)..................................................... 86
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system ......................................... 88
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ..................................................... 90
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve:
Out of control ........................................................................................................................... 4
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................... 6
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve:
Short circuit.............................................................................................................................. 7
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................. 8
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve:
Malfunction .............................................................................................................................. 10
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve:
Out of control ........................................................................................................................... 12
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................... 14
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve:
Short circuit.............................................................................................................................. 15
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................. 16
14 HD785-7
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve:
Malfunction .............................................................................................................................. 18
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection .................................. 20
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit ...................................... 22
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line .... 24
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating) .............................................................................................. 26
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit:
Disconnection .......................................................................................................................... 28
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit:
Ground fault............................................................................................................................. 30
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit:
Short circuit.............................................................................................................................. 32
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate) ............................................................................................ 32
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating) .............................................................................................. 34
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit:
Disconnection .......................................................................................................................... 36
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit:
Ground fault............................................................................................................................. 38
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit:
Short circuit.............................................................................................................................. 40
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate) ............................................................................................ 40
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).............. 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) ................ 42
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)...................... 43
Failure code [DX21MA] Defective ABS control valve (Front right) .............................................. 44
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) ................ 45
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)................... 46
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) ........................ 47
Failure code [DX22MA] Defective ABS control valve (Front left) ................................................ 48
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) .............. 49
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................. 50
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ...................... 51
Failure code [DX23MA] Defective ABS control valve (Rear right) .............................................. 52
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)................. 53
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ................... 54
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) ........................ 55
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................. 56
Failure code [DX25MA] Defective ABS front wheel system control valve................................... 57
Failure code [DX26MA] Defective ABS rear wheel system control valve ................................... 57
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection............................ 4
Failure code [DXH1KB] Lock-up clutch solenoid output circuit: Short circuit .............................. 6
Failure code [DXH1KY] Lockup clutch solenoid output circuit:
Short circuit to power source line ............................................................................................ 8
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection .................................... 10
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit ....................................... 12
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power source line ...... 14
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection ................................... 18
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit....................................... 20
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power source line ...... 22
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .................................. 26
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit ...................................... 28
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power source line ..... 30
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection ................................. 34
HD785-7 15
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit ..................................... 36
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power source line .... 38
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection .................................. 42
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit...................................... 44
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power source line..... 46
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection..................................... 50
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit ........................................ 52
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power source line ....... 54
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.................................. 56
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit ..................................... 58
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power source line .... 60
Failure code [F@BBZL] (or VHMS_LED display: "n3" o "38")
(Blow-by pressure: High error)................................................................................................. 63
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61")
Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ..................... 64
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71")
Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ...................... 66
Failure code [F@BZNS] (or VHMS_LED display "n3" o "81")
Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise................... 68
Failure code [f@BZNS] (or VHMS_LED display "n3" o "91")
Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.................... 70
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62")
Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ..................... 72
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72")
Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ...................... 74
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82")
Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise................... 76
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92")
Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise.................... 78
Troubleshooting of electrical system (E-mode) SEN01948-04
Before troubleshooting of electric system ................................................................................... 3
E-1 Engine does not start............................................................................................................ 5
E-2 Automatic preheating does not operate................................................................................ 8
E-3 Machine monitor does not display all, when starting switch is turned ON ............................ 12
E-4 Machine monitor does not operate when starting switch is OFF .......................................... 14
E-5 Alarm buzzer does not sound ............................................................................................... 16
E-6 Alarm buzzer does not stop sounding .................................................................................. 18
E-7 Gauges of machine monitor, caution lamps or character display section
do not display properly. ............................................................................................................ 19
E-8 A selection of the display in character display section cannot be changed .......................... 21
E-9 Power mode selecting function does not operate properly................................................... 24
E-10 AISS function does not operate properly ............................................................................ 25
E-11 Seat belt caution lamp does not display properly ............................................................... 26
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly................................ 27
E-13 Night illumination (lighting) does not work properly ............................................................ 30
E-14 Emergency steering does not operate................................................................................ 42
E-15 Hoist lever does not operate normally ................................................................................ 48
E-16 Power supply system (Air conditioner does not operate) ................................................... 50
E-17 Compressor and refrigerant system (Air is not cooled) ...................................................... 52
E-18 Blower motor system (Air does not come out or air flow is abnormal)................................ 54
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01949-01
H-1 Machine does not start ......................................................................................................... 4
H-2 Machine does not travel smoothly (hunting)......................................................................... 6
H-3 Lockup cannot be cancelled ................................................................................................. 6
H-4 Excessive shock when starting or shifting excessive ........................................................... 7
16 HD785-7
H-5 Transmission does not shift up............................................................................................. 8

H-6 Machine lacks power or speed when traveling..................................................................... 10
H-7 Time lag is excessive when starting or shifting gear ............................................................ 14
H-8 Torque converter oil temperature is high .............................................................................. 16
H-9 Torque converter oil pressure is low..................................................................................... 17
H-10 Front brake is ineffective .................................................................................................... 18
H-11 Rear brake is ineffective ..................................................................................................... 19
H-12 Steering wheel is heavy...................................................................................................... 20
H-13 Steering wheel does not work ............................................................................................ 21
H-14 Steering wheel vibrates ...................................................................................................... 22
H-15 Dump body lifting speed is slow ......................................................................................... 23
H-16 Dump body does not work.................................................................................................. 24
H-17 Excessive hydraulic drift of dump body .............................................................................. 25
Troubleshooting of engine (S-mode) SEN01950-01
Method of using troubleshooting charts ...................................................................................... 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 16
S-9 Oil becomes contaminated quickly ....................................................................................... 17
S-10 Fuel consumption is excessive........................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 19
S-12 Oil pressure drops .............................................................................................................. 20
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 21
S-14 Coolant temperature becomes too high (overheating) ....................................................... 22
S-15 Abnormal noise is made ..................................................................................................... 23
S-16 Vibration is excessive ......................................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN01951-03
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 10
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 4
Removal and installation of cylinder head assembly .................................................................. 5
Removal and installation of engine hood assembly .................................................................... 18
Removal and installation of radiator assembly............................................................................ 19
Removal and installation of engine assembly ............................................................................. 28
Removal and installation of engine front oil seal ......................................................................... 33
Removal and installation of engine rear oil seal.......................................................................... 36
Removal and installation of front drive shaft ............................................................................... 2
Removal and installation of rear drive shaft ................................................................................ 4
Removal and installation of output shaft assembly ..................................................................... 5
Disassembly and assembly of damper assembly ....................................................................... 10
Removal and installation of torque converter and transmission assembly ................................. 12
Disconnection and connection of torque converter assembly and transmission assembly ........ 15
Disassembly and assembly of torque converter PTO assembly ................................................. 22
Disassembly and assembly of transmission assembly ............................................................... 35
HD785-7 17

Removal and installation of final drive carrier assembly ............................................................. 2
Disassembly and assembly of final drive carrier assembly ......................................................... 4
Removal and installation of differential assembly........................................................................ 6
Disassembly and assembly of differential assembly ................................................................... 9
Removal and installation of steering cylinder assembly .............................................................. 2
Disassembly and assembly of steering cylinder assembly ......................................................... 3
Removal and installation of steering valve assembly .................................................................. 7
Disassembly and assembly of steering valve assembly ............................................................. 8
Removal and installation of front wheel hub and brake assembly .............................................. 2
Disassembly and assembly of front wheel hub and brake assembly .......................................... 6
Removal and installation of final drive and rear brake assembly ................................................ 14
Disassembly and assembly of final drive and rear brake assembly............................................ 16
Removal and installation of front wheel assembly ...................................................................... 2
Removal and installation of rear wheel assembly ....................................................................... 4
Removal and installation of front suspension cylinder assembly ................................................ 6
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring) ... 8
Removal and installation of king pin............................................................................................ 11
Removal and installation of rear suspension cylinder assembly ................................................. 13
Disassembly and assembly of rear suspension cylinder assembly............................................. 14
Removal and installation of hoist valve assembly ....................................................................... 2
Disassembly and assembly of hoist valve assembly................................................................... 3
Disassembly and assembly of hoist cylinder assembly............................................................... 5
Body SEN04645-00
Removal and installation of body assembly ................................................................................ 2
Disassembly and assembly of operator's seat assembly ............................................................ 2
Removal and installation of air conditioner unit assembly........................................................... 12
Electrical system SEN04647-01
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of transmission controller assembly .................................................... 2
Removal and installation of retarder controller assembly............................................................ 3
Removal and installation of ABS controller assembly ................................................................. 3
Removal and installation of VHMS controller assembly .............................................................. 4
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01298-03
Power train hydraulic circuit diagram .......................................................................................... 3
Steering and hoist hydraulic circuit diagram................................................................................ 5
Brake hydraulic circuit diagram ................................................................................................... 7
Brake hydraulic circuit diagram (ASR specification).................................................................... 9
Brake hydraulic circuit diagram (ABS specification).................................................................... 11
Brake hydraulic circuit diagram (ASR and ABS specification) .................................................... 13
Electrical diagrams and drawings SEN01299-07
Electrical circuit diagram for outside cab (1/3) ............................................................................ 3
Electrical circuit diagram for inside cab (1/3)............................................................................... 9
Electrical circuit diagram for VHMS (If equipped)........................................................................ 15
18 HD785-7
Electrical circuit diagram for ABS (Outside cab) (If equipped) .................................................... 17
Electrical circuit diagram for ABS (Inside cab) (If equipped)....................................................... 19
Electrical circuit diagram for ASR (If equipped) .......................................................................... 21
Air conditioner electrical circuit diagram (If equipped) ................................................................ 23
Electrical circuit diagram for auto greasing (If equipped) ............................................................ 25
Electrical circuit diagram of external power supply heater .......................................................... 26
Connectors table and arrangement drawing ............................................................................... 27
HD785-7 19
HD785-7 Dump truck

Form No. SEN01276-15
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
20 HD785-7
SEN01277-04
HD785-7

HD785-7 7001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
HD785-7 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 HD785-7
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
HD785-7 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 HD785-7
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HD785-7 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 HD785-7
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
HD785-7 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 HD785-7
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
HD785-7 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 HD785-7
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HD785-7 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 HD785-7
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
HD785-7 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a 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 connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 HD785-7
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
HD785-7 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water 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.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a 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 related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 HD785-7
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HD785-7 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HD785-7
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HD785-7 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 HD785-7
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
HD785-7 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 HD785-7
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
HD785-7 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 HD785-7
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
HD785-7 25
Precautions when carrying out operation 1

[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

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
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
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
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 HD785-7
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
HD785-7 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 HD785-7
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a 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. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HD785-7 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 HD785-7
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
HD785-7 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 HD785-7
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
HD785-7 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 HD785-7
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.10 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.20 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.20
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
HD785-7 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it 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.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 HD785-7
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
Liters to U.S. Gallons

1 l = 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
HD785-7 37
Liters to U.K. Gallons

1 l = 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 7.699 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
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
38 HD785-7
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HD785-7 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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 81 177.8
–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 60 140.0 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
40 HD785-7
HD785-7 41
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (02)
42 HD785-7
SEN01279-04
DUMP TRUCK
HD785-7

HD785-7 7001 and up
01 Specification 1
Specification and technical data
Specification drawing ...................................................................................................................................... 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 7
Fuel, coolant and lubricants ............................................................................................................................ 8
HD785-7 1
SEN01279-04 01 Specification
Specification drawing 1
2 HD785-7
For EU
HD785-7 3
Specifications 1
Machine model HD785-7
Serial No. 7001 and up
Standard For EU
Empty kg 72,300 72,410
Max. load kg 91,000 91,000

Weight
Gross kg 163,300 163,410
(front) kg 33,980 (47%) 34,010 (47%)

Empty
distribution
Weight
(rear) kg 38,320 (53%) 38,400 (53%)
(front) kg 51,440 (31.5%) 54,910 (33.6%)

Gross
(rear) kg 111,860 (68.5%) 108,500 (66.4%)
Struck m3 40
Dump body capacity
Heaped (2 : 1) m3 60
Performance
Max. travel speed km/h 65
Gradeability (sin ) % 35
Min. turning radius m 10.1
Dumping angle ° 48
Adaptation to highland (high altitude) m 2,350
Overall length mm 10,290
Overall width mm 6,885

Dimensions
Overall height mm 5,050
Wheel base mm 4,950
Front wheel mm 4,326

Tread
Rear wheel mm 3,500
Ground clearance (Empty) mm 775
Model KOMATSU SAA12V140E-3
Type 4-cycle, water-cooled, V type in-line 12-cylinder,

direct injection, with turbocharger and after-cooler
No. of cylinders – Bore x stroke 12 – 140 x 165
mm
Piston displacement 30.5 {30,500}
{cc}
Engine
Rated output 895/1,900 {1,200/1,900}

kW/rpm{HP/rpm}
Max. torque 5,076/1,350 {518/1,350}
Nm/rpm{kgm/rpm}
Fuel consumption (Min.) 206 {154}
g/kWh {g/HPh}
Stating motor 24V, 7.5 kW x 2 units
Alternator 24V, 90A
Battery 12V, 200Ah x 4 units
4 HD785-7
Structure 3-element, 1-stage, 2-phase

Torque converter
Lock- up clutch Hydraulically actuated, wet-type, multiple-disc clutch
TORQFLOW planetary gear

Type Fully automatic, electrically-hydraulically
Transmission actuated, force-feed type pump
Power train
No. of speeds F7, R2
Type Spiral bevel gear, splash lubrication
Reduction gear Reduction ratio 3.357
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 6.333
Steering
system
Type Fully hydraulic steering system
Front axle Independent suspension (Mac Pherson type)

Suspension
Axle type Rear axle Full floating
Front axle Hydropneumatic

(Automatic damping force selection type)
Suspension method
Rear axle Hydropneumatic
Front tire 27.00R49aaE4

Size and No.
Tires
Rear tire 27.00R49aaE4
Tire pressure Front and rear tire kPa {kg/cm2} 686 {7}
Front wheel Oil cooled multiple disc brake, Hydraulically controlled

Service brake
Breke system
Rear axle Oil cooled multiple disc brake, Hydraulically controlled
Multiple disc wet type disc brake,

Parking brake Hydraulically released spring type
Retarder Oil cooled multiple disc type, Hydraulically controlled
HD785-7 5
For both steering and work equipment
Type Gear pump
Delivery /min 580

(at engine rated speed 1,900 rpm)
Hydraulic pump
For charging torque converter
Type Gear pump
Delivery /min 380

Hydraulic system
For brake cooling
Type Gear pump
Delivery /min 580

Hoist cylinder
Type 2-stage piston type

(only 2nd stage: double-acting)
Cylinder
No. 1st bore x stroke – 2nd bore x 2 – 215 mm x 1,045 mm – 180 mm x 1,040 mm
stroke
Steering cylinder
Type Piston type, double acting
No. – bore x stroke 2 – 110 mm x 475 mm
6 HD785-7
Weight table 1
This weight table is a guide for use when transporting or handling component.
Unit: kg
Serial Number 7001 and up
Engine assembly 3,365

Output shaft assembly 171
Radiator assembly 920
Fuel tank 495
Torque converter 626
Transmission assembly 1,812
Drive shaft assembly (front) 42
Drive shaft assembly (rear) 211
Rear axle assembly 10,930
• Differential 1,127
• Final drive (one-side) 2,870
• Rear brake (one-side) 1,170
Front axle (one-side) (with A frame, knuckle arm) 2,530
Front brake (one-side) 742
Front suspension cylinder (one-side) 706
Rear suspension cylinder (one-side) 246
Frame assembly (with rear support, mount bracket ) 9,194
Cab assembly 1,585
Operator's seat 45
Steering cylinder (one-side) 87
Hoist cylinder (one-side) 336
Steering control valve 66
Steering valve 24
Hoist valve 63
Hydraulic pump (SAR180+180+1) 49
Hydraulic pump (SDR100+100+SAR25) 46
Hydraulic pump (SAR180+180) 45
Dump body 15,200
HD785-7 7
Fuel, coolant and lubricants 1
q ASTM: America Society of Testing and Material
8 HD785-7
Transmission Steering, Front Rear

Engine oil pan
case hoist oil tank suspension suspension
29.8 each for 16.5 each for

Specified capacity ( ) 134 368 270
right and left right and left
Refill capacity ( ) 129 205 175 — —
Brake sub tank Differential case Final drive case Fuel tank Cooling system
64 each for right

Specified capacity ( ) 36 137 1,308 283
and left
64 each for right

Refill capacity ( ) 36 137 — 279
and left
Notice
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection
device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it
requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricat-
ing ability is used, there will be a big drop in durability.
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS (High-Temperature High-
Shear Viscosity @ 150 °C), specified by ASTM D4741 must be equal to or higher than 3.5mPa-
S(3.5cP).
Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of
pins and bushings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)

1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Super coolant (AF-NAC). Komatsu Super coolant (AF-
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2
years or 4,000 hours.
Komatsu Super coolant (AF-NAC) is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Mixing rate of water and super cool-
ant".
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more
Super coolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F).
(never dilute with water)
When temperature is below -10°C (14°F), adjust the ratio of Super coolant and water, see "Mixing rate of
water and super coolant".
3) To maintain the anticorrosion properties of Super coolant (AF-NAC), always keep the density of Super
coolant between 30% and 68%.
HD785-7 9
Mixing rate of water and super coolant

Min. atmospheric tem- °C –10 –15 –20 –25 –30
perature °F 14 5 –4 –13 –22
Liters 83.7 100.5 114.4 128.4 139.5
Amount of antifreeze
US gal 22.12 26.56 30.23 33.93 36.86
Liters 195.3 178.5 164.6 150.6 139.5
Amount of water
US gal 51.60 47.16 43.49 39.79 36.86
Volume ratio % 30 36 41 46 50
10 HD785-7
HD785-7 11
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
12 HD785-7
SEN01281-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist oil cooler.......................................... 2
Fuel system..................................................................................................................................................... 4
HD785-7 1
SEN01281-01 10 Structure, function and maintenance standard
Radiator, brake, torque converter oil cooler, aftercooler, steering, hoist

oil cooler 1
2 HD785-7
1. Pick up for radiator coolant level sensor Specifications

2. Upper tank Radiator
3. Radiator core Core type: 5 lines of aluminum waved tube
4. Oil cooler (brake, torque converter) Total radiation surface: 334.8 m2
5. Reservoir tank
6. Aftercooler (engine intake air) Torque converter, transmission, brake oil cooler
7. Air conditioner condenser Core type: PTO-LS
8. Steering hoist oil cooler Total radiation surface: 16.26 m2
A: Coolant inlet port (From engine) Steering hoist oil cooler

B: Aftercooler inlet port (From turbocharger) Core type: CF40-1
C: Aftercooler outlet port Total radiation surface: 5.18 m2
(To engine air intake manifold)
D: Coolant bypass inlet port (From engine) Aftercooler
E: Coolant outlet port (To water pump) Total radiation surface: 85.8 m2
F: Oil inlet port (From rear and front brakes)
G: Oil outlet port (To transmission) Air conditioner
Gas charge weight (HFC-134a): 900 ± 50 g
HD785-7 3
Fuel system 1
(Standard specification)
1. Fuel filter
2. Priming pump
3. Fuel pre-filter (with water separator)
4. Valve
5. Fuel tank
6. Breather
7. Block
8. Injector
9. Common rail
10. Supply pump
11. Feed pump
12. Fuel cooling plate
4 HD785-7
(Poor fuel arrangement specification)
1. Fuel filter
2. Electric priming pump
3. Fuel pre-filter (with water separator)
4. Water separator
5. Valve
6. Fuel tank
7. Breather
8. Block
9. Injector
10. Common rail
11. Supply pump
12. Feed pump
13. Fuel cooling plate
HD785-7 5
HD785-7 Dump truck

© 2007 KOMATSU
All Rights Reserved
6 HD785-7
SEN01282-03
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Power train, Part 1
Power train skeleton ....................................................................................................................................... 2
Output shaft .................................................................................................................................................... 4
Drive shaft....................................................................................................................................................... 6
Torque converter and transmission hydraulic piping....................................................................................... 8
Brake cooling oil control valve (BCV)............................................................................................................ 10
Torque converter ............................................................................................................................................11
Torque converter valve.................................................................................................................................. 19
Transmission................................................................................................................................................. 22
Transmission control valve............................................................................................................................ 50
ECMV............................................................................................................................................................ 52
Lubricating oil amount selector valve............................................................................................................ 59
HD785-7 1
Power train skeleton 1
2 HD785-7
1. Engine (SAA12V140)
2. Output shaft
3. Front drive shaft
4. Rear brake cooling pump
(SAR(4)180+180)
5. Torque converter, transmission (front brake
cooling), brake control pump
(SDR(30)100+100+SA(1)25)
6. PTO
7. Torque converter
8. Transmission
9. Rear drive shaft
10. Differential gear
11. Drive shaft
12. Brake
13. Tire
14. Final drive
15. Parking brake
16. Steering, hoist, hoist control pump
(SAR(4)180+180+(1)6)
HD785-7 3
Output shaft 1
1. Rubber cushion Function

2. Outer body The output shaft is installed to the engine flywheel,
3. Flange and absorbs the torsional vibration caused by
4. Shaft changes in the engine torque.
5. Inner body
6. Cover
4 HD785-7
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bearing size Shaft Hole clearance limit
1
and cover
–0.015 –0.008 –0.033
170 —
–0.025 –0.033 –0.017
Clearance between shaft and –0.015 –0.00 –0.017 Replace
2 95 —
bearing –0.003 –0.02 –0.003
Clearance between bearing –0.015 –0.008 –0.033
3 170 —
and cover –0.025 –0.033 –0.017
Clearance between bearing +0.015 –0.00 –0.017
4 95 —
and shaft +0.003 –0.02 –0.003
Standard size Repair limit
Wear of oil seal contact sur- Repair or
5 –0.087
face of shaft 115 replace
–0.087
Standard backlash
Original dimension: Lo
(Dimension at smallest width: L)
Defomation of rubber cushion
6 90 81 Replace
75 67
External No cracks
HD785-7 5
Drive shaft 1

2. Rear drive shaft
k Precautions for tightening torque of spider 3. For the above reason, when "retightening",
mounting bolts "removing" or "installing", be sure to replace
the existing bolts with new bolts and tighten
1. There are 2 types (new and old types) of the them to the torque specified for them.
spider mounting bolts which have the same a A new part No. is set for the new bolt. For
part No. the new part No., see the parts specifica-
a Different tightening torques are specified tions.
for the new bolt and old bolt. 3 * Spider mounting bolts (A):
376 – 446 Nm {38.3 – 45.5 kgm}

2. Since the new and old bolts cannot be distin- 3 Shaft mounting bolts (B):
guished from each other by appearances, the 490 – 608 Nm {50 – 62 kgm}
existing spider mounting bolts cannot be 3 * Spider mounting bolts (C):
reused. 337 – 400 Nm {34.4 – 40.8 kgm}
3 Shaft mounting bolt (D):
a The specified torque for the new bolt is
lower than that for the old bolt. Accord- 343 – 427 Nm {35 – 43.5 kgm}
ingly, if the new bolt is tightened to the
* Bolts of new tightening torque (New bolt
torque for the old bolt, it may be broken
values).
during operation and the machine may not
able to travel.
6 HD785-7
Front drive shaft
Rear drive shaft
Outline
q The power from the engine is transmitted
through the output shaft, the front drive shaft
(1) and the transmission, to the rear drive shaft
(2).
HD785-7 7
Torque converter and transmission hydraulic piping 1
8 HD785-7
1. Torque converter
2. Transmission
3. Oil filler tube
4. Torque converter valve
cooling), brake control pump
(SDR(30)100+100+SA(1)25)
6. Transmission oil filter (4 pieces)
7. Brake cooling oil control vale
HD785-7 9
Brake cooling oil control valve (BCV) 1
1. Pilot relief valve assembly Function

2. Body When the retarder is not being used, this valve
3. Solenoid valve bypasses part of the brake cooling oil to reduce the
4. Main valve spool power loss when traveling. The main valve spool
(4) is actuated by switching the solenoid vavle (3)
A: Pilot port ON/OFF.
B: Pilot port If abnormal pressure is generated in the retarder
S: To transmission oil pan because of a trouble in the rear retarder, oil cooler,
P: Pilot port etc., pilot relief valve (1) operates to operate main
Q: From pump valve spool (4). Accordingly, the brake cooling oil
R: To transmission oil pan control valve (BCV) works as an unload valve, too.
The figure shows the state when the brake is ON.
In this state, if the pressure of the oil from the pump
is below the pilot pressure (9 kg/cm 2), the brake
cooling oil control valve does not bypass the brake
cooling oil.
10 HD785-7
Torque converter 1
A: Main oil pressure pickup port Specifications

B: Torque converter oil inlet port Type: 3-element, 1-stage, 2-phase
C: Torque converter inlet oil pressure pickup port with modulation and lockup clutch
D: Torque converter oil outlet port Lockup clutch:Wet type multiple disc clutch
E: To transmission control valve hydraulic pressure control
F: To lockup clutch (with modulation valve)
G: Torque converter outlet oil pressure pickup port Stall torque ratio: 1.99
H: To transmission lubrication circuit
J: Main flow rate selector valve inlet pressure
pickup port
1. PTO gear (Number of teeth: 108)

2. PTO gear (Number of teeth: 91)
3. Brake cooling pump mounting port
4. Steering, hoist and hoist control pump mount-
ing port
5. Torque converter, transmission charge, brake
cooling, transmission lubrication and brake
control pump mounting port
6. Torque converter valve
7. Torque converter outlet oil temperature sensor
HD785-7 11
1. Coupling 10. Stator shaft

2. Input shaft (Number of teeth: 96) 11. Stator bushing
3. Case 12. Free wheel
4. Drive case 13. Stator
5. Boss 14. Lockup clutch disc
6. Turbine 15. Lockup clutch piston
7. Outer race 16. Lockup clutch housing
8. Pump 17. Retainer
9. Retainer
12 HD785-7
HD785-7 13
14 HD785-7
Unit: mm
Standard size Tolerance Repair limit
Outside diameter of coupling
1 –0.1
oil seal contact surface 125 124.8
–0.1
Inside diameter of input shaft +0.035
2 115 115.5
seal ring contact surface +0.035
Clearance between clutch size Shaft Hole clearance limit
3
housing and piston (outside)
–0.5 +0.097 0.500 –
420 0.88
–0.7 +0.097 0.797
Clearance between clutch –0.100 +0.072 0.110 –
4 245 0.27
housing and piston (inside) –0.172 +0.072 0.242
Inside diameter of retainer seal +0.046
5 190 190.5
ring contact surface +0.046
Inside diameter of stator shaft +0.035
6 90 90.1
seal ring contact surface +0.035
-0.1
Wear of stator Width 5.95 5.45
7 -0.1
shaft seal ring
Thickness 6.5 ±0.1 6.2
Replace
Inside diameter of free wheel
8 transmission surface of outer 140.53 ±0.013 140.56
race
Outside diameter of stator
9 shaft free wheel transmission 121.53 ±0.008 121.50
surface
Inner diameter sliding portion +0.013
10 121.65 121.73
of bushing (*1) –0.005
Thickness of sliding portion of –0.1
11 7 6.5
bushing (*1) –0.1
12 Thickness of clutch disc 5.4 ±0.1 4.8
Backlash between input shaft
13 0.18 – 0.46
and PTO gear
Clearance between PTO gear size Shaft Shaft clearance limit
14
and bearing
+0.030 –0.015 –0.045 –
65 —
+0.011 –0.015 –0.011
Clearance between bearing –0.015 +0.010 –0.025 –
15 120 —
and case –0.015 –0.025 0.025
*1 Refer to "Method of measuring dimension of bushing sliding portion"
HD785-7 15
Method of measuring dimension of bushing sliding portion
Measure inner diameter (A) and thickness (B) of

bushing sliding portion with output side bushing (2)
and input side bushing (3) installed to outer race
(1).
16 HD785-7
Power transmitting route
When lockup clutch is "disengaged" When lockup clutch is "engaged"
Drive case (4) is disconnected from boss (8) and Drive case (4) is connected to boss (8) and tur-
turbine (7) and lockup torque converter works as an bine(7) and lockup torque converter is locked up.
ordinary torque converter.
The power from engine
The power from engine O
O Output shaft
Output shaft O
O Front drive shaft
Front drive shaft O
O Coupling (1)
Coupling (1) O
O Input shaft (2), clutch housing (3), drive case (4)
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
and pump (5) rotate together O
O Lockup clutch (6)
Oil is used as medium O
O Boss (8)
Turbine (7) and boss (8) O
O Transmission input shaft (9)
Transmission input shaft (9)
q The power transmitted to input shaft (2) is also q The power transmitted to input shaft (2) is also
used as power for driving the pump after being used as power for driving the pump after being
transmitted through PTO gear. transmitted through PTO gear.
HD785-7 17
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows into inlet port (A), goes through the oil
passages of stator shaft (1), and flows into
pump (2).
q The oil is given a centrifugal force by pump (2),
and then it enters turbine (3) to transmit its
energy to turbine (3).
q The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4)
and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
transmission.
18 HD785-7
Torque converter valve 1
Unit: mm
Clearance between the torque size clearance limit
1 converter relief valve and valve Shaft Hole
body 32 –0.035 +0.016 0.035 – 0.081
–0.045 +0.016 0.061
Clearance between the main –0.035 +0.016 0.035 –
2 relief valve and valve body 32 –0.045 +0.016 0.061 0.081
Clearance between main flow –0.035 +0.013 0.035 –
3 rate selector valve and valve 25 –0.045 +0.013 0.058 0.078
body
Clearance between check –0.020 +0.052 0.020 –
4 valve and valve body 25 –0.041 +0.052 0.093 0.113
Replacement
Free length Installed Installed Free length Installed
5 Main relief valve spring length load load
1213.2 N 1153.8 N
123 99.5 {123.8 kg} 119.3 {117.6 kg}
Torque converter relief valve 331.2 N 315.0 N
6 spring 137 93.5 {33.8 kg} 132.9 {32.1 kg}
Poppet spring 32.0 N 30.8 N
7 (Torque converter relief and 26 17.0 {3.3 kg} 25.2 {3.1 kg}
main relief)
Main flow rate selector valve 96.7 N 91.9 N
8 spring 95 55.5 {9.87 kg} 92.2 (9.38 kg}
3.97 N 3.82 N
9 Check valve spring 45 30 {0.41 kg} 43.7 {0.39 kg}
10. Solenoid valve for main relief valve
11. Solenoid valve for main flow rate selector valve
12. Oil pressure switch for main relief valve
13. Oil pressure switch for main flow rate selector valve
HD785-7 19
Main flow rate selector valve

Outline
This valve switches the amount of oil to be fed to the main relief valve.
If one of the 2 charge pumps is enough to secure the main pressure, oil from the remaining pump is flown to
the torque converter bypassing the main relief valve. This arrangement reduces the pump load and improves
the fuel consumption.
This switching takes place automatically responding to the engine speed being set at each gear speed.
Operating condition
Engine speed (rpm)
Gear Speed
From ON to OFF From OFF to ON
F1, F2, RL, RH 1,000 1,100
N 1,450 1,550
Normal operation takes place at F3 - F7.
Principle of operation
When the solenoid is "de-energized" When the solenoid is "energized"
(When oil from the pump is merged) (When oil from the pump is divided)
q When current is not conducted to solenoid (1), q Conducting current to solenoid (1) generates
oil pressure force does not work on chamber oil pressure in chamber (A). Thus, main flow
(A). Thus, main flow rate selector valve (2) is rate selector valve (2) is pushed to the right.
pushed to the left by spring (3).
In this case, oil from pump (B) alone flows
In this case, all of oil delivered from pumps (B) through main relief valve (4). And oil from
and (C) flows through main relief valve (4) to pump (C) flows to the torque converter,
the torque converter. bypassing main relief valve (4).
20 HD785-7
Main relief valve When solenoid is "energized" (F4, F5, F6 or F7)

Outline
This valve has the function of switching the main
relief pressure. When a high gear speed (F4 - F7) is
selected and, thus, a lower clutch holding pressure
is required, function of this valve reduces the main
relief oil pressure, which decreases the pump load
and enhances the fuel consumption.
When solenoid is "de-energized" (RL, RH, N, F1,

F2 or F3)
q As current is conducted to solenoid (1), oil

pressure is generated in chamber (A). Thus, oil
pressure in chamber (A) is balanced against
force of spring (4), starting pressure regulation
by main relief valve (3). Since diameter of pis-
ton (2) at this point is larger than diameter of
chamber (B), the oil pressure as current is con-
ducted to solenoid (1) is adjusted to a level
lower than that when current is not conducted.
q When current is not conducted to solenoid (1), a Main relief pressure: 2.16 MPa {22.0 kg/cm2}
chamber (A) is connected to the drain port and (At engine speed 1,900 rpm)
no oil pressure is generated. Thus, oil pressure
in chamber (B) is balanced against force of
spring (4), starting pressure regulation by main
relief valve (3).
a Main relief pressure: 3.53 MPa {36.0 kg/cm2}

(At engine speed 1,900 rpm)
HD785-7 21
Transmission 1
22 HD785-7
A: Speed sensor (for input shaft speed)

B: Speed sensor (for intermediate shaft speed)
C: Speed sensor (for output shaft speed)
D: From sub-tank
E: Torque converter intermediate oil pressure
sensor
F: To pump (suction)
G: From torque converter (lubrication circuit)
H: From torque converter (main circuit)
J: From torque converter (drain circuit)
K: To lockup clutch
L: Lubricating oil temperature sensor
M: From oil cooler
N: Lubricating oil pressure pickup port
P: To breather
Q: To torque converter valve
(To pilot circuit of main flow rate selector valve
and main oil pressure selector valve)
R: Lubrication relief valve
1. Transmission input shaft

2. Transmission control valve
3. Transmission output shaft
4. Strainer
5. Drain valve
6. Lubricating oil amount selector valve
HD785-7 23
24 HD785-7
1. Transmission input shaft Outline

2. H sun gear (Number of teeth: 34) q The transmission employed consists of the unit
3. H hub planetary mechanism and disc clutch that pro-
4. H clutch vides "7 forward gear speeds and 2 reverse
5. H planetary pinion (Number of teeth: 32) gear speeds".
6. H carrier q Among the 7 sets of planetary gear system
7. L ring gear (hub) and disc clutches of the transmission, 2
8. L clutch clutches are fixed hydraulically with the ECMV
9. H ring gear (Number of teeth: 98) to select 1 rotating direction and gear speed.
10. L clutch housing q The transmission transmits the power being
11. 4th clutch housing transmitted to the transmission input shaft to
12. 4th clutch drum the output shaft after selecting a single speed
13. 4th clutch in the range of the 1st – 7th speed in the for-
14. 4th hub ward and the L – H speed in the reverse travel.
15. 3rd planetary pinion (Number of teeth: 20) In this case, the gear speed change is done
16. 3rd clutch through the combination of H and L clutches, 4
17. 3rd ring gear (Number of teeth: 86) speed clutches and R clutch.
18. 3rd sun gear (Number of teeth: 46)
19. R clutch Number of plates and discs used
20. R planetary pinion (Number of teeth: 20)
21. R sun gear (Number of teeth: 58) Clutch No. Number of plates Number of discs
22. R ring gear (Number of teeth: 98) H clutch 4 5
23. 2nd clutch L clutch 4 5
24. 2nd ring gear (Number of teeth: 98, 97)
4th clutch 3 4
25. 2nd planetary pinion (Number of teeth: 28)
26. 2nd sun gear (Number of teeth: 42) 3rd clutch 3 4
27. 1st, 2nd carrier 2nd clutch 5 5
28. 1st clutch 1st clutch 5 5
29. 1st ring gear (Number of teeth: 85)
R clutch 5 5
30. Transmission output shaft
31. 1st planetary pinion (Number of teeth: 31)
Combinations of clutches at respective gear
32. 1st clutch piston
33. 2nd clutch piston speeds and reduction ratio
34. Intermediate shaft (1st sun gear's number of Gear Speed Clutch used Reduction ratio
teeth: 23) Forward 1st L x 1st 4.696
35. R clutch piston
Forward 2nd L x 2nd 3.333
36. 3rd carrier
37. 4th clutch piston Forward 3rd H x 2nd 2.475
38. L clutch piston Forward 4th L x 3rd 1.838
39. H clutch piston Forward 5th H x 3rd 1.365
40. 3rd clutch piston
Forward 6th L x 4th 1.000
41. R carrier
42. Hub Forward 7th H x 4th 0.742
Revers L LxR 5.244
Revers H HxR 3.894
HD785-7 25
26 HD785-7
Unit: mm
Installed Installed Installed
Free length Free length
1 H clutch spring length load load
63.3 N 53.9 N
90 53.5 84.6
{6.5 kg} {5.5 kg}
125.4 N 106.8 N
2 3rd clutch spring 48.9 43 46
{12.8 kg} {10.9 kg}
203.8 N 173.4 N
3 2nd clutch spring 85.3 62.3 80.2
{20.8 kg} {17.7 kg}
199.2 N 169.5 N
4 1st clutch spring 85.3 62.8 80.2
{20.4 kg} {17.3 kg}
247.2 N 209.7 N
5 R clutch spring 85 74 79.9
{25.2 kg} {21.4 kg}
Total assembled thickness of 5 Standard size Tolerance Repair limit
6
discs and 4 plates for H clutch 50.2 ±0.30 46.4
Total assembled thickness of 5
7 50.2 ±0.30 46.4
discs and 4 plates for L clutch
8 discs and 3 plates for 4th 39 ±0.26 36.0
clutch
9 discs and 3 plates for 3rd 39 ±0.26 36.0
clutch
Total assembled thickness of 5 Replace
10 discs and 5 plates for 2nd 56 ±0.40 52.0
clutch
11 discs and 5 plates for 1st 56 ±0.40 52.0
clutch
12 55 ±0.32 51.0
discs and 5 plates for R clutch
H,L,4th 5.4 ±0.1 4.8
Thickness of a sin- 3rd 5.4 ±0.1 4.8
13
gle disc 2nd,1st 5.4 ±0.15 4.8
R 5.2 ±0.1 4.6
H 5.8 ±0.1 5.6
L,4th 5.8 ±0.1 5.6
Thickness of a sin-
14 3rd 5.8 ±0.1 5.6
gle plate
2nd,1st 5.8 ±0.1 5.6
R 5.8 ±0.1 5.6
Wear of transmis- –0.01
Width 3 2.7
15 sion input shaft –0.03
seal ring Thickness 3.7 ±0.12 3.55
–0.1
Wear of H carrier Width 3.95 3.56
16 –0.1
seal ring
Thickness 4.95 ±0.1 4.8
HD785-7 27
Unit: mm
Wear of 4th ring –0.1
17 Width 4.36 3.92
gear seal ring –0.1
Thickness 3 ±0.1 2.85
–0.01
Wear of 3rd sun Width 3 2.7
18 –0.03
gear seal ring
Wear of L and 4th –0.04
Width 4.5 4.05
19 clutch collars seal –0.08
ring Thickness 5 ±0.15 4.85
–0.1
Wear of 3rd car- Width 3.95 3.56
20 –0.1
rier seal ring
Thickness 5.3 ±0.15 5.15
Wear of 2nd and –0.01
Width 4 3.6
21 1st carriers seal –0.04
ring Thickness 4 ±0.15 3.85
–0.1
Wear of R carrier Width 4.45 4.01
22 –0.1
seal ring (inside)
–0.01
Wear of R carrier Width 4 3.6
23 –0.04
seal ring (outside)
Backlash between H sun gear
24 0.11 – 0.33
and planetary pinion
Backlash between H planetary Replace
25 0.12 – 0.43
pinion and ring gear
Backlash between 3rd sun
26 0.11 – 0.36
gear and planetary pinion
Backlash between 3rd plane-
27 0.12 – 0.46
tary pinion and ring gear
Backlash between 2nd sun
28 0.13 – 0.37
Backlash between 2nd plane-
29 0.13 – 0.46
Backlash between 1st sun
30 0.14 – 0.33
Backlash between 1st plane-
31 0.14 – 0.49
Backlash between R sun gear
32 0.16 – 0.36
and planetary pinion
Backlash between R planetary
33 0.13 – 0.46
pinion and ring gear
Deterioration of disc internal
34 Repair limit: 0.5
gear
Thickness of thrust washer Standard size Tolerance Repair limit
35
(H and 3rd planetary pinions) 2 ±0.1 1.5
Thickness of thrust washer
36 3 ±0.1 2.5
(2nd and 1st planetary pinions)
Thickness of thrust washer
37 2 ±0.1 1.5
(R planetary pinion)
28 HD785-7
Unit: mm
Location Standard clearance Clearance limit
H gear train 0.30 – 0.80 1.5
3rd gear train 0.30 – 0.80 1.5 Replacement of
Side clearance on planetary
38 thrust washer
pinion 2nd gear train 0.30 – 0.80 1.5 or carrier
1st gear train 0.30 – 0.80 1.5
R gear train 0.30 – 0.80 1.5
Stepped-type wear on seal ring Standard size Amount of wear
39
mating surface — Max. 0.05
Standard size Tolerance Amount of wear Replace
Contact surface of output shaft
40 –0.100
oil seal 130 129.8
–0.100
Clutch No.
size Shaft Hole clearance limit
H –0.5 +0.097 0.5 –
425 0.88
(outside) –0.7 +0.097 0.797
H –0.135 +0.097 0.135 –
405 0.36
(inside) –0.232 +0.097 0.329
L and 4th –0.1 +0.081 0.1 – In case there is
310 0.64 damage on the
(outside) –0.5 +0.081 0.581
surface such as
L and 4th –0.110 +0.081 0.11 – streaks by sei-
285 0.30
(middle) –0.191 +0.081 0.272 zure, but the
L and 4th –0.5 +0.063 0.5 – clearance can
Clearance 180 0.84
(inside) –0.7 +0.063 0.763 be maintained
41 between cylinder
within the spec-
and piston 3rd, 2nd
–0.5 +0.063 0.5 – ified limit after
and 1st 470 0.84 the repair, the
–0.7 +0.063 0.763
(outside) parts can be
3rd –0.135 +0.097 0.135 – reused.
425 0.32 Replace if dam-
(inside) –0.198 +0.097 0.295
aged severely.
2nd and
–0.135 +0.063 0.135 –
1st 410 0.29
–0.198 +0.097 0.261
(inside)
R –0.5 +0.110 0.5 –
540 0.89
(outside) –0.7 +0.097 0.81
R –0.135 +0.097 0.135 –
465 0.36
(inside) –0.232 +0.097 0.329
HD785-7 29
Disc clutch Operation

Structure When clutch is "engaged" (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through the oil passage
return spring (6) and washer (8). of housing (7) and pushes piston (2) right-
q Inside teeth of disc (4) are engaged with outward.
side teeth of ring gear (1). q Piston (2) contacts plate (3) closely against
q Plate (3) is assembled to clutch housing (7) disc (4) to stop rotation of disc (4) by use of the
with pin (5). friction force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is "disengaged" (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back leftward by return spring (6).
q The friction force between plate (3) and disc
(4) is released and ring gear (1) is released.
q Washer spring (8) is installed between plate (3)
of the pin block and plate (3). This spring
quickens return of piston (2) as the clutch is
disengaged by providing smooth separation of
plate (3) and disc (4). At the same time, it is
used for preventing the dragging.
30 HD785-7
HD785-7 31
Power transmitting route

Forward 1st speed
32 HD785-7
L ring gear (3) of the L clutch and 1st ring gear (22) of the 1st clutch are fixed hydraulically.
Power from torque converter

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (6)
O
H ring gear (7)
O
L clutch housing (8)
O
Intermediate shaft (9)
O
1st planetary pinion (21)
O
1st, 2nd carrier (23)
O
Output shaft (29)
HD785-7 33
Forward 2nd speed
34 HD785-7
L ring gear (3) of the L clutch and 2nd ring gear (18) of the 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (6)
O
H ring gear (7)
O
O
O
2nd sun gear (19)
O
2nd planetary pinion (20)
O
O
Output shaft (29)
HD785-7 35
Forward 3rd speed
36 HD785-7
H sun gear (4) of the H clutch and 2nd ring gear (18) of the 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
H planetary pinion (5)
O
H ring gear (7)
O
O
O
2nd sun gear (19)
O
2nd planetary pinion (20)
O
O
Output shaft (29)
HD785-7 37
Forward 4th speed
38 HD785-7
L ring gear (3) of the L clutch and 3rd ring gear (16) of the 3rd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (6)
O
H ring gear (7)
O
O
Intermediate shaft (9) o o o
O O
3rd sun gear (14) 2nd sun gear (19)
O O
3rd planetary pinion (15) O
O O
3rd carrier (17) O
O O
2nd ring gear (18) O
O O
2nd planetary pinion (20) i i i
O
O
Output shaft (29)
HD785-7 39
Forward 5th speed
40 HD785-7
H sun gear (4) of the H clutch and 3rd ring gear (16) of the 3rd clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
O
H ring gear (7)
O
O
O O
3rd sun gear (14) 2nd sun gear (19)
O O
3rd planetary pinion (15) O
O O
3rd carrier (17) O
O O
O O
O
O
Output shaft (29)
HD785-7 41
Forward 6th speed
42 HD785-7
L ring gear (3) of the L clutch and 4th clutch drum (11) of the 4th clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (6)
O
H ring gear (7)
O
O
O O
4th clutch housing (10) 2nd sun gear (19)
O O
4th clutch drum (11) O
O O
4th clutch (12) O
O O
4th hub (13) O
O O
3rd carrier (17) O
O O
O O
O
O
Output shaft (29)
HD785-7 43
Forward 7th speed
44 HD785-7
H sun gear (4) of the H clutch and 4th clutch drum (11) of the 4th clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
O
H ring gear (7)
O
O
O O
4th clutch housing (10) 2nd sun gear (19)
O O
4th clutch drum (11) O
O O
4th clutch (12) O
O O
4th hub (13) O
O O
3rd carrier (17) O
O O
O O
O
O
Output shaft (29)
HD785-7 45
Reverse L speed
46 HD785-7
L ring gear (3) of the L clutch and R ring gear (27) of the R clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
L ring gear (3)
O
L clutch (6)
O
H ring gear (7)
O
O
O
1st planetary pinion (21) i i i
O I
1st ring gear (22) 1st, 2nd carrier (23)
O I
Hub (24) I
O I
R sun gear (25) I
O I
R planetary pinion (26) I
O I
R carrier (28) I
(R ring gear (27) is fixed with R clutch = I
R carrier (28) is rotated reverse to input I
shaft (1)) I
O I
Output shaft (29) o o o
HD785-7 47
Reverse H speed
48 HD785-7
H sun gear (4) of the L clutch and R ring gear (27) of the R clutch are fixed hydraulically.

O
Input shaft (1)
O
H carrier (2)
O
O
H ring gear (7)
O
O
O
1st planetary pinion (21) i i i
O I
1st ring gear (22) 1st, 2nd carrier (23)
O I
Hub (24) I
O I
R sun gear (25) I
O I
R planetary pinion (26) I
O I
R carrier (28) I
(R ring gear (27) is fixed with R clutch = I
R carrier (28) is rotated reverse to input I
shaft (1)) I
O I
Output shaft (29) o o o
HD785-7 49
Transmission control valve 1
A: H clutch oil pressure pickup port 1. H clutch ECMV

B: L clutch oil pressure pickup port 2. L clutch CMV
C: Lockup clutch oil pressure pickup port 3. Lockup clutch ECMV
D: 4th clutch oil pressure pickup port 4. 4th clutch ECMV
E: R clutch oil pressure pickup port 5. R clutch ECMV
F: 3rd clutch oil pressure pickup port 6. 3rd clutch ECMV
G: 2nd clutch oil pressure pickup port 7. 2nd clutch ECMV
H: 1st clutch oil pressure pickup port 8. 1st clutch ECMV
J: To breather 9. Last chance filter
K: To torque converter valve 10. Valve seat
(To pilot circuit of main flow rate selector valve
and main oil pressure selector valve)
L. To Lubricating oil amount selector valve
50 HD785-7
Operation table of ECMV

ECMV
gear L H 1st 2nd 3rd 4th R L/U
speed
F1 Q Q Q
F2 Q Q Q
F3 Q Q Q
F4 Q Q Q
F5 Q Q Q
F6 Q Q Q
F7 Q Q Q
N
R1 Q Q Q
R2 Q Q Q
L/U: Indicates the lockup clutch ECMV
Outline
q In the forward and reverse travel, lockup clutch ECMV operates at a speed faster than the travel speed
being set from the transmission controller.
q There are 3 types of ECMV's used, which have the following distinctions and differences.
Fill switch
Printing on nameplate Color Stamp
Flow detection valve (Operation pressure: Used clutch
(A) (B) (C)
MPa {kg/cm2})
Equipped Equipped
D******* — — H, 1st, 2nd, 3rd, R
(Without slit) (0.24 {2.45})
K******* — — Not equipped Not equipped L/U
Equipped Equipped
Q******* Pink S L, 4th
(With slit) (0.24 {2.45})
HD785-7 51
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For L, H, 1st, 2nd, 3rd and 4th clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1: The pressure control valve spool of the unit for
P: From pump H, 1st, 2nd, 3rd and R clutches is different from
T: Drain one for L and 4th clutches.
Dr: Drain
P1: Clutch oil pressure pickup port *2: The nameplate stamp of unit for H, 1st, 2nd,
3rd and R clutches is different from one for L
1. Fill switch connector and 4th clutches.
2. Proportional solenoid connector
Clutch used Printing on nameplate
3. Flow detection valve
4. Fill switch H, 1st, 2nd, 3rd, R D*******
5. Proportional solenoid L, 4th Q*******
6. Pressure control valve (*1)
7. Nameplate (*2)
52 HD785-7
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust

This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure.
The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current - propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force - Hydraulic pressure charac-

teristics of proportional solenoid
Range A : Before shifting gear (When draining)

Range B : During filling ECMV and fill switch
Range C : Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D : During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E : Start of filling turned "ON" by the pressure of the clutch. The
Point F : Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
HD785-7 53
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned "OFF".
Range A : Before shifting gear (When draining)
Range B : During filling
Range C : Pressure regulation
Range D : During filling (During triggering)
Point E : Start of filling
Point F : Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
54 HD785-7
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is applied to proportional solenoid (1) q As current is conducted to proportional sole-

while no pressure is applied to the clutch pis- noid (1), the solenoid generates thrust in pro-
ton, the thrust of the solenoid pushes ball (6) to portion to the current. The pressure is settled
the left to choke the drain circuit. as the sum of this thrust of the solenoid, thrust
q Hydraulic force balanced with the thrust of the generated by the oil pressure in clutch port and
solenoid is applied to chamber (B) and pres- the repulsive force of pressure control valve
sure control valve (3) moves to the left. spring (2) is balanced.
q Oil starts flowing from pump port (P) through
orifice (a) of flow detection valve (4) into the
clutch chamber.
q Differential pressure is generated between the
upstream side and downstream side of orifice
(a) of flow detection valve (4) and flow detec-
tion valve (4) moves to the left.
q If the clutch chamber is filled with oil and no oil
flows from pump port (P) into clutch port (A),
the differential pressure between both sides of
orifice (a) of flow detection valve (4) lowers to
zero.
q Flow detection valve (4) is pushed to the right
by the hydraulic force generated by the area
difference between clutch port (A) side and
drain port side of flow detection valve and the
fill switch (5) is turned "ON".
HD785-7 55
For lockup clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump
Clutch used Printing on nameplate
T: Drain
Dr: Drain Lockup K*******
P1: Clutch oil pressure pickup port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
56 HD785-7
Outline Operation
q This valve is used to switch the clutch in order When traveling in torque converter range
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
q While no current is flowing into proportional

At gear shift (in direct travel)
solenoid (1), pressure control valve (3) drains
the oil from clutch port (A) through drain port
(T).
HD785-7 57
When traveling in direct range

(Torque converter travel o direct travel)
q If current is applied to proportional solenoid

(1), the thrust of the solenoid pushes ball (4) to
the left to choke the drain circuit.
q Hydraulic force balanced with the thrust of the
solenoid is applied to chamber (B) and pres-
sure control valve (3) moves to the left.
q Pump port (P) and clutch port (A) open and oil
starts flowing into the clutch.
q As the clutch is filled with oil, the solenoid
thrust is balanced with the sum of the thrust
generated from oil pressure of the clutch port
and the tension of the pressure control valve
spring (2), then the pressure is settled.
q To reduce gear shift shocks, the hydraulic
pressure applied to the clutch piston is lowered
temporarily when the gear is shifted. At this
time, the force pressing the clutch piston is bal-
anced with the internal pressure of the torque
converter.
58 HD785-7
Lubricating oil amount selector valve 1
Unit: mm
Clearance between the spool size Shaft Hole clearance limit
1
and valve body
–0.035 +0.016 0.035 –
40 0.081
–0.045 +0.016 0.061
Standard size Repair limit Replace
Lubricating oil amount selector Free length Free length
2 length load load
valve spring
134.3 N 127.4 N
103.5 65 100.4
{13.7 kg} {13.0 kg}
HD785-7 59
Outline When the solenoid is "energized"

This valve switches the amount of lubricating oil to
be fed to the transmission.
If the amount of oil needed for lubricating the trans-
mission is small, it reduces the oil less than the nor-
mal level.
This arrangement reduces oil loss in the operation
and improves the fuel consumption.
This switching takes place automatically when F6
or F7 is selected.
Principle of operation
When the solenoid is"de-energized"
q As current is conducted to solenoid (1), oil

pressure is generated in chamber (A) and
spool (2) is pushed to the left. As the result,
space of passage (B) of lubricating oil is
reduced.
Unlike when the solenoid is de-energized, the
reduced passage flows a large amount of oil to
relief valve (4) in front of the valve, reducing
the lubricating oil in the transmission.
q While current is not conducted to solenoid (1),

chamber (A) is connected to the drain port.
Thus oil pressure is not generated. Thus, spool
(2) is constantly pushed rightward by force of
spring (3).
60 HD785-7
HD785-7 61
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
62 HD785-7
SEN01283-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Power train, Part 2
Axle ................................................................................................................................................................. 2
Differential ....................................................................................................................................................... 4
Final drive ....................................................................................................................................................... 5
Wheels ............................................................................................................................................................ 6
HD785-7 1
Axle 1
Front
1. Wheel hub
2 HD785-7
Rear
1. Differential Specifications
2. Axle housing Reduction ratio
3. Brake Differential: 3.357
4. Final drive Final drive : 6.333
Oil
Differential: T030 (137 liters)
Final drive : T030 (64 liters each side)
Tire size : 27.00R49
Rim size: 19.50 x 49
HD785-7 3
Differential 1
1. Coupling Specifications
2. Cross shaft Type: Spiral bevel gear, splash-type lubrication
3. Bevel gear (No. of teeth: 47) Reduction ratio: 3.357
4. Side gear (No. of teeth: 24) Differential: Straight bevel gear, splash-type
5. Pinion gear (No. of teeth: 20) lubrication
6. Bevel pinion (No. of teeth: 14) Oil: T030 (137 liters)
Unit: mm
Wear of oil seal contact sur- Repair or
7 –0.100
face of coupling 150 — replace
–0.100
Thickness of side gear thrust –0.100
8 9 8.5 Replace
washer –0.050
Backlash between bevel gear
9 0.41 – 0.56 Adjust
and pinion
4 HD785-7
Final drive 1
1. Sun gear (No. of teeth: 18) Specification

2. Planetary gear (No. of teeth: 37) Type: Planetary gear, splash-type lubrication
3. Planetary gear shaft Reduction ratio: 6.333
4. Ring gear (No. of teeth: 96) Oil: T030 (64 liters each side)
5. Inner hub
6. Wheel hub
7. Drive shaft
Unit: mm
Backlash between planetary Standard backlash Repair limit
8
gear and sun gear 0.21 – 0.73 0.8
Replace
Backlash between planetary
9 0.25 – 0.83 1.0
gear and ring gear
Repair or
10 Curvature of drive shaft Repair limit: 1.5 TIR
replace
11 Thickness of spacer Replace
51 ±0.1 49
HD785-7 5
Wheels 1
Front wheel Rear wheel
1. Tire 1. Tire
2. Rim assembly 2. Rim assembly
3. Valve 3. Valve
4. Extension
Specifications Specifications
Rim size: 19.50 x 49 Rim size: 19.50 x 50
Tire size : 27.00R49 Tire size : 27.00R49
6 HD785-7
HD785-7 7
HD785-7 Dump truck

© 2007 KOMATSU
All Rights Reserved
8 HD785-7
SEN01284-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Steering system
Steering column .............................................................................................................................................. 2
Steering linkage .............................................................................................................................................. 3
HD785-7 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
2 HD785-7
Steering linkage 1
1. Center lever 3. Arm (A-frame)

2. Tie rod 4. Knuckle arm
HD785-7 3
4 HD785-7
Unit: mm
Clearance between inner and size Shaft Hole clearance limit
5
outer for knuckle arm bushing
0.150 –
190 0.7
0.270
Clearance between bushing –0.035 +0.054 0–
6 105 0.3
and pin –0.022 +0.054 0.076
Clearance between steering
–0.025 +0.069 0.055 –
7 cylinder mounting pin and 50 0.3
–0.064 +0.030 0.133
bushing
Clearance between inner and 0.120 –
8 100 0.4
outer bushing 0.250
Clearance between tie rod –0.025 +0.069 0.055 –
9 50 0.3
mounting pin and bushing –0.064 +0.030 0.133
10 120 0.4
outer bushing 0.250
Replace
Clearance between arm –0.030 +0.076 0.060 –
11 60 0.3
12 120 0.4
outer bushing 0.250
Clearance between arm –0.030 +0.076 0.060 –
13 60 0.3
Clearance between center
–0.030 +0.197 0.167 –
14 lever mounting pin and bush- 60 1.0
–0.076 +0.137 0.273
ing
15 100 0.4
outer bushing 0.250
Clearance between tie rod –0.025 +0.069 0.055 –
16 50 0.3
Clearance between suspen-
–0.030 +0.046 0.030 –
17 sion cylinder mounting pin and 80 0.3
–0.076 +0.054 0.122
bushing
HD785-7 5
HD785-7 Dump truck

© 2007 KOMATSU
All Rights Reserved
6 HD785-7
SEN01285-04
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Brake system
Brake piping .................................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Secondary brake valve ................................................................................................................................... 7
Accumulator charge valve............................................................................................................................... 8
Accumulator .................................................................................................................................................. 12
Slack adjuster ............................................................................................................................................... 14
Brake, parking brake ..................................................................................................................................... 18
Parking brake solenoid ................................................................................................................................. 24
Retarder control valve................................................................................................................................... 25
Exhaust brake ............................................................................................................................................... 26
HD785-7 1
Brake piping 1
2 HD785-7
1. Slack adjuster (Front) 7. Accumulator (parking brake)

2. Slack adjuster (Rear) 8. Accumulator (rear brake)
3. Secondary brake valve 9. Accumulator (front brake)
4. Brake valve (Service brake valve) 10. Retarder control valve
5. Parking brake valve 11. Brake system tank
6. Accumulator change valve 12. Check valve
a For the brake control hydraulic circuit diagram, see the hydraulic circuit diagram in the circuit diagram
collection.
HD785-7 3
Brake valve 1
1. Pilot piston A: To rear brake

2. Rod B: To front brake
3. Lower cylinder C: To brake system tank
4. Spool D: From front accumulator
5. Upper cylinder E: From rear accumulator
6. Spool
4 HD785-7
Operation Applying brake when upper valve fails

Upper portion • Even if there is leakage of oil in the upper pip-
• When brake pedal (1) is depressed, the operating, spool (5) is moved down mechanically
ing force is transmitted to spool (3) through rod when pedal (1) is depressed, and the lower por-
(2) and spring (4). When spool (3) goes down, tion is actuated normally.
drain port (a) is closed, and the oil from the The upper valve is not actuated.
pump and accumulator flows from port (A) to
port (C) and actuates the rear brake cylinders. Applying brake when lower valve fails
• Even if there is leakage of oil in the lower pip-
Lower portion ing, the upper portion is actuated normally.
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port (b) is closed,
and the oil from the pump and accumulator
flows from port (B) to port (D) and actuates the
front brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the rear brake cylinders and the
pr e s s ur e b et we en p or t ( A ) an d po r t ( C )
becomes high, the oil entering port (H) from ori-
fice (e) of spool (3) pushes against spring (4). It
pushes up spool (3) and shuts off the circuit
between port (A) and port (C). When this hap-
pens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
HD785-7 5
Lower portion Brake released

• When spool (3) in the upper portion moves up Upper portion
and the circuit between port (A) and port (C) is • When pedal (1) is released and the operating
shut off, oil also fills the front brake cylinder at force is removed from the top of the spool, the
the same time, so the pressure in the circuit back pressure from the brake cylinder and the
between port (B) and port (D) rises. The oil force of the spool return spring move spool (3)
entering port (J) from orifice (f) of spool (5) up. Drain port (a) is opened and the oil from the
pushes up spool (5) by the same amount that brake cylinder flows to the brake system tank
spool (3) moves, and shuts off port (B) and port return circuit to release the rear brakes.
(D). Drain port (b) is closed, so the oil entering
the brake cylinder is held, and the brake is Lower portion
applied. • When the pedal is released, spool (3) in the
• The pressure in the space in the upper portion upper portion moves up. At the same time, the
is balanced with the operating force of the back pressure from the brake cylinder and the
pedal, and the pressure in the space in the force of the spool return spring move spool (5)
lower portion is balanced with the pressure in up. Drain port (b) is opened and the oil from the
the space in the upper portion. When spools (3) brake cylinder flows to the brake system tank
and (5) move to the end of their stroke, the cir- return circuit to release the front brake.
cuits between ports (A) and (C) and between
ports (B) and (D) are fully opened, so the pres-
sure in the space in the upper and lower por-
tions and the pressure in the left and right brake
cylinders is the same as the pressure from the
pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
6 HD785-7
Secondary brake valve 1
1. Rod Function
2. Spool q This valve operates the brake depending on
3. Cylinder the parking brake release pressure controlled
by the secondary brake pedal.
A: To parking brake valve
P: From accumulator
T: To brake system tank
HD785-7 7
Accumulator charge valve 1
1. Main relief valve (R3) Specification

2. Valve body q Cut in pressure: 11.8 MPa {120 kg/cm2}
3. Relief valve (R1) q Cut out pressure: 20.6 MPa {210 kg/cm2}
4. Relief valve (H1)
5. Filter Function
6. Filter
q The accumulator charge valve is actuated to
maintain the oil pressure from the pump at the
ACC:To parking brake accumulator (right)
specified pressure and to store it in the accu-
P: From hydraulic pump
mulator.
PP: From parking brake accumulator (right)
q When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
8 HD785-7
HD785-7 9
Operation 2. When oil supplied to accumulator

1. When no oil is being supplied to accumula- 1) Cut-in condition
tor (cut-out condition) q When the pressure at port (B) is lower
q The pressure at port (B) is higher than the set than the set pressure of the relief valve
pressure of the relief valve (R1), so piston (8) (R1), piston (8) is pushed back down by
is forcibly pushed up by the oil pressure at port spring (5).
(B). Poppet (6) is opened, so port (C) and port Valve seat (7) and poppet (6) are brought
(T) are short circuited. into tight contact, and port (C) and port (T)
q The spring chamber at the right end of spool are shut off.
(15) is connected to port (C) of the relief valve q The spring chamber at the right end of
(R1), so the pressure becomes the brake oil spool (15) is also shut off from port (T), so
tank pressure. The oil from the pump enters the pressure rises, and the pressure at
port (P), pushes spool (15) to the right at a low port (P) also rises in the same way.
pressure equivalent to the load on spring (14). q When the pressure at port (P) goes above
q It also passes through orifices (17), (18) and the pressure at port (B) (accumulator
(16), and flows to the brake oil tank. pressure), the supply of oil to the accumu-
lator starts immediately. In this case, it is
decided by the size (area) of orifice (17)
and the pressure difference (equivalent to
the load on spring (14)) generated on both
sides of the orifice. A fixed amount is sup-
plied regardless of the engine speed.
10 HD785-7
2) When cut-out pressure is reached 3. Main relief valve (R3)

q When the pressure at port (B) (accumula- q If the pressure at port (P) (pump pressure)
tor pressure) reaches the set pressure of goes above the set pressure of the relief valve
the relief valve (R1), poppet (6) separates (R3), the oil from the pump pushes spring (3).
from valve seat (7), so an oil flow is gener- Ball (11) is pushed up and the oil flows to the
ated and the circuit is relieved. brake oil tank circuit, so this set the maximum
q When the circuit is relieved, a pressure pressure in the brake circuit and protects the
difference is generated above and below circuit.
piston (8), so piston (8) moves up, poppet
(6) is forcibly opened, and port (C) and
port (T) are short circuited.
q The spring chamber at the right end of
spool (15) is connected to port (C) of the
relief valve (R1), so the pressure becomes
the brake oil tank pressure.
q The pressure at port (P) drops in the same
way to a pressure equivalent to the load
on spring (14), so the supply of oil to port
(B) is stopped.
HD785-7 11
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
q The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibil-
ity of the gas to absorb the pulse of the hydrau-
lic pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Front brake, rear brake, parking brake
Gas used : Nitrogen gas
Charge amount : 4,000 cc
Charging pressure:
6.2 ± 0.2 MPa {63 ± 2 kg/cm2}
12 HD785-7
HD785-7 13
Slack adjuster 1
Front
1. Cylinder Specifications
2. Check valve Piston operation pressure:
3. Piston 9.8 – 19.6 kPa {0.1 – 0.2 kg/cm2}
4. Air bleeding valve Check valve cracking pressure
(When cooling pressure is 0):
A: Inlet port 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2}
B: Outlet port Check valve closing pressure:
1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}
Unit: mm
Clearance between body and size Shaft Hole clearance limit
5
piston
–0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Spring Installed Installed Installed
Free length
6 Slack adjuster spring coefficient length load load
0.45 N/mm 54.9 N
76.3 — —
{0.046 kg/mm} {5.6 kg}
14 HD785-7
Function q When the braking force generated by stroke

q The slack adjuster is installed to the brake cyl- (S) is insufficient because of wear of the brak-
inder directly and used to keep the brake time ing distance etc., if the brake pedal is kept
lag constant. depressed and the oil pressure discharged
through the brake valve exceeds the set pres-
Operation sure, check valve (2) opens and a pressure is
1. When brake pedal is depressed applied to port (B) and it acts as an additional
q Before the brake pedal is depressed, piston (3) braking force.
is kept returned by stroke (S) (full stroke). If
the brake pedal is depressed, the oil dis-
charged from the brake valve flows through
port (A) of the slack adjuster into cylinder (1)
and moves piston (3) in the braking direction
by stroke (S).
2. When brake pedal is released

q If the brake is released, the oil discharged
through the brake valve returns to the tank.
Brake piston (6) is returned by the brake cool-
ing oil pressure and piston (3) is returned by
stroke S.
q As the result, the pressure in (C) increases, In other words, the relationship between stroke
brake piston (6) moves, and a braking force is (S) of the slack adjuster and return stroke (T)
generated. of brake piston (6) is kept constant, regardless
of the wear of the brake disc.
Accordingly, the constant braking force is
secured and the brake time lag is kept con-
stant.
HD785-7 15
Rear
1. Cylinder Specifications
2. Check valve Piston operation pressure:
3. Piston 9.8 – 19.6 kPa {0.1 – 0.2 kg/cm2}
4. Air bleeding valve Check valve cracking pressure
(When cooling pressure is 0):
A: Inlet port 1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2}
B: Outlet port Check valve closing pressure:
1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}
Unit: mm
Clearance between body and size Shaft Hole clearance limit
5
piston
–0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Spring Installed Installed Installed
Free length
6 Slack adjuster spring coefficient length load load
0.45 N/mm 45.6 N
97 — —
{0.046 kg/mm} {4.7 kg}
16 HD785-7
Function q When the braking force generated by stroke

q The slack adjuster is installed to the brake oil (S) is insufficient because of wear of the brak-
line from the brake valve to the brake piston ing distance etc., if the brake pedal is kept
and used to keep the brake time lag constant. depressed and the oil pressure discharged
through the brake valve exceeds the set pres-
Operation sure, check valve (2) opens and a pressure is
1. When brake pedal is depressed applied to port (B) and it acts as an additional
q Before the brake pedal is depressed, piston (3) braking force.
is returned by stroke (S) (full stroke). If the
brake pedal is depressed, the oil discharged
from the brake valve flows through port (A) of
the slack adjuster into right and left cylinders
(1) and moves pistons (3) to the right and left
by stroke (S).
2. When brake pedal is released

q If the brake is released, the oil discharged
through the brake valve returns to the tank.
Brake piston (6) is returned by the brake cool-
ing oil pressure and piston (3) is returned by
stroke S.
q As the result, the pressure in (C) increases, In other words, the relationship between stroke
brake piston (6) moves, and a braking force is (S) of the slack adjuster and return stroke (T)
generated. of brake piston (6) is kept constant, regardless
of the wear of the brake disc.
Accordingly, the constant braking force is
secured and the brake time lag is kept con-
stant.
HD785-7 17
Brake, parking brake 1

Front
1. Outer gear
2. Floating seal
3. Oil seal
4. Hub (inner gear)
5. Plate
6. Disc
7. Piston (for service brake and retarder brake)
8. Piston (for parking brake)
9. Cylinder
10. Spring
18 HD785-7
Unit: mm
Transformation of outer gear
11 No transformation
spline
Transformation of inner gear
spline
13 Thickness of plate
2.4 2.15
14 Thickness of disc 5.1 4.6
15 Thickness of damper 6.9 5.1 Replace
16 Thickness of plate 4.4 3.9
Distortion of disc friction Standard distortion Repair limit
17
surface Max. 0.45 0.7
Distortion of plate and
18 Max. 0.5 0.7
damper friction surface
Assemble thickness of plate Standard size Repair limit
19
and disc 63.8 59.0
HD785-7 19
Function Operation of parking brake

q The front brake is of an oil cooled multiple disc q The parking brake contained in the front brake
type, and it operates as a parking brake by use is structurally designed to operate mechani-
of spring. cally by spring (10) force and to be released by
hydraulic pressure.
Operation of brake q The parking releasing hydraulic pressure acts
q When the brake pedal is depressed, oil pres- on the parking brake piston (8) from the accu-
sure from the brake valve moves brake piston mulator through the secondary brake valve
(7) to the right in the direction of the arrow. and parking brake solenoid.
This presses disc (6) and plate (5) together q With the parking brake switch at the driver's
and generates friction between the disc and seat in the travel position, the parking releas-
plate. The wheel is rotating together with the ing hydraulic pressure releases the parking
disc, so this friction reduces the travel speed brake by pressing the parking brake piston (8)
and stops the machine. and retracting the spring (10).
q If the brake pedal is released, the hydraulic q With the parking brake switch in the parking
pressure on brake piston (7) is released and position, the parking brake solenoid is demag-
the piston is moved to the left by the brake netized and the parking releasing hydraulic
cooling oil pressure and consequently the pressure is released. Then, the parking brake
brake is released. is engaged through the parking brake piston
(8), brake piston (7), plate (5), and disc (6)
pressed by spring (10) force.
20 HD785-7
Rear
1. Inner gear
2. Retainer
3. Outer gear
4. Plate
5. Disc
6. Damper
7. Piston (for parking brake)
8. Cylinder (for parking brake)
9. Spring (for parking brake)
10. Cylinder
11. Piston
HD785-7 21
Unit: mm
Transformation of outer gear
12 spline No transformation
Transformation of inner gear

spline
14 Thickness of plate
2.4 2.15
15 Thickness of disc 6.5 6
16 Thickness of damper 6.9 5.1 Replace
17 Thickness of damper 3.4 3.0
Distortion of disc friction Standard distortion Repair limit
18
surface Max. 0.45 0.7
Distortion of plate and damper
19 Max. 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
20
and disc 88 82.3
22 HD785-7
Function Operation of parking brake

q The rear brake is of an oil cooled multiple disc q The parking brake contained in the rear brake
type, and it operates as a parking brake by use is structurally designed to operate mechani-
of spring. cally by spring (9) force and to be released by
hydraulic pressure.
Operation of brake q The parking releasing hydraulic pressure acts
q When the brake pedal is depressed, oil pres- on the parking brake piston (7) from the accu-
sure from the brake valve moves brake piston mulator through the secondary brake valve
(11) to the right in the direction of the arrow. and parking brake solenoid.
This presses disc (5) and plate (4) together q With the parking brake switch at the driver's
and generates friction between the disc and seat in the travel position, the parking releas-
plate. The wheel is rotating together with the ing hydraulic pressure releases the parking
disc, so this friction reduces the travel speed brake by pressing the parking brake piston (7)
and stops the machine. and retracting the spring (9).
q If the brake pedal is released, the hydraulic q With the parking brake switch in the parking
pressure on brake piston (11) is released and position, the parking brake solenoid is demag-
the piston is moved to the left by the brake netized and the parking releasing hydraulic
cooling oil pressure and consequently the pressure is released. Then, the parking brake
brake is released. is engaged through the parking brake piston
(7), brake piston (11), plate (4), and disc (5)
pressed by spring (9) force.
HD785-7 23
Parking brake solenoid 1
1. Connector Function
2. Solenoid q The parking brake solenoid is installed in the
brake oil circuit between the secondary brake
B: To parking brake valve and the brake. When the parking brake
P: From secondary brake valve switch is set to PARK, the solenoid valve is
T: To brake system tank demagnetized and cut off the parking brake
release oil pressure. Then, the spring force of
brake will operate the parking brake.
24 HD785-7
Retarder control valve 1
1. Filter Function
2. Connector q The retarder control valve is a valve used for
3. Solenoid assembly retarder control. It is installed between the
brake valve and the system tank in the brake
A: To slack adjuster circuit.
P: From accumulator It varies the discharge pressure of the pres-
T: To brake system tank sure oil in accordance with the turning angle of
the retarder control lever, so the retarder con-
trol can be carried out as desired.
HD785-7 25
Exhaust brake 1
(If equipped)
1. Exhaust brake valve (right bank) 5. Exhaust brake solenoid valve

2. Exhaust brake valve (left bank). 6. Pressure reducing valve
3. Cylinder(For right bank) 7. Pressure switch
4. Cylinder(For left bank)
26 HD785-7
Outline
q The exhaust brake is a device to block the out-
let exhaust pipe of the turbocharger of the
engine with exhaust brake valves (1) and (2) to
utilize the exhaust stroke of the engine as a
compressor to improve the effect of the engine
used as a brake.
q The exhaust brake is used as the retarder for
traveling down slopes.
q Hydraulic pressure used to move the cylinder
is taken out of the dump control circuit and
adjusted with pressure reducing valve (6). The
exhaust brake solenoid changes the passage
of this pressure to operate the exhaust brake Operation
cylinder. As a result, exhaust valves (1) and
Operating condition of exhaust brake
(2) are closed and the exhaust brake operates.
The operation of the exhaust brake depends on the
q If the exhaust brake operates, pressure is
exhaust brake switch position.
applied to pressure switch (7). Upon receiving
the pressure switch signal, the exhaust brake
q Position A: While the accelerator pedal is
pilot lamp of the monitor panel in the operator's
released and the torque converter
cab lights up to notify the operator that the
is locked up, the solenoid valve
exhaust brake is in operation.
opens to operate the exhaust
brake upon receiving the signal
from the retarder controller.
q Position B: While the accelerator pedal is
released and the torque converter
is locked up, if the foot brake is
depressed or the retarder control
lever is operated, the solenoid
valve opens to operate the exhaust
brake upon receiving the signal
from the retarder controller.
q Position C: The exhaust brake does not oper-
ate.
HD785-7 27
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
28 HD785-7
SEN01286-02
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 4
Rear axle support.......................................................................................................................................... 12
HD785-7 1
Suspension 1
1. Front suspension cylinder

2. Radius rod (Upper rod)
3. Rear suspension cylinder
4. Radius rod (Lower rod)
5. Arm (A-frame)
Outline gas. This acts as a shock absorber (spring and

q The suspension system supports the weight of damper) by contracting and expanding the
the machine, and absorbs the shock from nitrogen gas and oil to absorb the load from
uneven road surfaces to provide a comfortable the road surface.
ride for the operator. At the same time, it main- q In addition to these functions, the front suspen-
tains the stability of the machine by ensuring sion employs an automatic suspension sys-
that all four wheels are always in contact with tem. In this system, the force of the suspension
the ground surface. In this way, it allows the is automatically changed by selecting the
machine to demonstrate its full performance in dumping force to match the travel conditions
items such as acceleration, braking, and turn- and load conditions. This further increases the
ing, even when traveling at high speed. stability and riding comfort of the machine.
q Hydropneumatic cylinders are used for the
suspension cylinders to reduce the shock. With
hydropneumatic cylinders, the suspension cyl-
inder is charged (sealed) with oil and nitrogen
2 HD785-7
Function
1. Front suspension
The front suspension cylinder functions as a
shock absorber and spring, and is connected
by spherical bearings to the lower arm (A-
frame) and main frame. The wheels move up
and down in accordance with the retraction
and extension of the suspension cylinder to
maintain the proper alignment for the wheels
and to improve the stability of the machine.
2. Rear suspension
The differential housing is supported by the
frame and two radius rods at the bottom, and at
the top by two inverted-V-shaped rods and two
suspension cylinders. It is connected to these at
both ends by spherical bearings. It transmits the
load and motive force through the top and bot-
tom rods.
The inverted-V-shaped rods at the top also
function to maintain the center of the machine
(axle).
Employment of the inverted-V-shaped link im-
proves the rolling steering characteristics.
HD785-7 3
Suspension cylinder 1
Front
1. Feed valve 7. Valve assembly

2. Cylinder
3. Rod A: Port
4. Valve (for bleeding air and mounting B: Port
pressure sensor)
5. Air bleeding valve
6. Tube
4 HD785-7
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit Replace
8
and bushing bushing
+0.050 +0.96 0.31 –
210 1.1
–0.122 +0.36 1.082
Clearance between piston rod +0.050 +0.186 0.010 – Replace
9 210 0.4
and bushing –0.122 +0.060 0.308 bushing
Clearance between cylinder –0.05 +0.275 0.05 – Replace
10 238 0.5
and wear ring –0.10 +0.275 0.375 wear ring
Measuring method: Repair limit
Place the spring on a flat bench and mea-
11 Elasticity of leaf spring
sure the amount that the spring curves. Max. 0.3 mm
(See Fig. 1)
Elongation : Replace
Measuring method: Max. 5 mm
12 Deformation of stopper Measure protrusion and elongation of stop- Protrusion:
per. (See Fig. 2) Max. 2 mm
No cracks
Fig. 1 Fig. 2
HD785-7 5
Auto suspension (If equipped)
1. Feed valve 7. Hydraulic cylinder

2. Cylinder 8. Valve assembly
3. Rod
4. Valve (for bleeding air and mounting A: Port
pressure sensor) B: Port
5. Air bleeding valve
6. Tube
6 HD785-7
Unit: mm

9
and bushing bushing
+0.050 +0.96 0.31 –
210 1.1
–0.122 +0.36 1.082
Clearance between piston rod +0.050 +0.186 0.010 – Replace
10 210 0.4
and bushing –0.122 +0.060 0.308 bushing
Clearance between cylinder –0.05 +0.275 0.05 – Replace
11 238 0.5
and wear ring –0.10 +0.275 0.375 wear ring
Measuring method: Repair limit
Place the spring on a flat bench and mea-
12 Elasticity of leaf spring
sure the amount that the spring curves. Max. 0.3 mm
(See Fig. 1)
Elongation : Replace
Measuring method: Max. 5 mm
13 Deformation of stopper Measure protrusion and elongation of stop- Protrusion:
per. (See Fig. 2) Max. 2 mm
No cracks
Fig. 1 Fig. 2
a For the auto-suspension system, see Structure, function and maintenance standard, Electrical system,
Part 2.
HD785-7 7
Structure and operation 2. Principle of generation of damping force

The suspension cylinder acts as a shock absorber Inside of valve body (8) are orifice plate (8a)
and spring. The inside of the cylinder is divided into and leaf springs (8b) and (8c). They restrict
gas chamber (A) which is charged with nitrogen the flow of oil between oil chamber (B) and oil
gas, and oil chamber (B) which is filled with oil. Oil chamber (C), and create a damping force.
chamber (B) and oil chamber (C) are conmected by 1) Action when retracting
tube (6) and valve body (8). When the nitrogen gas is compressed by
1. Nitrogen gas the external force from the road surface,
While the machine is traveling, the wheels fol- the oil in oil chamber (B) flows from oil
low the unevenness of the road surface, and an chamber (B) through the valve (8) and
external force in the updown direction is applied tube (6) to oil chamber (C). The oil flowing
to the suspension cylinder. When this happens, through the valve from direction (Y) to ori-
the volume of the nitrogen gas in gas chamber fice plate (8a) is throttled by orifices in four
(A) changes elastically under the input force, places to generate a damping force.
and absorbs the external force. The nitrogen 2) Action when extending
gas is sealed by a rod and oil, so it is always When the external force from the road sur-
subjected to a pressure corresponding to the face gets weak, the pressure of the nitro-
external force, and acts as an air spring. gen gas extends the rod, and the oil in oil
chamber (C) passes through tube (6) and
valve (8) and flows to oil chamber (B).
The oil inside the valve flows from direc-
tion (Z) and passes through two orifices
from orifice plate (8a) to generate a damp-
ing force.
8 HD785-7
3. Variable shaft mechanism

In the valve body, bypass circuit (D) is provided
before and after orifice plate (8a), so the oil
flow is divided into oil flowing through orifice
plate (8a) and oil flowing through the bypass
circuit (D).
The oil flowing through bypass circuit (D)
passes through a shaft with orifices at two
places on the inside circumference, and flows
to oil chamber (C) or oil chamber (B) according
to whether it is retracting or extending.
The shaft is connected to an hydraulic cylinder
driven by a signal from the retarder controller,
and the size of the orifices automatically
changes according to the condition of the
machine.
The damping force is set at three levels (ME-
DIUM, HARD, SOFT) according to the size of
the orifices through which the oil is passing.
HD785-7 9
Rear
1. Feed valve
2. Cylinder
3. Rod
4. Valve (for bleeding air and mounting pressure sensor)
5. Ball
10 HD785-7
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit
6
and bushing
–0.050 +0.306 0.110 –
210 0.5
–0.122 +0.060 0.428
Replace
Clearance between piston rod –0.050 +0.306 0.110 –
7 210 0.5
and bushing –0.122 +0.060 0.428
Clearance between cylinder –0.050 +0.115 0.05 –
8 250 0.8
and wear ring –0.260 –0.008 0.375
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(6) through orifices (4) and (5) to cavity (2), the oil is
throttled by the orifices and a shock-absorbing
effect is obtained.
1) Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (7) is compressed, the oil in chamber
(6) is sent through both orifices (4) and (5) to
cavity (2), and cavity (2) is filled more quickly
than when extending.
2) Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and
axle and the pressure of the nitrogen inside
chamber (7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil
remaining in cavity (2). 1. Air intake valve 7. Nitrogen gas chamber
This pressurized oil closes orifice (4) with 2. Cavity 8. Cylinder rod
check ball (3), and is sent to chamber (6) 3. Check ball 9. Cylinder
through only orifice (5), so the flow of oil pass- 4. Orifice 10. Air bleeding valve
ing through the orifice is controlled so that it is 5. Orifice
less than during retraction. 6. Oil chamber a: When extending
In this way, the amount of oil returning to b: When retracting
chamber (6) is restricted to provide a shock
absorbing effect.
HD785-7 11
Rear axle support 1
1. Lower rod 3. Axle

2. Upper rod 4. Suspension cylinder
12 HD785-7
Unit: mm
Clearance between rod mount- size Shaft Hole clearance limit
5
ing pin and bushing
–0.030 +0.091 0.075 –
90 1.1
–0.060 +0.045 0.970
6 130 — — 0.3 Replace
outer bushing 0.190
Clearance between suspen-
–0.030 +0.091 0.075 –
7 sion cylinder mounting pin and 90 1.1
–0.060 +0.045 0.970
frame or axle
8 130 — — 0.3
outer bushing 0.190
HD785-7 13
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
14 HD785-7
SEN01287-03
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Hydraulic system
Steering and hoist hydraulic piping ................................................................................................................. 2
Steering, hoist filter (high pressure circuit)...................................................................................................... 4
Dump body control.......................................................................................................................................... 6
Hydraulic tank ................................................................................................................................................. 8
Steering valve ................................................................................................................................................. 9
Crossover relief valve ................................................................................................................................... 13
Steering cylinder ........................................................................................................................................... 14
Steering control valve.................................................................................................................................... 15
Hoist valve .................................................................................................................................................... 24
Dump control valve (EPC valve) ................................................................................................................... 30
Hydraulic pump ............................................................................................................................................. 34
HD785-7 1
Steering and hoist hydraulic piping 1
2 HD785-7
1. Cross-over relief valve

2. Steering cylinder
3. Steering, hoist, hoist control pump
(SAR(4)180+180+(1)6)
4. Steering hoist filter (high pressure circuit)
5. Steering control valve
6. Hydraulic tank
7. Hoist valve
8. Steering valve
9. Hoist cylinder
10. Steering hoist filter (low pressure circuit)
HD785-7 3
Steering, hoist filter (high pressure circuit) 1
1. Case Function
2. Cover q If the steering pump, hoist line pump, etc. is
3. O-ring broken or has another trouble, the steering and
4. Ring hoist filter protects the steering circuit.
5. Element
4 HD785-7
HD785-7 5
Dump body control 1
6 HD785-7
1. Dump control lever Function

2. Hydraulic pump (SAR(4)180+180+(1)6) q The positioner sensor senses the body control
3. Hoist valve operation, and from this data the retarder con-
4. Dump control valve (EPC valve) troller controls output to the dump control
5. Body positioner sensor valve (EPC valve).
6. Hoist cylinder As a result, the body lowering speed is con-
7. Manual body lowering valve trolled to reduce the seating shock.
q The signal from the dump lever is controlled by
the retarder controller, and actuates the dump
control valve (EPC valve). The pilot pressure
generated by the dump control valve(EPC
valve) moves the spool of the hoist valve and
controls the hoist cylinder.
q If the body does not lower because of a trouble
in the controller or electrical equipment, open
manual body lowering valve (7) and drain the
body holding oil in hoist cylinder (6) to the tank
to lower the body.
(For the operating procedure, see Testing and
adjusting.)
HD785-7 7
Hydraulic tank 1
1. Steering, hoist oil filter (low pressure circuit)

2. Oil filter
3. Oil level gauge
4. Drain
5. Transmission, brake cooling oil filter
6. Breather
7. By-pass valve
Capacity: 156l
8 HD785-7
Steering valve 1
1. Input shaft 8. Ball a: From steering control valve

2. Upper cover 9. Torsion bar (P port)
3. Valve spool 10. Link b: To tank (R port)
4. Housing 11. Sleeve c: To steering cylinder (RT port)
5. Ball 12. Rotor d: To steering control valve
6. Stator 13. Manifold (LS port)
7. Lower cover 14. Commutator e: To steering cylinder (LT port)
HD785-7 9
Operation
1. When steering is at neutral
q The oil from the pump passes through the

steering control valve and enters port (P) of the
steering valve
q Valve spool (3) is at the neutral position, so
port (P) and the port (RT and LT) to steering
cylinder are closed. No oil flows to the steering
cylinder, so the steering cylinder does not
move.
q At the same times, port (LS) is connected
trough port (R) to the tank. As a result, there is
no oil pressure at port (LS), so all the oil from
the pump at the steering control valve flows to
the hoist valve.
10 HD785-7
2. Steering to right
(When steering wheel is turned to the right)
q When the steering wheel is turned (to the q The oil returning from the steering cylinder
right), input shaft (1) rotates. When this hap- flows from port (LT) trough port (E) and port (R)
pens, valve spool (3) moves down. (Input shaft and goes back to the tank.
(1) has a spiral groove in which ball (8) moves, q At the same time, the oil pressure at port (P) is
so when input shaft (1) rotates, torsion bar (9) restricted by valve spool (3), and passes
is twisted, and ball (8) moves up or down to trough port (A), so a lower oil pressure (the
move valve spool (3).) drop in pressure (pressure difference) differs to
q The oil from the steering control valve flows according to the area of the opening of the
from port (P) through port (A) and port (G) and spool) than the pressure at port (P) is applied
goes to port (F). to port (LS).
q The oil at port (F) then passes between stator q The steering control valve spool is actuated by
(6) and rotor (12) in the metering position. After the difference in pressure between the oil pres-
the amount of oil flowing to steering cylinder is sure at port (P) end and the oil pressure at the
measured here, it enters the inside of valve port (LS) end. As a result, only the necessary
spool (3), passes through drill hole (a) in the amount of oil flows to the steering circuit, and
valve spool through port (RT) and flows to the remaining oil flows from the steering control
steering cylinder. valve to the hoist valve.
q In this way, the two cylinders are actuated and
the wheels turn to the right.
HD785-7 11
3. Steering to left
(When the steering wheel is turned to the left.)
q When steering wheel is turned (to the left), q At the same time, the oil pressure at port (P) is
input shaft (1) rotates. When this happens, restricted by valve spool (3), so a lower oil
valve spool (3) moves up. pressure than the pressure at port (P) is
q The oil from the steering control valve flows applied to port (LS).
from port (P) enters port (B) passes trough drill q The steering control valve spool is actuated by
hole (a) in valve spool (3), and enters the the difference in pressure between the oil pres-
inside of the valve spool. sure at port (P) end and the oil pressure at the
q The oil inside valve spool (3) passes between port (LS) end. As a result, only the necessary
stator (6) and rotor (12) in metering portion. amount of oil flows to steering circuit, and
After the amount of oil flowing to the steering remaining oil flows from the steering control
cylinder is measured here, it flows to port (F). valve to the hoist valve.
q The oil at port (F) passes trough port (LT) and
flows to steering cylinder.
q In this way, the two cylinders are actuated and
the wheels turn to the left.
q The oil returning from the steering cylinder
flows from port (RT) trough port (D) and port
(R) and goes back to the tank.
12 HD785-7
Crossover relief valve 1
1. Valve body Function

2. Valve seat q When abnormal pressure is generated in the
3. Relief valve steering circuit by an external force, the cross-
4. Valve spring over relief valve relieves the oil pressure to
5. Sleeve protect the circuit.
6. Adjustment screw
7. Lock nut
A1: To steering cylinder

A2: To steering cylinder
B1: To steering cylinder
B2: To steering cylinder
PA: From steering valve
PB: From steering valve
HD785-7 13
Steering cylinder 1
Unit: mm
1
and bushing bushing
–0.030 +0.075 0.105 –
70 0.647
–0.076 +0.271 0.347
Clearance between piston rod +0.039
2 50 — — 1.0
supports shaft and bushing +0.039
Clearance between cylinder Replace
+0.039
3 bottom support shaft and bush- 50 — — 1.0
+0.039
ing
14 HD785-7
Steering control valve 1
A: From steering and hoist pump

B: From steering and hoist pump
C: To hoist valve
D: From emergency steering pump
E: To steering valve
F: Drain port
G: LS port
HD785-7 15
16 HD785-7
1. Spool
2. Check valve
3. Plug
4. Relief valve
Unit: mm
Free length
x Outside Free length
5 Spool return spring length load load If damaged or
diameter
deformed,
1,230 N 986 N replace spring.
221.7 x 40 155 —
{125.6 kg} {100.5 kg}
3.38 N 2.71 N
6 Check valve spring 56 x 21.4 47 —
{0.345 kg} {0.276 kg}
Function
q The steering control valve distributes the
hydraulic oil from the steering and hoist pump
to the steering circuit and hoist circuit accord-
ing to pressure signals from the steering valve.
q The steering control valve is a load sensing
type valve, which controls spool (1) by operat-
ing the steering system.
q While the machine is not being steered (While
the steering circuit does not need the pressur-
ized oil), the steering control valve supplies all
of the pressurized oil from the pump to the
hoist valve.
q If the machine is steered, the steering control
valve supplies the necessary hydraulic oil for
the steering operation to the steering valve and
supplies the rest to the hoist valve.
q The above operation reduces the hydraulic
horsepower lost in the steering circuit.
HD785-7 17
18 HD785-7
Operation
1. When steering valve is in neutral
q The pressurized oil from the steering and hoist
pump flows in ports (A) and (B).
q Since port (P) of the steering valve is closed
while the steering valve is in neutral, the pres-
sure in port (P) rises.
q The pressurized oil in port (A) flows through
orifice (a) to chamber (C) and moves spool (1)
to the right.
q Since port (LS) and chamber (D) are con-
nected to the tank, only the force of spool
return spring (5) is used to move spool (1) to
the left.
q The pressure in chamber (C) rises until it
exceeds the force of spool return spring (5).
q Spool (1) stops in the position shown in the fig-
ure and all of the pressurized oil from the
steering and hoist pump flows to the hoist
valve.
2. When steering valve is operated

q If the machine is steered, port (P) is connected
to port (LS) and tank port (R) is disconnected
from port (LS).
q The pressurized oil in port (P) of the steering
valve acts on chamber (C) of spool (1).
q The pressurized oil in port (LS) of the steering
valve acts on chamber (D).
q The open area of orifice (b) changes according
to the turning speed of the steering wheel.
q The pressurized oil changes when it flows
through orifice (b) and consequently differential
pressure is generated.
q Spool (1) moves until [the rightward force of
the pressurized oil in chamber (C)] is balanced
with [the leftward force of the pressurized oil in
chamber (D) + the force of spool return spring
(5)].
q The higher the pressurized oil in port (P) of the
steering valve is, the more spool (1) moves to
the right.
HD785-7 19
1) When steering wheel is turned quickly
q The open area of orifice (b) is wide.

q Spool (1) moves much to the right until the dif-
ferential pressure between before and after ori-
fice (b) is balanced with spool return spring (5).
q The pressurized oil flows according to the
operation of steering wheel (7).
20 HD785-7
2) When steering wheel is turned slowly
q The open area of orifice (b) is narrow.

q Spool (1) moves a little to the right until the dif-
ferential pressure between before and after ori-
fice (b) is balanced with spool return spring (5).
q The pressurized oil flows according to the
operation of steering wheel (7).
HD785-7 21
Steering relief valve q If the pressure in ports (A and B) reaches the

set poppet spring force (set pressure), pilot
poppet (3) opens and the pressurized oil in
port (B) is relieved through port (D) to port (C),
and consequently the pressure in port (B) low-
ers.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q If the pressure in port (B) lowers, differential
Function pressure is generated in ports (A and B)
because of the orifice of main valve (1), and
q The steering relief valve is in the demand
then main valve (1) is pushed open by the
valve. When the steering cylinder is at the
pressure of port (A) and the pressurized oil in
stroke end or when abnormal pressure is gen-
port (A) is relieved.
erated, the pressurized oil sent from the pump
is relieved through this valve to prevent break-
age of the pump etc. (This valve sets the maxi-
mum circuit pressure).
Operation
q Port (A) is connected to the pump circuit and
port (C) is connected to the tank drain circuit.
q The pressurized oil fills port (B) through the ori-
fice of main valve (1).
q Pilot poppet (3) is in contact with valve seat
(2).
22 HD785-7
HD785-7 23
Hoist valve 1
a ADT: Set pressure is increased or decreased by 19.6 MPa {200 kg/cm2} per turn.
24 HD785-7
A: To hoist cylinder head

B: To hoist cylinder bottom
P: From steering control valve
PA: From EPC valve (LOWER, FLOAT)
PB: From EPC valve (RAISE)
T: To tank
1. Valve body
2. Hoist spool
3. Check valve
4. Housing
5. Relief valve
Unit: mm
Free length
Installed Installed Free Installed
x Outside
6 Spool return spring diameter length load length load
308 N 246 N
63.4 x 61 61 —
{31.4 kg} {25.1 kg}
340 N 273 N
7 Spool return spring 47 x 36 45 —
{34.7 kg} {27.8 kg} If damaged or
deformed,
308 N 246 N replace spring.
8 Spool return spring 47.5 x 41 45.2 —
{31.4 kg} {25.1 kg}
1,370 N 1,100 N
9 Spool return spring 87.6 x 52 60 —
{140 kg} {112 kg}
823 N 658 N
10 Spool return spring 97.8 x 35 86 —
{83.9 kg} {67.1 kg}
12.7 N 10.2 N
11 Check valve return spring 84.7 x 26.6 47.5 —
{1.3 kg} {1.04 kg}
HD785-7 25
Operation
1. When hoist valve is in "HOLD" position
q The pressurized oil from the steering control q Since the port to the hoist cylinder is blocked
valve flows in chamber (C). Since the passage on both bottom side and head side, the hoist
to the hoist cylinder is blocked by hoist spool cylinder is held in the current position.
(2), the pressurized oil flows through chamber
(D) to the tank.
26 HD785-7
2. When hoist valve is in "RAISE" position
q If the hoist lever in the cab is set in the q The pressurized oil returning from the head
"RAISE" position, the pressurized oil from the side flows through chambers (B) and (D) to the
EPC valve moves hoist spool (2) to the left. tank.
q Accordingly, the pressurized oil flows through
chamber (C), opens check valve (3), and
enters chamber (A).
q The pressurized oil flows through chamber (A)
to the bottom side of the hoist cylinder to
extend the hoist cylinder and raise the body.
HD785-7 27
3. When hoist valve is in "FLOAT" position
q If the hoist lever in the cab is set in the q The pressurized oil from the steering control
"FLOAT" position, the pressurized oil from the valve flows through chambers (C) and (B) to
EPC valve moves hoist spool (2) to the right. the hoist cylinder. A part of it flows through
Then, chamber (C) is connected to chamber chambers (C) and (D) to the steering oil cooler,
(D), and chambers (B) and (H) are connected too.
to chamber (D). q Since the bottom side and head side of the
hoist cylinder are connected by the hoist valve,
the hoist cylinder is free.
28 HD785-7
4. When hoist valve is in "LOWER" position
q If the hoist lever in the cab is moved from the q The pressurized oil flows through chamber (B)
"FLOAT" position to the "LOWER" position, the to the head side of the hoist cylinder to retract
pressurized oil from the EPC valve moves the hoist cylinder and lower the body.
hoist spool (2) to the right further from the q The pressurized oil returning from the head
"FLOAT" position. Accordingly, the pressur- side of the hoist cylinder flows through cham-
ized oil flows through chamber (C), opens ber (A) to chamber (H).
check valve (3), and enters chamber (B).
HD785-7 29
Dump control valve (EPC valve) 1

Serial No.: 7001 – 7592
1. Hoist charge solenoid (Solenoid a) Function

2. Hoist EPC solenoid (Solenoid b) q The dump control valve (EPC valve) controlled
by the retarder controller switches the pilot
A: To hoist valve (RAISE side) pressure of the hoist valve, and controls pres-
B: To hoist valve (LOWER side) sure, and controls the hoist valve.
P1: From hydraulic tank
P2: Pick up port
T1: To hydraulic tank
30 HD785-7
HD785-7 31
Serial No.: 7593 and up
32 HD785-7
1. Manual operation button

2. Solenoid assembly (Solenoid a)
3. Relief valve (R)
4. Solenoid assembly (Solenoid b)
5. Strainer
A: To hoist valve (RAISE side)

B: To hoist valve (LOWER side)
P1: From hydraulic tank
P2: Pick up port
Function
q The EPC valve sends the oil from the hydraulic
pump to the hoist valve spool to change the
pilot pressure and control the hoist valve.
HD785-7 33
Hydraulic pump 1
Steering, hoist, hoist control pump
SAR(4)180+180+(1)6
34 HD785-7
Unit: mm
Model Standard clearance Clearance limit
SAR(4)-180
1 Side clearance 0.11 – 0.16 0.20
SAR(4)-180
SAR(1)-6 0.10 – 0.15 0.19
Clearance between inside SAR(4)-180
diameter of plain bearing and 0.06 – 0.141 0.20
2 SAR(4)-180
outside of diameter of gear
shaft SAR(1)-6 0.06 – 0.119 0.20
Model Standard size Tolerance Repair limit Replace
–0.5
SAR(4)-180 21
–0.5
SAR(4)-180/
3 Depth to knock in pin SAR(4)-180 –0.5
14 —
SAR(4)-180/ –0.5
SAR(1)-6
–0.5
SAR(1)-6 10
–0.5
4 Rotating torque of spline shaft 21.6 – 34.3 Nm {2.2 – 3.5 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
MPa amount
(rpm) ( /min)
Discharge amount {kg/cm2} ( /min)
—
— Oil: EO10-CD SAR(4)-180 20.6
Oil temperature: 45–55°C 335.8 310.2
SAR(4)-180 {210}
2,000
24.5
SAR(1)-6 10.1 9.4
{250}
HD785-7 35
Rear brake cooling pump

SAR(4)180+100
Unit: mm
Clearance between gear case Model Standard clearance Clearance limit
1
and side plate, gear SAR(4)-180 0.11 – 0.16 0.20
Clearance between inside
2 diameter of plain bearing and SAR(4)-180 0.06 – 0.14 0.20
outside diameter of gear shaft
Replace
Model Standard size Tolerance Repair limit
SAR(4)-180 21
3 Depth to knock in pin –0.5
SAR(4)-180/ —
14 –0.5
SAR(4)-180
4 Rotating torque of splined shaft 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
Delivery Standard Delivery
Rotating
pressure delivery amount
Delivery amount Model speed
MPa amount limit
— Oil: EO10-CD (rpm) —
{kg/cm2} ( /min.) ( /min.)
Oil temperature: 45 – 55°C
2.9
SAR(4)-180 2,000 350.4 310.2
{30}
36 HD785-7
Torque converter, transmission (front brake cooling), brake control pump

SDR(30)100+100+SA(1)25
Unit: mm
Model Standard clearance Clearance limit
1 Side clearance SDR(30)-100 0.16 – 0.20 0.24
SA(1)-25 0.10 – 0.15 0.19
Clearance between inside SDR(30)-100 0.06 – 0.131
diameter of plain bearing and
2 0.20 Replace
outside of diameter of gear SA(1)-25 0.06 – 0.119
shaft
Model Standard size Tolerance
3
Depth to knock in pin SDR(30)-100
10 — —
4 SA(1)-25
5 Rotating torque of spline shaft 15.6 – 28.4 Nm {1.6 – 2.9 kgm}
Rotating pressure delivery amount
Model speed MPa amount limit
(rpm)
Discharge amount {kg/cm2} ( /min) ( /min) —
— Oil: EO10-CD
Oil temperature: 45–55°C 20.6
SDR(30)-100 230.9 213.3
{210}
2,500
24.5
SA(1)-25 56.5 50.7
{250}
HD785-7 37
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
38 HD785-7
SEN04681-00
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Work equipment (Body)
Auto greasing system ..................................................................................................................................... 2
Hoist cylinder ................................................................................................................................................ 13
HD785-7 1
Auto greasing system 1
2 HD785-7
HD785-7 3
1. Grease pump L1: A-frame L.H. (front)

2. Pressure switch L2: Steering cylinder L.H.
3. Pressure gauge L3: Tie rod L.H.
4. Controller L4: A-frame L.H. (rear)
5. Manual lubrication switch L5: Front suspension L.H. upper
6. A-frame L6: A-frame L.H. (front)
7. Front suspension L7: Steering cylinder L.H.
8. Rear suspension L8: Center lever
9. Tie rod L9: Tie rod R.H.
10. Steering cylinder L10: Tie rod L.H.
11. Radius rod L11: Steering cylinder
12. Body hinge pin L12: Hoist cylinder upper L.H.
13. Center lever L13: Hoist cylinder upper R.H.
14. Hoist cylinder L14: Radius rod lower L.H. (front)
L15: Radius rod lower L.H. (rear)
L16: Radius rod upper L.H. (front)
R1: A-frame R.H. (front) L17: Radius rod upper L.H. (rear)
R2: Front suspension R.H. L18: Rear suspension L.H. lower
R3: A-frame R.H. (rear) L19: Rear suspension L.H. upper
R4: Tie rod R.H. L20: Body hinge pin L.H.
R5: Steering cylinder R.H.
R6: A-frame R.H.
R8: Hoist cylinder upper R.H.
R9: Hoist cylinder lower R.H.
R10: Radius rod lower R.H. (front)
R11: Radius rod upper R.H. (rear)
R12: Radius rod upper R.H. (front)
R13: Radius rod lower R.H. (rear)
R14: Rear suspension R.H. lower
R15: Rear suspension R.H. upper
R16: Body hinge pin R.H.
4 HD785-7
System diagram
Outline
q When the starting switch is turned ON, the
auto grease system supplies grease according
to the set time of the timer.
q If the manual lubrication switch on the dash-
board is depressed, the auto grease system
starts supplying grease, regardless of the set
time of the timer.
HD785-7 5
Controller
1. Connector Specification
2. Lubrication button Rated output: DC 24 V
3. Power LED Using voltage range: DC 21 – 30V
4. Pump ON LED Current consumption: 100 mA
5. Warning LED
6. ON TIME switch
7. MODE switch
6 HD785-7
Grease pump
1. Tank Specification
2. Pump (with built-in motor) Using voltage: 24 V DC
3. Air bleed plug Power consumption:
4. Pressure gauge When relief valve operates: 11 A
5. Pressure switch In normal state: 9.6 A
6. Connector (motor) Using temperature range: -40 – 65 °C
7. Connector (pressure switch) Motor output: 0.37 kW
Delivery: 260 cc/min
(at pressure of 24.5 MPa {250 kg/cm2})
Using pressure range:
0 – 34.5 MPa {0 – 352 kg/cm2}
Amount of grease: 27 kg
Grease to be used: NLGI No.2 or equivalent
HD785-7 7
Injector
Right side of machine
1. Manifold Specification
2. Injector Max. using pressure: 41.3 MPa {421 kg/cm2}
3. Slide valve Normal pressure: 21.0 MPa {214 kg/cm2}
4. Piston Using temperature range: -40 – 80 °C
5. Indicator stem Grease delivery range: 0.25 – 1.31 cc
6. Adjusting screw
7. Spring
A: Grease inlet
B: Grease outlet
8 HD785-7
Left side of machine
6. Adjusting screw
7. Spring
A: Grease inlet
B: Grease outlet
HD785-7 9
Rear side of machine
6. Adjusting screw
7. Spring
A: Grease inlet
B: Grease outlet
10 HD785-7
Operation
q The grease enters the inlet port and then is q If more pressure is applied, slide valve (3)
distributed to both sides of piston (4) through moves against the force of spring (7).
slide valve (3). q As slide valve (3) moves, passage (B) is
q Piston (4) is moved down by the grease pres- closed and passage (D) to outlet port (C) is
sure which enters the inlet port and acts on opened. Under this condition, the grease from
both sides of piston (4) and then chamber (A) the inlet port acts on only the bottom of the pis-
is filled with the grease. ton.
q Indicator shaft (5) is pulled into a position far- q The grease from the inlet port moves piston (7)
thest from the stopper of adjustment screw (6). and then piston (4) sends the grease in cham-
ber (A) forcibly to each lubrication point
through passage (D), slide valve (3) and outlet
port (C).
HD785-7 11
q Piston (4) sends out the grease until indicator q If the supply line grease pressure lowers to 6.9
shaft (5) touches the stopper of adjustment MPa {70 kg/cm2}, slide valve (3) moves down
screw (6). to close passage (D) and open passage (B).
q The amount of the grease sent out can be Then, the supply line grease pressure acts on
adjusted by limiting the piston movement. both sides of piston (4) to move the piston
q Piston (4) and slide valve (3) stay at the cur- down.
rent positions until the supply line grease pres- q As piston (4) moves down, a certain amount of
sure is released. the grease flows from the lower side of piston
(4) to the upper side of piston (4) through slide
valve (3) and passage (B).
q Since the volume of the upper side of the pis-
ton is greater than that of the lower side,
excessive grease flows from the supply line to
the upper side of the piston. The pressure low-
ers quickly because of the grease leaving from
the supply line.
q The piston may or may not fully return,
depending on the volume of the grease in the
supply line.
The injector is now ready for the next cycle.
12 HD785-7
Hoist cylinder 1
Unit: mm
Clearance between cylinder and size Shaft Hole clearance limit
1
bushing
–0.050 +0.056 0.106 –
200 0.725
–0.165 +0.260 0.425
Clearance between piston rod –0.043 +0.034 0.077 – Replace
2 130 0.657
and bushing –0.143 +0.214 0.357
Clearance between piston rod +0.004
3 80 — — 1.0
support pin and bushing –0.015
Clearance between cylinder sup- +0.004
4 80 — — 1.0
port pin and bushing –0.015
HD785-7 13
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
14 HD785-7
SEN01288-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 3
Rear view monitor ......................................................................................................................................... 12
Controller related .......................................................................................................................................... 15
HD785-7 1
ROPS cab 1
1. Front wiper
2. Front glass
3. Air conditioner fresh air filer
4. Door (Left)
5. Rear glass
6. Door (Right)
7. Washer tank
2 HD785-7
Air conditioner 1
(If equipped)
1. Receiver dryer Heating

2. Air conditioner unit q Heating is carried out using the coolant from
3. Compressor the engine.
4. Condenser High-temperature coolant from the hot water
5. Hot water take-off port take-off port flows to the air conditioner unit,
6. Hot water return port and hot air is blown out by a fan.
When the temperature of the coolant drops, it
Specifications is returned to the hot water return port.
Refrigerant used HFC134a (R134a)
Cooling
Refrigerant refilling level (g) 900 ± 50
q The refrigerant gas compressed and pressur-
Function ized by the air conditioner compressor enters
the air conditioner condenser where it is
q The air conditioner makes a pleasant operating
cooled by dissipating the heat It then enters
environment for the operator and acts to
the air conditioner unit and cold air is blown out
reduce fatigue.
by the fan. When the temperature of the refrig-
erant gas rises, it is returned to the compres-
sor.
HD785-7 3
Refrigerant flow system
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
• Condenser refrigerant outlet side
• Air conditioner unit refrigerant inlet side
12 – 15 {1.2 – 1.5}
A • Connecting part to cab (Screw size: M16 x 1.5)
(Between receiver drier and air conditioner
unit)
20 – 25 {2.0 – 2.5}
B • Condenser refrigerant inlet side
(Screw size: M22 x 1.5)
Retighten
• Air conditioner unit refrigerant outlet side
30 – 35 {3.0 – 3.5}
C • Connecting part to cab (Screw size: M24 x 1.5)
(Between air conditioner unit and compressor)
4.0 – 7.0 {0.4 – 0.7}
D • Receiver refrigerant pipe set bolt
(Screw size: M6 bolt of receiver)
20 – 25 {2.0 – 2.5}
E • Compressor refrigerant piping lock bolt
(Screw size: M8 bolt of compressor)
4 HD785-7
Air conditioner unit
1. Hot water outlet port Outline

2. Hot water inlet port q The vertical air conditioner unit on which evap-
3. Refrigerant gas inlet side orator and heater core is synchronized with the
4. Refrigerant gas outlet side blower and intake unit to generate cool and hot
air.
q The temperature adjusting switch on the air
conditioner panel controls air mix dampers to
adjust the spurting out temperature.
Cooler
q The cooler circulates refrigerant through evap-
orator to cause heat exchange (dehumidifica-
tion and cooling).
q Air taken in by the blower and intake unit is
cooled with evaporator and then blown out
from the grille through the duct.
Heater
q The heater circulates engine coolant in heater
core to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core and then blown out
from the grille through the duct.
HD785-7 5
Receiver dryer
1. Sight glass Function

q It is used to store liquefied high-pressure, high-
A: Refrigerant gas inlet port temperature misty refrigerant from the con-
B: Refrigerant gas outlet port denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
6 HD785-7
Condenser
1. Fin Function
2. Tube q The condenser cools and liquefies the high-
pressure and high-temperature refrigerant gas
A: Refrigerant gas inlet port compressed by the compressor.
B: Refrigerant gas outlet port
a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m )
2 6.55
Max. pressure used (MPa {kg/cm }) 2
3.6 {36}
HD785-7 7
Compressor
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature gas so
that it may be easily regenerated (liquefied) at
normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x Stroke (mm)
Piston capacity
129.2
(cc/rev)
Allowable maximum speed
4,000
(rpm)
8 HD785-7
HD785-7 9
Air conditioner panel
Display section
Display
No. Display type Display item Display range Display method Remarks
color
Outlet air All segments of current level and below
1 See above figure
temperature light up (Display in 8 levels).
Gauges
All segments of current level and below
2 Air flow rate See above figure
light up (Display in 4 levels).
RECIRC or FRESH is displayed accord-
RECIRC and RECIRC or
3 ing to RECIRC/FRESH selector switch
FRESH air FRESH air
position.
Turning "ON" of Black LCD
Air When air conditioner switch is turned
4 air conditioner
conditioner "ON", lamp lights up.
Pilot switch
Turning "ON" of When DEF switch is turned "ON", lamp
5 DEF air flow
DEF switch lights up.
FACE, FACE, FACE/FOOT or FOOT air outlet is
6 Mode FAC/FOOT of displayed according to mode selector
FOOT mode switch position.
10 HD785-7
Switch section
No. Name Function Operation
RECIRC
Switch to select RECIRC or FRESH air
7 RECIRC/FRESH switch I O
(Pilot display on display section changes according to setting)
FRESH
8 Air conditioner switch Switch to turn ON and OFF air-conditioning function. OFF io ON
Switch to turn ON and OFF main power supply for air conditioner
9 ON/OFF switch ON: Setting in "OFF" state is displayed on display section. OFF io ON
OFF: Display section is turned OFF and fan is stopped.
Switch to control air flow from fan
10 Fan switch LO io HI
(Control in 4 levels [LO, M1, M2, HI])
Low temperature
Switch to control outlet air temperature
11 Temperature control switch I O
(Control in 8 levels)
High temperature
12 DEF switch Switch to turn ON and OFF defroster OFF io ON
FACE
Switch to change air outlet position O
13 Mode selector switch (3 modes [FACE, FACE/FOOT, FOOT]) FACE/FOOT
If pressed in DEF mode, setting before DEF mode is selected. O
FOOT
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals

JAE IL-AG5-14P JAE IL-AG5-22P
Pin Input/output Pin Input/output
No. Signal name signals No. Signal name signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Internal/external air changeover damper ac- 3 Blower motor relay Input
3 Input
tuator limiter Internal/external air changeover damper
4 Output
4 NC — actuator output 1
5 Evaporator temperature sensor Input 5 Internal/external air changeover damper Output
actuator output 2
6 NC —
6 Mode selector actuator output 2 Output
7 Starting switch (ON) Input
7 Mode selector actuator output 1 Output
8 Night lamp signal Input
8 Air mix damper actuator output 2 Output
9 NC —
9 Air mix damper actuator output 1 Output
10 NC —
10 Actuator potentiometer power supply (5V) —
11 NC —
11 NC —
12 NC —
12 NC —
13 NC —
13 NC —
14 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
HD785-7 11
Rear view monitor 1

(If equipped)
1. Monitor
2. Camera
3. Cable
12 HD785-7
Monitor
1. Auto switch Specifications

2. Manual switch TV signal method:
3. Zoom/Iris switch As per Japanese standard TV method
(Reverse light compensation switch) Scanning method: 2:1 Interlace method
4. Bright/Dim light selector switch CRT: 4.5 inch, black and white, 90-deg. deflection
5. Mark switch Resolution:
Horizontal 400 lines and vertical 300 lines
6. Contrast adjustment knob
Power supply voltage: DC 24/12 V
7. Brightness adjustment knob
HD785-7 13
Camera
1. Camera Specifications
2. Connector TV signal method:
As per Japanese standard TV method
Scanning method: 2:1 Interlace method
Image sensor:
1/4 inch color CCD with 250,000 pixels
Lens: 1.7 mm, 1:2.8
Angle of view: Horizontal; Approx. 118 deg.,
Vertical; Approx. 97.6 deg.
Electronic zoom: Approx. 1.4 power
Using luminance range:
Min. luminance of object; 3 lux
Power supply voltage:
DC 5.5 V – 99.5 V for main unit
(supplied by monitor)
Power consumption: Max. 120 mA
14 HD785-7
Controller related 1
Controller layout
1. Engine controller (See Engine Shop Manual)

2. Transmission controller (See Electrical system, Part 2)
3. Retarder controller (See Electrical system, Part 2)
4. VHMS controller (See Electrical system, Part 3)
5. Orbcomm controller (if equipped) (See Electrical system, Part 3)
6. ABS controller (if equipped) (See Electrical system, Part 3)
HD785-7 15
HD785-7 Dump truck

© 2007 KOMATSU
All Rights Reserved
16 HD785-7
SEN01289-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HD785-7 1
Machine monitor system 1
Network data
1. From machine monitor to each controller
q Switch input data
q Option setting data
2. From each controller to machine monitor
q Display data related to each controller
q Service mode data
q Troubleshooting data
3. From transmission controller to machine monitor
q Model selection data
2 HD785-7
Outline q Deletes data from memory

The controllers on the network use the data 2. Displaying trouble history data for ma-
from the sensors installed to all parts of the chine
machine to observe and control the condition Displays machine failure occurrence data
of the vehicle and transmit those data as net- from each controller that is saved in
work data to the machine monitor. The machine monitor.
machine monitor, in return, displays these data 3. Real-time monitor
and inform the operator of the condition of the Takes input, output signal, and calculation
machine. values recognized by each controller on
q There are two types of display on the machine network and displays them in real time.
monitor: the normal mode and the service 4. Reduced cylinder mode
mode. This function is used to stop the supply of
q The items that are always displayed for the
fuel sprayed from the fuel injector to each
operator are the normal mode items. Their
of the cylinders. This function is used for
main content is as follows.
the purpose of, for example, determining
(For details, see "Operation and Maintenance Man-
the cylinder where there is defective com-
ual", "Operation".)
bustion.
1. Normal display items
5. No injection cranking
q Meters (speedometer, tachometer)
This function is used to lubricate an
q Gauges (engine coolant tempera-
ture, torque converter oil temperature, engine without starting the engine to drive
retarder oil temperature, fuel level) a vehicle after a long-term storage.
q Pilot display 6. Adjusting function
q Service meter, odometer (character This function is used to correct installation
display) errors of sensors, solenoid valves, and
2. Items displayed when there is abnormality compensate production tolerances of
Caution, action code display (while an parts and components.
action code is being displayed, press 7. Maintenance monitor
machine monitor mode selector switch (>). This function is used to change filter oil
A failure code (6-digit) is then displayed.) replacement interval and stop the func-
3. Maintenance monitor function tion.
When the filter, oil replacement interval is 8. Operation information display function
reached, the item needing replacement is This function is used to display fuel con-
displayed in the character display. sumption amount per operation hour.
4. Others 9. Engine mode fixing function
In combination with the character display This function is used to check the perfor-
and the machine monitor mode selector mance.
switch, which is used to operate the char- 10. Snapshot function
acter display, the following items can be For details of this function, see "Testing
displayed, set, and adjusted. and adjusting" of "Manual snapshot".
1) Dumping counter (if equipped) 11. Payload meter function (if equipped)
2) Display reverse travel distance mea- This function is used to setting and adjust-
surement value ing of payload meter.
3) Reset filter oil replacement interval For details of this function, see "Operation
4) Input telephone number and maintenance manual" or "Structure,
5) Select language function and maintenance standard" of
6) Reverse R1/R2 selection "Payload meter (having VHMS)".
7) Payload meter calibration ID setting 12. Option selection function
(if equipped)
This function is used to select controller
q To make it easier to carry out troubleshooting
information and optional equipment to be
of the controllers on the network (including the
operated.
machine monitor itself), a service mode func-
tion is provided. Its main content is as follows. 13. Model selection function
For detail, see "Special function of machine Input model information to be mounted.
monitor" of "Testing and adjusting". 14. Initialize
1. Displaying trouble history data for electri- This function is used to set the machine
cal components monitor when the machine is shipped from
q Displays electrical component failure the factory.
occurrence data from each controller
that is saved in machine monitor.
HD785-7 3
Machine monitor
1. Speedometer 26. Emergency steering pilot lamp

2. Engine tachometer 27. Turn signal pilot lamp (right)
3. Retarder oil temperature gauge 28. Turn signal pilot lamp (left)
4. Torque converter oil temperature gauge 29. Head lamp high beam pilot lamp
5. Coolant temperature gauge 30. Shift lever position pilot lamp
6. Fuel gauge 31. Shift indicator
7. Character display 32. Retarder pilot lamp
8. Centralized warning lamp 33. Lockup pilot lamp
9. Retarder oil temperature caution lamp 34. Output mode pilot lamp (power mode)
10. Torque converter oil temperature caution lamp 35. Suspension mode pilot lamp (hard)
11. Coolant temperature caution lamp (if equipped)
12. Fuel level caution lamp 36. Suspension mode pilot lamp (medium)
13. Maintenance caution lamp (if equipped)
14. Battery charging circuit caution lamp 37. Suspension mode pilot lamp (soft) (if equipped)
15. Steering oil temperature caution lamp 38. ABS pilot lamp (if equipped)
16. Engine oil pressure caution lamp 39. ASR pilot lamp (if equipped)
17. Retarder oil pressure caution lamp 40. Preheater pilot lamp
18. Parking brake caution lamp 41 Automatic retarder READY pilot lamp
19. Machine monitor option system caution lamp 42. Automatic retarder set speed indicator
20. Engine system caution lamp 43. Automatic retarder set speed unit indicator
21. Transmission system caution lamp (km/h)
22. Retarder system caution lamp 44. Automatic retarder set speed unit indicator
23. Inclination caution lamp (if equipped) (MPH)
24. Seat belt caution lamp 45. Exhaust brake pilot lamp (if equipped)
25. Body caution lamp
4 HD785-7
46. Rotary switch [SW1] a Setting do not change them.

47. Rotary switch [SW2]
48. Rotary switch [SW3]
49. Dipswitch [SW5-4]
52. SI Spec, Non-SI Spec selection switch [SW5-1]
HD785-7 5
Machine monitor normal display functions

: Lighted up : Discontinuous sounds
A1: The mark shows that the light is lit up while the machine monitor check switch is ON.
A2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
Related A1
operation When A2
machine Immedi-
Display Display Display range/ Display Central monitor ately
No. item category Device Color conditions method Remarks
warn- Alarm check after
ing buzzer switch is turning
lamp oper- key ON.
ated.
Note: When machine

monitor check
Scale: switch is oper-
white 0 – 80 km/h or ated, pointer
Move- Back- 0 – 50 MPH Analog starts at current
Meter ment ground (MPH is dis- display — — — position and
played when (Note)
1 Machine color: moves around
speed black non-SI is used.) indication range
and then returns
to starting point.
When the
Backlight LED Amber small lamp is Lit up during — —
lit up. operation
Analog display Note: When machine

monitor check
Scale: * When the switch is oper-
white, red overrun pre- ated, pointer
Move- Back- vention brake starts at current
Meter 0 – 3,400 rpm is operated, —
ment ground (Note) position and
Engine color: the buzzer and moves around
2 speed central warn-
black indication range
ing lamp are and then returns
turned ON. to starting point.
When the Lit up during

Backlight LED Amber small lamp is operation — —
lit up.
Note: When machine

monitor check
white, red 50 – 150°C ated, pointer
Gauge Move- Back- (120°C or higher Analog — — — starts at current
ment ground in the red zone) display (Note) position and
Oil tem- color: moves around
3 perature black indication range
9 of and then returns
retarder to starting point.
Caution LED Red At 120°C Lit up during

or higher warning
When the
lit up. operation.
Note: When machine

monitor check
white, red ated, pointer
Move- Back- 50 – 135°C Analog starts at current
Gauge ment ground (120°C or higher display — — — position and
Oil tem- color: in the red zone) (Note)
moves around
black
4 perature indication range
of torque and then returns
10 con- to starting point.
verter
At 120°C Lit up during
Caution LED Red or higher warning
When the
lit up. operation.
6 HD785-7
Related When
operation machine Immedi-
Display Display Display range/ Display monitor ately
No. item category Device Color conditions method check after Remarks
Central switch is turning
warn- Alarm oper-
ing buzzer ated. key ON.
lamp
Note: When machine
monitor check
white, red ated, pointer
50 – 135°C
Move- Back- Analog starts at current
Gauge (102°C or higher — — —
ment ground display (Note) position and
in the red zone)
Coolant color: moves around
5 temper- black indication range
11 ature and then returns
to starting point.
At 102°C or Lit up during
Caution LED Red
higher warning
When the
Lit up during
Backlight LED Amber small lamp is — —
operation.
lit up.
Note: When machine
monitor check
white ated, pointer
Move- Back- Analog starts at current
Gauge EMPTY – FULL — — —
ment ground display (Note) position and
color: moves around
black indication range
6 Fuel and then returns
12 level to starting point.
Specified level
or less Lit up during
Caution LED Red — —
(At 76.2 z or operation
higher)
When the small Lit up during
Backlight LED Amber — —
lamp is lit up. operation.
Service 0 – 65535.0h Operates
meter when the
(Regu- Service * Displayed in engine is
When 65535.0h is
the "upper col- — — Note 1 Note 2 exceeded, fixed at
lar dis- meter running.
umn" on the 65535.0h.
play 1:1 against
item) character display clock time
Odome- 0 – 999999.9 km
ter
(Regu-
* Displayed in Operates dur- When 999999.9 km is
Odometer Display the "lower col- — — Note 1 Note 2 exceeded, fixed at
lar dis- ing traveling.
charac- umn" on the 999999.9 km.
play
ter: character display
item)
black
7 LCD
Back- When any
ground problem or
color: failure occurs,
When any prob-
green the action
lem or failure
occurs on the code is dis-
played in the
Action Action machine, * Dis-
upper col- — — Note 1 Note 2
code code played in the umn and rem-
upper and lower edies or
columns on the description of
character display. problem in
the lower col-
umn.
Note 1: Nothing is displayed in the " upper column " and Program No, is displayed in the " lower column ".
But, if equipped the payload meter and when detect the load, display Program No, and Service
meter alternately.
Note 2: KOMATSU is displayed in the " upper column " and Nothing is displayed in the " lower column ".
HD785-7 7
Related When
warn- Alarm oper-
ing buzzer ated. key ON.
lamp
The failure
Press machine code
monitor mode (6 digits) and
selector switch > detection
during the occur- controller are
rence of the For information on how
displayed in
problem or to operate display, see
Failure Failure the upper col-
failure on the — — Note 1 Note 2 the Operation & Main-
code code umn and the
machine. tenance Manual.
faulty system
* Appears in the or descrip-
Display upper and lower tion of prob-
charac- columns on the lem in the
ter: character display. lower
black column.
Reverse LCD Back-
travel ground
integrat- color:
7 ing meter green
Reset of
time to Switch screen
Press machine by operating
change monitor mode
Other filter and machine For details, see the
selector switch monitor mode Note 1 Note 2 Operation & Mainte-
displays oil.
Tele- " " selector nance Manual.
phone switch
number ">" or "<".
setting
Lan-
guage
selection
Dimmed
When the down by a
Night Backlight LED Green small lamp is step when the — —
lighting lit up. small lamp is
lit up.
Central
8 warning LED Red During system is Lit up when
lamp abnormal abnormal.
Note 3:The moment

when the lamp
lights up, the
action code: E01
and the location
When mainte- where an alarm
nance-related has been given
Mainte- alarm is given or Lit up or appear on the
13 nance LED Red the time to flashed — — character
caution change filter and display.
oil has elapsed. Note 4:For details on
Caution the target items,
etc., see the
Operation &
Maintenance
Manual.
Battery
charg- During battery
Lit up when
14 ing cir- LED Red charging circuit
abnormal.
cuit being abnormal
caution
Steer-
When the
ing oil
steering oil Lit up when
15 temper- LED Red
temperature abnormal.
ature
rises.
caution
Note 1: Nothing is displayed in the " upper column " and Program No, is displayed in the " lower column ".
But, if equipped the payload meter and when detect the load, display Program No, and Service
meter alternately.
Note 2: KOMATSU is displayed in the " upper column " and Nothing is displayed in the " lower column ".
8 HD785-7
Related When
warn- Alarm oper- key ON.
ing buzzer ated.
lamp
Engine
When the engine
oil pres- Lit up when
16 LED Red oil pressure
sure abnormal.
drops.
caution
Retarder When the Note :
oil pres- retarder Lit up when Operates when the
17 LED Red
sure oil pressure abnormal. (Note) (Note) alternator R terminal is
caution drops. ON.
Note :
Operates when the
Parking When the
Lit up during parking brake is oper-
18 brake LED Red parking brake is
operation. (Note) (Note) ated and the shift lever
caution operated.
is in other than the "N"
position.
Machine
During being
monitor Under present condi-
abnormal in
or Lit up when tions, used in the event
19 LED Red machine moni-
abnormal. of failure of the
optional
tor or optional
system machine monitor.
controller system
caution
During being
Engine
abnormal in Lit up when
20 system LED Red engine control abnormal.
caution
system.
Caution
Trans-
When transmis-
mission Lit up when
21 LED Red sion control sys-
system abnormal.
tem is abnormal
caution
Retarder When retarder
Lit up when
22 system LED Red control system is
abnormal.
caution abnormal
Inclina- When the body
tion is lifted and
Lit up when
23 caution LED Red inclined exces-
abnormal.
(if sively
equipped) from side to side.
During
operation:
When the seat-
Seatbelt lit up
24 LED Red belt is not — —
caution During non-
fastened.
operation:
turned OFF.
During
operation: Note: Operates when
Body See the lit up the shift lever is in
25 LED Red instruction During non- other than the "N"
caution manual (Note) (Note)
operation: position.
turned OFF.
During
operation:
Emer- When the emer- lit up
26 gency LED Red gency steering is During non- — —
steering operated. operation:
turned OFF.
During
Turn operation:
27 signal, Pilot LED Green During operation lit up — —
During non-
right operation:
turned OFF.
During
Turn operation:
28 signal, LED Green During operation lit up — —
During non-
left operation:
turned OFF.
HD785-7 9
Related When
ing buzzer ated.
lamp
During
Head- operation:
light, lit up
29 LED Blue During operation — —
high During non-
beam operation:
turned OFF.
Shift
30 When the shift
lever
LED Green lever is in the "R" Lit up (*) — — * Blinks when the neu-
(R) position position tral safety is operated.
R
Shift
30 When the shift
lever
LED Orange lever is in the "N" Lit up — —
(N) position position
N
Shift
30 When the shift
lever
LED Green lever is in the "D" Lit up (*) — — * Blinks when the neu-
(D) position position tral safety is operated.
D
Shift
30 When the shift
lever
LED Green lever is in the "6" Lit up (*) — — * Blinks when the neu-
(6) position position tral safety is operated.
6
Shift
30 When the shift
lever
5
Shift
30 When the shift
lever
4 Pilot
Shift
30 lever
When the shift * Blinks when the neu-
LED Green lever is in the "3" Lit up (*) — — tral safety is operated.
(3) position position
3
Shift
30 lever
LED Green lever is in the "2" Lit up (*) — — tral safety is operated.
(2) position position
2
Shift
30 lever
LED Green lever is in the "L" Lit up (*) — — tral safety is operated.
(L) position position
L
F1, F2, F3, F4,
F5, F6, F7, N, R
* According to
the gear shift
signal received
from the When the
transmission gear shift
Back- controller. range
Shift
LCD
ground * When an alarm signal is
— — All lit All lit
indicator color: is raised in the received
gray from the up. up.
31 event of
emergency transmission
escape, "E-" and controller.
the
"gear speed
range" are alter-
natively
displayed.
When the During
Night
Backlight LED Amber small lamp is operation: — —
lighting
lighted up. lit up
10 HD785-7
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
During
operation:
When the
lit up
32 Retarder LED Orange retarder brake is — —
During non-
operated.
operation:
turned OFF
When lockup of During
the torque con- operation:
verter is acti- lit up
33 Lockup LED Green — —
vated During non-
and direct drive operation:
is effective turned OFF
High-power
mode
Output
in operation:
mode At high-power
34 LED Green lit up — —
(power mode
During non-
mode)
operation:
turned OFF
Suspen-
sion mode At suspension Lit up in
35
(hard) (if
LED Green — —
"hard" mode "hard" mode
equipped)
Suspen-
sion
Lit up in
mode In suspension
36 LED Green "medium" — —
(medium) "medium" mode
mode
(if
equipped)
Suspen-
sion
In suspension Lit up in "soft"
37 mode LED Green — —
Pilot "soft" mode mode
(soft) (if
equippe)
During
operation:
ABS (if When ABS is lit up
38 LED Orange — —
equippe) operated. During non-
operation:
turned OFF
During
operation:
ASR (if When ASR is lit up
39 LED Orange
equippe) operated. During non-
operation:
turned OFF
During
When electric
operation:
intake air heater
Preheat- lit up
40
ing
LED Red for preheating — —
During non-
engine is
operation:
operated.
turned OFF
Auto-
When auto- When ready
matic
matic retarder is to be
41 retarder LED Green — —
ready to be oper- operated:
being
ated. lit up
ready
Auto-
Back-
matic
ground
When automatic Display of set * Zero is displayed
42 retarder LCD retarder switch is — — when the set speed is
set
color:
turned ON. speed (*)
gray cancelled.
speed
HD785-7 11
Related opera- When

tion machine Immedi-
ing buzzer ated.
lamp
Auto- During
When automatic
matic operation:
retarder switch is
retarder lit up
43 LED Green turned ON and — —
unit During non-
the unit km/h is
display operation:
selected.
(km/h) turned OFF
Auto- During
When automatic
matic operation:
retarder switch is
retarder lit up
44 Pilot LED Green turned on and — —
display During non-
the unit MPH is
unit operation:
selected.
(MPH) turned OFF
During
Exhaust operation:
brake When exhaust lit up
45 LED Orange — —
(if brake is operated During non-
equipped) operation:
turned OFF
Self-diagnostic function when starting switch is

operated
1. When the starting switch is turned to the ON
position before starting the engine, the system
check is carried out for 3 seconds.
2. If the starting switch is turned to the START
position before 3 seconds have passed with
the starting switch at the ON position, every-
thing will go to the normal operating condition.
However, even if everything goes to the normal
operating condition, the indicator gauges and
meters will not work until 3 seconds have
passed after the starting switch is turned to the
ON position.
Check function of central warning lamp, alarm

buzzer, monitor lamps, and meters
To check the normal display function of the
machine monitor, press the machine monitor check
switch to check the actuation. For details of the
actuation, see "Machine monitor normal display
functions when machine monitor check switch is
operated".
12 HD785-7
HD785-7 13
Table of signals for each monitor connector
Machine monitor
No. Specification
CN PIN I/0 A/D
1 CN1 1 – – –
2 CN1 2 – – –
3 CN1 3 – – –
4 CN1 4 – – NSW power supply (+24 V)
5 CN1 5 – – NSW power supply (+24 V)
6 CN1 6 – – SW power supply (+24 V)
7 CN1 7 – – SW power supply (+24 V)
8 CN1 8 – – –
9 CN1 9 – – GND
10 CN1 10 – – GND
11 CN1 11 0 D D_OUT_3, (Sync 200 mA)
12 CN1 12 0 D D_OUT_2, (Sync 200 mA)
13 CN1 13 0 D D_OUT_1, (Sync 200 mA)
14 CN1 14 0 D D_OUT_0, (Sync 200 mA)
15 CN1 15 – – Sensor power output (+24 V, 100 mA)
16 CN1 16 – – Sensor power output (+5 V, 100 mA)
17 CN1 17 – – GND
18 CN1 18 – – GND
19 CN1 19 – – GND
20 CN1 20 – – GND
21 CN2A 1 I D D_IN_0, (+24 V, 5 mA, PULL DOWN)
27 *1 CN2A 7 I D D_IN_12, (NSW+24 V, 5 mA, PULL DOWN)
28 *1 CN2A 8 I D D_IN_14, (NSW+24 V, 5 mA, PULL DOWN)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
14 HD785-7
Signal and model

Model name
Remarks
Signal name HD325-7 HD465-7E0 HD465-7R
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – – (–) : NON CONNECT
– – – – – OPEN (RESERVED)
– – – – – OPEN (RESERVED)
BAT DIRECT +24 V Q Q Q Q Directly from battery +24 V
BAT DIRECT +24 V Q Q Q Q Directly from battery +24 V
POWER SUPPLY +24 V Q Q Q Q Key switch +24 V (ACC)
POWER SUPPLY +24 V Q Q Q Q Key switch +24 V (ACC)
– – – – – (–) : NON CONNECT
GND (for power supply) Q Q Q Q +24 V POWER CONNECT
GND (for power supply) Q Q Q Q +24 V POWER CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
BUZZER OUTPUT Q Q Q Q Warning buzzer (Max. 200 mA sync)
HEAD LIGHT H/L SWITCHING Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
HI BEAM Q Q Q Q
AISS SW Q Q Q Q
EXHAUST SW2 – – – Q Exhaust brake switch lower side
PASSING SW Q Q Q Q
Used to detect improper connector,
CONNECTER CHECK Q Q Q Q connection
MODE SW2-1 > Q Q Q Q Mode SW2 upper side
RIGHT TURN Q Q Q Q
MODE SW1-1 U Q Q Q Q Mode SW1 upper side
HD785-7 15
Machine monitor
No. Specification
CN PIN I/0 A/D
29 CN2A 9 – – GND
30 CN2A 10 I D D_IN_1 (+24 V, 5 mA, PULL DOWN)
31 CN2A 11 I D D_IN_3 (+24 V, 5 MA, PULL DOWN)
36 *1 CN2A 16 I D D_IN_13 (NSW+24 V, 5 MA, PULL DOWN)
37 *1 CN2A 17 I D D_IN_15 (NSW+24 V, 5 MA, PULL DOWN)
38 CN2A 18 I A D_IN_0 (0 – 30 V)
39 CN2B 1 I D D_IN_16 (+24 V, 5 MA, PULL UP)
43 CN2B 5 I D D_IN_24 (+24 V, 5 MA, PULL DOWN)
44 CN2B 6 – – GND
49 CN2B 11 I D D_IN_25 (+24 V, 5 MA, PULL DOWN)
50 CN2B 12 I A A_IN_1 (0 – 30 V)
54 *2 CN3A 4 I D D_IN_32 (GND, 5 MA, PULL UP)
*1: NSW +24 V input port is active even if the setting is made to KEY OFF when power is supplied directly
from battery.
*2: Setting is made to PULL UP.
16 HD785-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
SENSOR GND Q Q Q Q
CHECK SW Q Q Q Q
EXHAUST BRAKE SW1 – – – Q Exhaust brake switch upper side
ABS CHECK SW Q Q Q Q
ENGINE MODE SW Q Q Q Q
MODE SW1-2 t Q Q Q Q Mode SW1 lower side
MODE SW1-2 < Q Q Q Q Mode SW1 lower side
LEFT TURN Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
ARSC SYSTEM SW1 Q Q Q Q ARSC system switch (upper)
ABS SYSTEM SW1 Q Q Q Q ABS system switch (upper)
ASR SYSTEM SW1 Q Q Q Q ASR system switch (upper)
FRONT BRAKE CUT OFF Q Q Q – (–) : NON CONNECT

Head Light SW recognition for Night
NIGHT LIGHTING SW +24 V Q Q Q Q Lighting function
SENSOR GND Q Q Q Q
ARSC SYSTEM SW2 Q Q Q Q ARSC system switch (lower)
ABS SYSTEM SW2 Q Q Q Q ABS system switch (lower)
ASR SYSTEM SW2 Q Q Q Q ASR system switch (lower)
– – – – – (–) : NON CONNECT
SEAT BELT Q Q Q Q
PANEL DIMMER SWITCH Q Q Q Q
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT

CONNECTOR CHECK 2 (–) : NON CONNECT, Used to detect
(OPEN) Q Q Q Q improper connector connection
– – – – – (–) : NON CONNECT
HD785-7 17
Machine monitor
No. Specification
CN PIN I/0 A/D
57 *2 CN3A 7 I D D_IN_38 (GND, 5 mA, PULL UP)
58 CN3A 8 I P P_IN_0 (0.5 Vp-p)
59 CN3A 9 – – GND
62 CN3A 12 I D –
67 CN3A 17 I P P_IN_0 (0.5 Vp-p)
68 CN3A 18 – – NC
69 CN3B 1 I A A_IN_2 (High resistance input)
71 CN3B 3 I A A_IN_6 (Low resistance input)
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 – – GND
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 – – GND
80 CN3B 12 – – NC
81 CN4 1 – – S_NET (+)
82 CN4 2 – – S_NET (+)
83 CN4 3 – – CAN (+)
84 CN4 4 – – S_NET (–)
*2: Setting is made to PULL UP.
18 HD785-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
OP7 Q Q Q Q For service mode
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
– – – – – (–) : NON CONNECT
CAN (+) Q Q Q Q
– – – – – (–) : NON CONNECT
HD785-7 19
Machine monitor
No. Specification
CN PIN I/0 A/D
85 CN4 5 – – S_NET (–)
86 CN4 6 – – GND
87 CN4 7 – – GND
88 CN4 8 – – CAN (–)
89 CN4 9 – – NC
90 CN4 10 – – NC
91 CN4 11 – – NC
92 CN4 12 – – NC
93 CN5 1 – – NC
94 CN5 2 – – RA232C_1_RTS
95 CN5 3 – – RA232C_1_RD
96 CN5 4 – – RA232C_2_RD
97 CN5 5 – – RA232C_2_RTS
98 CN5 6 – – NC
99 CN5 7 – – NC
100 CN5 8 – – RA232C_1_CTS
101 CN5 9 – – RA232C_1_TX
102 CN5 10 – – RA232C_1_SG
103 CN5 11 – – RA232C_2_SG
104 CN5 12 – – RA232C_2_TX
105 CN5 13 – – RA232C_2_CTS
106 CN5 14 – – NC
107 CN6 1 – – –
108 CN6 2 – – –
109 CN6 3 – – –
110 CN6 1 – – NC
111 CN6 5 – – –
112 CN6 6 – – NC
113 CN6 7 – – –
114 CN6 8 – – GND
20 HD785-7
Signal and model

Model name
Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– Q Q Q Q (–) : NON CONNECT
CAN SHIELD GND Q Q Q Q
CAN (–) Q Q Q Q
– Q Q Q Q
– Q Q Q Q
– Q Q Q Q
Q Q Q Q
Q Q Q Q (–) : NON CONNECT
CAN (+) Q Q Q Q (–) : NON CONNECT
– Q Q Q Q
HD785-7 21
a Switch input on monitor panel board
No. SW Position I/0 A/D Specification
1 SW1 0 I D
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
Rotary switch (16 pousitions)
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
17 SW2 0 I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
Rotary switch (16 positions)
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
22 HD785-7
Model name
Signal name HD325-7 HD465-7E0 HD465-7R Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD785-7 23
No. SW Position I/0 A/D Specification
33 SW3 0 I D
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
Rotary switch (16 positions)
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
49 SW5 1 I D Dip switch (2 positions)
50 SW5 2 I D
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D Rotary switch (16 positions)
54 SW6 2 I D
55 SW6 3 I D
56 SW6 4 I D
24 HD785-7
Model name
Signal name HD325-7 HD465-7E0 HD465-7R Remarks
HD785-7
HD405-7 HD605-7E0 HD605-7R
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
ON: SI specification
– – – –
OFF: Non-SI specification
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
– – – – –
HD785-7 25
HD785-7 Dump truck

© 2007 KOMATSU
All Rights Reserved
26 HD785-7
SEN01290-06
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Automatic shift control system ........................................................................................................................ 2
External power supply heater ....................................................................................................................... 22
Automatic emergency steering system ......................................................................................................... 24
Automatic suspension system ...................................................................................................................... 28
Retarder control system ................................................................................................................................ 31
Battery disconnector switch .......................................................................................................................... 44
Dump control lever........................................................................................................................................ 48
HD785-7 1
Automatic shift control system 1

1. Electrical circuit diagram
2 HD785-7
HD785-7 3
Outline RTCDB2(Machine monitor, retarder controller, and

q Upon receiving the shift position signal of the other) (Updated every 100 msec)
gear shift lever, acceleration signal of the No. Item
accelerator pedal, speed signal of the trans-
1 Gear speed
mission, and signals of various switches and
2 Shift lever position
sensors, the transmission controller automati-
3 Lock-up operation state
cally sets the transmission in the most suitable
gear speed. 4 –
q The transmission controller controls the torque 5 Emergency escape state
converter lockup system and the brake to pre- 6 Operating state of overrun prevention brake
vent overrun, as well as the transmission. 7 Model setting abnormality state
Each of the clutch packs of the transmission 8 Option setting abnormality state
and the torque converter lockup clutch pack 9 Neutral safety alarm
has the electronically controlled modulation 10 Operation of overrun alarm
valves to control the clutches independently. 11 Reverse gear speed select state
Those valves control the initial pressure, build- 12 Torque converter oil temperature
up rate, and torque-off time of each clutch
13 Alternator R terminal
according to the condition of the machine to
14 Key switch C terminal
reduce the gearshift shocks, prevent gearshift
15 Emergency steering operation
hunting, and improve the durability of the
clutch. 16 Tilting alarm command
q Upon receiving the signals of the switches and 17 Fuel level
sensors to drive the display, cautions, and pilot 18 Control state of grid heater
lamps of the machine monitor, the transmis- 19 Engine coolant temperature
sion controller sends them to the network. 20 Engine speed
21 Momentary fuel consumption
Data items transmitted from transmission con- 22 Body seating
troller to network 23 Float caution
24 Auto suspension mode
RTCDB1(Machine monitor, retarder controller, and
25 Retarder brake signal
other) (Updated every 10 msec)
26 Parking brake signal
No. Item 27 Exhaust brake operation
1 Output shaft speed Tail lamp operation (secondary brake operation
28
2 Brake command (Front wheel) recognition)
3 Brake command (Rear wheel) 29 ARSC operation (ready lamp)
4 Exhaust brake operation command 30 ASR command (oparation ON/OFF)
31 ABS operation state
Retarder controller model setting abnormality
RTCDB1(Special to engine controller) 32
state
(Updated for 10 msec)
Retarder controller option setting abnormality
33
No. Item state
1 Throttle correction value Accumulator oil temperature drop state
34
2 Throttle lower limit (front,rear)
3 Throttle upper limit 35 ARSC overheat alarm
4 2nd method throttle 36 ABS controller model setting abnormality state
5 HSI line / brake point speed 37 ABS controller option setting abnormality state
6 Torque curve select (engine mode) 38 ARSC setting travel speed
7 ABS reference type 39 Retarder oil temperature (front)
8 Droop switch 40 Retarder oil temperature (rear)
9 ABS droop trim 41 Body positioner signal
RTCDB2(Special to engine controller)

(Updated every 100 msec)
No. Item
1 Automatic warm-up cancel flag
4 HD785-7
Data items sent from network to transmission RPC-k (irregularly updated)

controller
No. Item
1 Model selection information
RTCDB1 (Updated every 10 msec)
Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator position b. Maximum gear speed setting for the body-up
state
3 Seat unoccupied judgment
2 c. Exhaust brake equipped / not equipped
4 Reverse not-permitted command d. Correction amount of tire size
5 Retarder switch (front) state e. Tilting alarm function Installed/Not installed
6 Retarder switch (rear) state f. ABS function Installed/Not installed
7 Foot brake (service brake) state g. Parking brake interlock provided / not pro-
vided
Adjustment mode information
RTCDB2 (Updated for 100 msec) (Adjustment mode information)
No. Item a. Trigger correction amount leaning value reset
3
1 Service meter b. Auto IP mode command
c. Manual IP mode command
2 Engine mode switch
d. Torque converter stall command
3 Exhaust brake switch 1 (Pressed up)
4 Exhaust brake switch 1 (Pressed down)
5 AISS inhibit switch
6 Reverse travel speed gear selector switch
7 Accelerator sensor abnormality state
8 Engine coolant temperature
9 Control state of grid heater
10 Momentary fuel consumption
11 Parking brake operation
12 Retarder brake operation
13 Body seating
14 Hoist lever state
Tail lamp output (secondary brake operation
15
recognition)
16 Float caution
17 ASR command (operation ON/OFF)
18 ARSC operation (ready lamp)
19 ARSC setting travel speed
20 ARSC overheat alarm
21 Exhaust brake operation
22 Retarder oil temperature (front)
23 Retarder oil temperature (rear)
24 Auto suspension mode
Retarder controller option setting abnormality
25
state
Retarder controller model setting abnormality
26
state
27 Body position sensor
28 ABS operation state
ABS controller option setting abnormality
29
state
ABS controller model setting abnormality
30
state
HD785-7 5
Transmission controller
Outline
q The transmission controller controls the trans- 8. The self-diagnostic function is installed for
mission system. each of the input and output systems.
It has the following features and functions. 9. The self-diagnostic function is displayed
1. The gear shifting patter is set in the power on the monitor.
mode or economy mode. 10. If a trouble is detected, its contents are
2. In the braking mode, the brake is used and sent to the network.
the gear shifting point is heightened to in- 11. It uses the machine monitor to display if the
crease the brake cooling pump speed. Ac- failure is still existing.
cordingly, the retarder cooling effect is 12. It provides an escape function for use
increased and the engine is used as a when there is a failure in the electrical sys-
brake efficiently. tem.
3. It controls the brake through the retarder
controller for the torque converter lock-up
solenoid valve, exhaust brake (if equipped)
and overrun prevention.
4. To reduce the gear shift shocks, the throt-
tle correction command is output to the en-
gine controller to adjust the engine speed
during gear shifting operation.
5. Speed sensors are installed to 3 places of
the transmission input shaft, intermediate
shaft and output shaft to sense slip of the
transmission clutch and protect the trans-
mission when the hydraulic system has a
trouble.
6. It connects to the network and shares var-
ious data with other controllers.
7. It receives the model selection data (what
model it is mounted on) through the net-
work.
6 HD785-7
Input and output signal

CN1
Pin Signal name Input/output Pin Signal name Input/output
No. signal No. signal
1 Torque converter oil pressure Input 13 Accumulator oil pressure sensor (front) Input
2 – – 14 –
3 Transmission oil temperature Input 15 Alternator R terminal Input
4 – – 16 Sensor power supply Output
5 Emergency escape switch Input 17 Transmission filter clogging switch 1 Input
6 Shift lever position N Input 18 – –
7 Accumulator oil pressure sensor (rear) Input 19 Machine inclination angle Input
8 Fuel level sensor Input 20 Steering oil temperature Input
9 Torque converter oil temperature Input 21 GND (for sensor) –
10 – – 22 Sensor power supply (5V) Output
11 Transmission filter clogging switch 2 Input 23 – –
12 Emergency steering operation Input 24 Start Input
CN2
1 – – 21 –
2 – – 22 Network Low Input/output
3 Transmission oil quantity variable valve operation Input 23 –
4 – – 24 –
5 Shift lever position 5 Input 25 Shift lever position D Input
6 Shift lever position L Input 26 Shift lever position 3 Input
7 Transmission main variable valve operation Input 27 Coolant level Input
8 – – 28 – –
GND (for input shaft speed, output shaft
9 – – 29 speed)
10 – – 30 Transmission output shaft speed Output
11 – – 31 –
12 – – 32 Network High Input/output
13 Main oil quantity exchange valve operation Input 33 – –
14 – – 34 – –
15 Shift lever position 6 Input 35 Shift lever position R Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Air cleaner clogging switch Input 37 – –
18 – – 38 – –
19 – – 39 GND (intermediate shaft speed) Input
20 Transmission intermediate shaft speed Input 40 Transmission input shaft speed Input
CN3
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24 V Input 22 Proportional solenoid power supply 24 V Input
ECMV output Hig 1st, 4th, ECMV output Rev. 2nd, lock-up, T/M lubrica-
3 main oil quantity change valve (-) Output 23 tion oil quantity variable valve (-) Output
4 – – 24 KEY switch ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV Low (+) Output 26 ECMV High (+) Output
7 – – 27 – –
8 Torque converter oil pressure sensor power Output 28 Main oil quantity exchange valve Output
supply (24V)
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Fill switch Low Input 30 Fill switch High Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24 V Input 32 GND Input
ECMV output Low, 3rd, transmission main
13 Output 33 GND Input
pressure variable valve (-)
14 KEY switch ACC Input 34 – –
15 ECMV 3rd (+) Output 35 ECMV lock-up (+) Output
16 ECMV 4th (+) Output 36 ECMV 1st (+) Output
17 – – 37 Transmission main pressure variable valve Output
18 – – 38 Transmission oil quantity variable valve Output
19 Fill switch 3rd Input 39 – –
20 Fill switch 4th Input 40 Fill switch 1st Input
HD785-7 7
Gear shift lever position and automatic gearshifting range

q The relationship between each gearshift position and the automatic gearshifting range is as shown in
the table below.
(When the gear shift lever is in the reverse position,

the default is RH. RL can be selected for the
reverse travel, however, with the machine monitor.)
8 HD785-7
Gearshifting characteristics
q Shifting the transmission up and down is car- Economy mode:
ried out according to the shift map saved in the This standard mode uses for normal work. Com-
controller memory. pare with power mode, the engine speed is main-
There are five types of shift map, depending on tained at a lower level, and the fuel consumption,
the condition of the input signals. noise, and transmission shock are improved opti-
The settings for each mode are as shown in mum.
the table below. In addition, the acceleration sensitive type variable
shifting point is employed, which senses the
Mode Set conditions
machine acceleration and shifts up the gear early to
Braking mode Brake signal ON accelerate the machine sharply and reduce the fuel
When the following conditions are fulfilled consumption, noise and gear shift shock when the
Coasting
mode
1. Brake signal OFF machine is empty or loaded little (when the acceler-
2. Accelerator idle ation is high).
When the following conditions are fulfilled
1. Within certain time after brake signal is turned Skip shift during uphill travel
Partial delay OFF
2. Accelerator pedal is not in idle position or full
In the power mode or economy mode, when the
position gear is shifted down with the accelerator pedal
depressed fully while traveling up hill, if the system
1. Certain time after brake signal is turned OFF judges that the gear does not need to be (should
Power mode
2. Accelerator pedal depressed not be) shifted one level by one as usual, it skips 1
3. Power mode selector switch is at power or 2 levels.
Economy 1. Certain time after brake signal is turned OFF
mode 2. Accelerator pedal depressed
3. Power mode selector switch is at economy
Braking mode:
The shift-down point and the shift-up point are both
raised, the engine speed is maintained at a higher
level, and the amount of cooling oil for the retarder
is ensured to provide greater effect when the engine
is used as a brake.
Coasting mode:
The difference between the shift-down point and the
shift-up point is increased to reduce the number of
unnecessary gear shifting operations.
Partial delay:
The number of unnecessary gear shifting opera-
tions caused by change of the mode is reduced and
hunting caused by repeated gear shifting is prevent-
ed.
Power mode:
The power mode uses the power of the machine to
the maximum to provide the maximum payload.
In addition, the acceleration sensitive type variable
shifting point is employed, which senses the ma-
chine acceleration and shifts up the gear early to ac-
celerate the machine sharply and reduce the fuel
consumption, noise and gear shift shock when the
machine is empty or loaded little (when the acceler-
ation is high).
HD785-7 9
Automatic gearshifting graph

q The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking
(for overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note:
1. Power mode q If the travel speed lowers below 2 km/h or the
q The optimum shift-up point is selected foot brake is not applied or the lock-up is kept
between 1,725 and 2,080 rpm according to the turned on for a long period, the lock-up is
accelerating condition of the machine and gear turned off and a gear speed proper for the
speed. travel speed is selected.
q The optimum shift-down point is selected 4. Coasting mode
between 1,200 and 1,350 rpm according to the q The shift-down point is set to 1,200 rpm or
accelerator pedal position and gear speed. 1,250 rpm, depending on the current gear
2. Economy mode speed.
q The optimum shift-up point is selected 5. Partial delay mode
between 1,725 and 2,050 rpm according to the q The shift-down point is set to 1,200 rpm or
accelerating condition of the machine and gear 1,250 rpm, depending on the current gear
speed. speed.
q The optimum shift-down point is selected 6. Lock-up
between 1,200 and 1,300 rpm according to the q The optimum lock-up ON point is selected
accelerator pedal position and gear speed. between 1,250 and 1,475 rpm according to the
torque converter inlet speed (engine speed)
3. Braking mode
and outlet speed (transmission input shaft
q While the foot brake is operated, if the travel
speed).
speed lowers below about 21 km/h at the 4th
q The lockup OFF point in RL, RH, F1 and F2 is
gear speed, about 15 km/h at 3rd gear speed,
1,100 rpm.
or 11 km/h at the 2nd gear speed, the current
q If the accelerator pedal is released to start trav-
gear speed (F4, F3, or F2) is maintained.
eling down a slope in RL, RH, F1 or F2, the
Accordingly, if the operator drives the machine
torque converter is not locked up until the
down a slope with the foot brake applied and
accelerator pedal is depressed or the brake is
the engine speed is kept low by the gear speed
applied.
maintaining function, the cooling oil becomes
insufficient and the engine tends to overheat.
10 HD785-7
Gear shift lever positions and method of shift- If the operation is not correct, gear shifting is
ing restricted.
1) Gear shift lever position D 4) Gear shift lever position N
When shifting up (in power mode) At the neutral position, none of the transmis-
I) When the gear shift lever is set at position D, sion clutches are actuated.
the transmission is set to F2 torque converter
range. No - shift time
II) When the accelerator pedal is depressed, the q In the automatic shift range, no-shift time is
engine speed rises and accelerates. When the secured during each gear shifting operation to
transmission input shaft speed reaches 1,250 prevent a malfunction caused by transient
– 1,475 rpm, the lock-up clutch is engaged, so change of the speed at the gear shifting opera-
the torque converter is directly engaged and tion. The gear is not shifted in this no-shift
the transmission is set to direct travel. time.
III) As the engine speed rises further and reaches q The no-shift time is controlled finely for each
1,750 – 2,080 rpm, the transmission shifts up gear shift pattern by the all-range electronic
to F3. modulation system.
While the transmission is shifting up, the
engine speed is also lowered (a command is The no-shift time for each gear shift pattern is
output to the engine controller) in order to roughly shown below.
reduce the shock when shifting gear.
IV) Immediately after shifting up, the engine speed
momentarily goes down, but as the machine
accelerates, it rises again and the transmission
shifts up to F4 to F7 in the same way as in III)
above.
When shifting down (in power mode)

I) When the load increases and the engine
speed drops to 1,200 – 1,350 rpm, the trans-
mission shifts down one speed.
(For example, when traveling in F7, the trans-
mission shifts down to F6.)
While the transmission is shifting down, the
engine speed is also raised (a command is
output to the engine controller) in order to
reduce the shock when shifting gear.
II) As the engine speed goes down further and
the transmission shifts down to F2, the torque
converter lock-up clutch is disengaged and the
transmission enters the torque converter drive.
a The set speed and operating condition in the

above explanation are subject to change,
depending on the travel condition. For details,
see the automatic gear shifting graph.
2) Gear shift lever positions 6, 5, 4, 3, 2, L

The method of shifting automatically from F1 to
F6 (F5, F4, F3, F2) is the same as for "gear
shift lever position D" above.
3) Gear shift lever positions R
There is the gear shift lever position for travel-
ing in reverse (RH). (By setting it changeable
to RL position.)
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
HD785-7 11
Safety functions 4) When engine speed rises to more than 2,550

1) Down-shift inhibitor function rpm (more than 2,150 rpm for RH), central
If the travel speed is still high after the gear is warning lamp flashes and alarm buzzer
shifted down with the gear shift lever, shift- sounds. (When engine speed drops to less
down operation starts after the travel speed than 2,300 rpm (less than 1,950 rpm for RH),
decreases. warning and alarm stop.)
For example, when traveling in D (F7), even if When engine speed rises to more than 2,300
the gear shift lever is operated to 5, the trans- rpm (more than 2,400 rpm for F6 and F7, more
mission does not shift directly F7 o F5. It than 1,950 rpm for RH), rear brake begins to
shifts down F7 o F6 o F5 according to the work automatically and then works fully at
travel speed. 2,600 rpm. (When engine speed drops to less
(Even if the operator makes a mistake in oper- than 2,300 rpm (less than 1,950 rpm for RH),
ation of the gear shift lever, the transmission rear brake stops working.)
does not skip a gear speed. This is to prevent If a symptom of overrun is detected, the brake
overrunning of the engine.) is actuated automatically to prevent overrun
2) Neutral safety function even if the engine speed is below the above
This circuit prevents the engine from starting if value.
the gear shift lever is not at the N position, (To prevent overrun of engine, torque con-
even if the starting switch is turned to the verter, and transmission, to improve durability
START position. and reliability)
(This is a safety circuit to prevent the machine 5) REVERSE safety
from moving unexpectedly when the engine is The machine will not travel in reverse if the
started.) dump control lever is not at FLOAT and the
3) Directional inhibit function dump body is not completely lowered.
When traveling in reverse at a speed of more (Turnover prevention function)
than 4.0 km/h, even if the gear shift lever is 6) Speed range limit function when dump body is
operated to D or positions 6 to L, the transmis- raised
sion will not be shifted immediately to travel After dumping the load, if the body is not com-
forward. The engine speed is lowered to pletely lowered, shifting up is limited.
reduce the travel speed, and when the travel If the gear shift lever is at D, the machine starts
speed goes below 4.0 km/h, the transmission in F1. If the former is at positions 6 to L, the
is shifted to FORWARD. latter starts in F1. The gear is not shifted up
(To prevent overload on power train, to improve until the body is completely lowered.
durability and reliability)
Self-diagnostic function
When traveling forward at a speed of more q The controller carries out self-diagnosis of the
than 4.0 km/h, even if the gear shift lever is system and displays any abnormalities.
operated to position R, the transmission will q The details of the self-diagnosis are displayed
not be shifted immediately to travel in reverse. on a monitor.
The speed range is shifted to N and the engine q If any abnormality is detected by the self-diag-
speed is lowered to reduce the travel speed. nosis function, the abnormality data is trans-
When the travel speed goes below 4.0 km/h, mitted to the network and is displayed as an
the transmission is shifted to REVERSE. action code on the machine monitor. The
transmission system caution, warning lamp, or
When starting the engine, if the machine is alarm buzzer may also be actuated.
already traveling forward or in reverse at a
speed of more than 4.0 km/h, even if the gear
shift lever is operated to a position R, the
machine will not move and the transmission
will be held at N.
When the travel speed goes below 4.0 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
12 HD785-7
HD785-7 13
Transmission controller list of real-time monitoring display contents

The input and output signal states of the transmission controller can be checked with the real-time mon-
itoring function of the machine monitor.
Real-time monitoring display items related to transmission controller and contents displayed in normal
state are as follows.
No. Item ID number Displayed spec Data contents
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version No. is output (Soft logic part ver-
sion No.)
3 Data version 20224 VERSION (DATA) Software version No. is output (Soft data part ver-
sion No.)
4 Transmission input shaft speed 31200 T/M SPEED:IN Input shaft speed is output
5 Transmission intermediate shaft 31300 T/M SPEED:MID Intermediate rotation speed is output
speed
6 Transmission output shaft speed 31400 T/M SPEED:OUT Output shaft speed is output
7 Fuel level 04201 FUEL SENSOR Resistance-converted value of fuel level sensor
(A_IN_5) is output
8 Fuel level 04201 FUEL SENSOR Input voltage of fuel level sensor (A_IN_5) is
output
9 Alternator R 04301 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
10 Torque converter oil temperature 30100 T/C OIL TEMP Torque converter oil temperature (A_IN_1) is
output
11 Torque converter oil temperature 30101 T/C OIL TEMP Torque converter oil temperature (A_IN_1) voltage
is output
12 Transmission oil temperature 32500 T/M OIL TEMP Transmission oil temperature is output
13 Transmission oil temperature 32501 T/M OIL TEMP Transmission oil temperature voltage is output
14 Steering oil temperature 32701 STRG OIL TEMP Steering oil temperature (A_IN_3) is output
15 Steering oil temperature 32702 STRG OIL TEMP Steering oil temperature (A_IN_3) voltage is
output
16 Torque converter oil pressure 32600 T/C OIL PRESS Torque converter oil pressure (A_IN_10) conver-
sion value is output
17 Torque converter oil pressure 32605 T/C OIL PRESS Torque converter oil pressure (A_IN_10) input
voltage is output
18 Accumulator oil pressure (front) 35500 ACC OIL PRE F Pressure-converted value of front accumulator oil
pressure (A_IN_8) is output
19 Accumulator oil pressure (rear) 35501 ACC OIL PRE R Pressure-converted value of rear accumulator oil
pressure (A_IN_9) is output
20 Accumulator oil pressure (front) 35504 ACC OIL PRE F Voltage sensed by front accumulator oil pressure
(A_IN_8) is output
21 Accumulator oil pressure (rear) 35505 ACC OIL PRE R Voltage sensed by rear accumulator oil pressure
(A_IN_9) is output
22 Solenoid output (H) 31600 ECMV H DIR ECMV output command current to HIGH clutch is
output
23 Solenoid output (L) 31601 ECMV L DIR ECMV output command current to LOW clutch is
output
24 Solenoid output (1st) 31602 ECMV 1 DIR ECMV output command current to 1st clutch is
output
25 Solenoid output (2nd) 31603 ECMV 2 DIR ECMV output command current to 2nd clutch is
output
14 HD785-7
Data range Remarks

Depending upon software part number
Depending upon software version No.
x1 [min-1] (0 – 32767 [min-1])

---- [Other than above]
x1 [min-1] (0 – 32767 [min-1])
x1 [min-1] (0 – 32767 [min-1])
x1 [z] (0 – 250 [z])
x.001 [V] (0 – 5 [V])
0:OFF
1:ON
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0 °C
4.33 V = 30 °C
3.55 V = 60 °C
2.20 V = 100 °C
1.61 V = 120 °C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
x1 [mV] (0.00 – 5.00 [V])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
HD785-7 15

26 Solenoid output (3rd) 31604 ECMV 3 DIR ECMV output command current to 3rd clutch is
output
27 Solenoid output (4th) 31605 ECMV 4 DIR ECMV output command current to 4th clutch is
output
28 Solenoid output (R) 31606 ECMV R DIR ECMV output command current to REV clutch is
output
29 Solenoid output (Lockup) 31609 ECMV LU DIR ECMV output command current to Lockup clutch
is output
30 Transmission main oil pressure vari- 31643 ECMV MAIN P Transmission main oil pressure variable solenoid
able solenoid output output condition is output
31 Main oil quantity exchange solenoid 31644 ECMV MAIN V Main oil quantity exchange solenoid output condi-
output tion is output
32 Angle sensor 32900 ANGLE SENSOR Converted pitch angle of pitch angle sensor input
for pitch alarm (A_IN_7) is output
33 Angle sensor 32903 ANGLE SENSOR Voltage of pitch angle sensor input for pitch alarm
(A_IN_7) is output
34 Brake output (front wheel) command 33807 BK OUTP DIR F Brake command amount of brake (retarded) con-
value troller
35 Brake output (rear wheel) command 33808 BK OUTP DIR R Brake command amount of brake (retarded) con-
value troller
36 Exhaust brake 35900 EXH BRAKE Exhaust brake output (ON/OFF output) condition
is output
37 Throttle modified value 36000 THROTTLE MOD Throttle modified value to be sent to engine con-
troller is output
38 Transmission oil quantity variable 38001 ECMV LUB V Transmission oil quantity variable solenoid output
solenoid output is output
39 Low clutch trigger modification value 38900 TRIGGER MOD L Low clutch trigger modification value is output (all
oil temperature mode)
40 High clutch trigger modification value 38901 TRIGGER MOD H High clutch trigger modification value is output (all
41 1st clutch trigger modification value 38902 TRIGGER MOD 1 1st clutch trigger modification value is output (all
16 HD785-7
Data range Remarks

x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 100 [mA])
x1 [mA] (0 – 100 [mA])
x1 [° ] (-25.0 – +25.0 [° ])
x1 [mV] (0.00 – 5.00 [V])
x1 [%] (0 – +100.0 [%])
x1 [%] (0 – +100.0 [%])
0: OFF
1: ON
x1 [%] (-100.0 – +100.0 [%])
x1 [mA] (0 – 100 [mA])
Hexadecimal numbers show below
Display of 8 characters
AABBCCDD
AA: Low temperature correction value [x10msec]
BB: Medium temperature correction value [x10msec]
CC: Normal temperature correction value [x10msec]
DD: High temperature correction value [x10msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HD785-7 17

42 2nd clutch trigger modification value 38903 TRIGGER MOD 2 2nd clutch trigger modification value is output (all
43 3rd clutch trigger modification value 38904 TRIGGER MOD 3 3rd clutch trigger modification value is output
(all oil temperature mode)
44 4th clutch trigger modification value 38905 TRIGGER MOD 4 4th clutch trigger modification value is output
(all oil temperature mode)
45 Revolution clutch trigger modification 38906 TRIGGER MOD R Revolution clutch trigger modification value is out-
value put (all oil temperature mode)
46 Clutch FILL switch 38919 FILL HL1234R FILL SW recognition condition of each clutch is
output
[H,L,1,2,3,4,R]
18 HD785-7
Data range Remarks

AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
Corresponding data is displayed by [1 (ON), 0 (OFF)] just under H: H Fill switch recognition [1:ON, 0:OFF]
HLR1234R. L: L Fill switch recognition [1:ON, 0:OFF]
1: One Fill switch recognition [1:ON, 0:OFF]
Example 2: Two Fill switch recognition [1:ON, 0:OFF]
0110000: when in F1 3: Three Fill switch recognition [1:ON, 0:OFF]
0001001: when in R2 4: FOUR Fill SW recognition [1:ON, 0:OFF]
0000000: when in N R: R Fill switch recognition [1:ON, 0:OFF]
1000010: when in F4
HD785-7 19

47 Trigger initial learning flag 38920 TRIG HL1234R Trigger time initial learning flag state for each
clutch is output
[H, L, 1, 2, 3, 4, R]
8 characters are displayed in following order

[HLR123]
H: H flag [1:ON, 0:OFF]
L: L flag [1:ON, 0:OFF]
R: R flag [1:ON, 0:OFF]
1: One flag [1:ON, 0:OFF]
2: Two flag [1:ON, 0:OFF]
3: Three flag [1:ON, 0:OFF]
48 Fill time (L) 41800 FILL TIME L LOW clutch fill time is output
(Last gear shifting condition)
x10 [msec] (0 – 2.55 [sec], No fill :0)
49 Fill time (H) 41801 FILL TIME H HIGH clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (1) 41802 FILL TIME 1 1st clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
52 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
53 Fill time (4) 41805 FILL TIME 4 4th clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
54 Fill time (R) 41806 FILL TIME R REV clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
55 Throttle lower limit output 44201 THROT LIMIT LO Throttle lower limit to be sent to engine controller
is output
x0.1 [%] (0 – +100.0 [%])
56 Throttle higher limit output 44200 THROT LIMIT HI Throttle upper limit to be sent to engine controller
is output
x0.1 [%] (0 – +100.0 [%])
57 Input signal D_IN_0-7 40905 D-IN--0------7 Input signal condition is output
58 Input signal D_IN_8-15 40906 D-IN--8-----15 Input signal condition is output
59 Input signal D_IN_16-23 40907 D-IN-16-----23 Input signal condition is output
60 Input signal D_IN_24-31 40908 D-IN-24-----31 Input signal condition is output
61 Input signal D_IN_32 40942 D-IN-32 Input signal condition is output

62 Output signal D_OUT_0-7 40949 D-OUT-0------7 ON/OFF output state of SOL_OUT_0 - 7. When
power supply output is set, 0 is displayed.
63 Output signal D_OUT_8-15 40950 D-OUT-8-----15 Corresponds to SOL_OUT_8, 9, 10A, 10B, 11A,
11B, SIG_OUT_0 and SIG_OUT1. When power
supply output is set, 0 is displayed.
64 Output signal D_OUT_16-23 40951 D-OUT-16----23 Corresponds to SIG_OUT_2, 3, HSW_OUT_0, 1,
BATT_RY_OUT. Not used D_OUT_21 - 23. When
power supply output is set, 0 is displayed.
20 HD785-7
Data range Remarks

Corresponding clutch learning flag ON/OFF state is displayed by
[1 or 0] just below HLR1234R.
HLR1234R
1111111 (All clutches have been learned)
HLR1234R
0000000 (No clutch has been learned)
x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])

*0******: Transmission oil filter 1 clogging D_IN_1: Transmission oil filter switch 1
****1***: Cranking D_IN_3: Emergency escape switch
******0*: Emergency steering not operated D_IN_4: C terminal signal
******1*: Emergency steering operated D_IN_6: Emergency steering relay
*******1: Shift lever N D_IN_7: Shift lever N
1*******: L fill D_IN_8: Fill signal L
*1******: 4th fill D_IN_9: Fill signal 4th
**1*****: H fill D_IN_10: Fill signal H
***1****: 1st fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
10010000: When in F1
00010010: When in R1
00000000: When in N
11000000: When in F6
10000000: Shift lever R D_IN_16: Shift range R
01000000: Shift lever D D_IN_17: Shift range D
00100000: Shift lever 6 D_IN_18: Shift range 6
00000001: Shift lever L D_IN_23: Shift range L
*0******: Lowering of coolant level D_IN_25: Coolant level
**0*****: Clogging of air cleaner D_IN_26: Air cleaner switch
***0****: Operation of main pressure variable valve D_IN_27: Main pressure variable valve pressure switch
****0***: Operation of main oil flow selector valve D_IN_28: Main oil flow selector valve pressure switch
*****0**: Operation of lubricating oil flow variable valve D_IN_29: Lubricating oil flow variable valve pressure switch
* Not used
* Not used
* Not used
* Not used
HD785-7 21
External power supply heater 1

Engine oil pan heater, coolant heater
1. Junction box
2. Engine oil pan heater
3. Coolant heater
22 HD785-7
HD785-7 23
Automatic emergency steering system 1
1. Timer Outline
2. Battery If the engine should stop when the machie is travel-
3. Emergency steering oil pressure switch ing, or there is any abnormality in the hydraulic
4. Emergency steering motor pump and the steering circuit oil pressure is
5. Emergency steering pump become below the specifed value, the emergency
6. Steering control valve system automatically actuates an electric pump to
ensure the hydraulic pressure for the steering,
thereby making it possible to use the steering.
This system can also be operated manually.
24 HD785-7
Relay timer
1. Dial Outline
2. Lock The relay timer is a delay timer which prevents the
3. Pin emergency steering system from operating when
the oil pressure switch malfunctions because of oil
Set time: 1 seconds pulsation etc.
After power is applied to the timer coil for the set
time, the relay contacts are changed.
HD785-7 25
Emergency steering motor
1. Terminal E Function
2. Terminal M q If there is an abnormal drop in the oil pressure
in the steering circuit, the emergency steering
motor receives a signal from the transmission
controller and drives the emergency pump.
Specifications
Type DC motor
Rated voltage 24V
Rated output 0.9kW
26 HD785-7
Emergency steering pump

SBL(1)-24
Unit: mm
Clearance between gear case Model Standard clearance Clearance limit
1
and side plate, gear SBL(1)-24 0.10 – 0.15 0.19
Clearance between inside
2 diameter of plain bearing and SBL(1)-24 0.06 – 0.119 0.20
outside diameter of gear shaft Replace
Model Standard size Tolerance Repair limit
3 Depth to knock in pin –0.5
SBL(1)-24 10 —
–0.5
4 Rotating torque of splined shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Rotating
pressure delivery amount
Delivery amount Model speed
MPa amount limit
— Oil: EO10-CD (rpm) —
{kg/cm2} ( /min.) ( /min.)
Temperature: 45 – 55°C
20.6
SBL(1)-24 3,000 67.9 62.7
{210}
HD785-7 27
Automatic suspension system 1

(If equipped)
1. Suspension cylinder (Left) Outline

2. Solenoid valve The front suspension mode (damper force) is auto-
3. Suspension cylinder (Right) matically switched according to the travel condition
and load condition to give a more comfortable ride
to the operator and to improve the travel stability.
a For details of the internal mechanism of the
suspension, see Suspension
28 HD785-7
Automatic suspension mode selection control

With the front suspension, the mode (damping
force) is automatically changed according to the
travel conditions and load conditions to ensure a
comfortable ride and to improve the travel stability
of the machine. The control patterns and functions
of the modes (damping force) are as shown in the
table below.
S: Soft
M: Medium
H: Hard
Set mode
Control pattern Function Content of control Empty Loaded
S M H S M H
Distinguishing To set damping force Internal pressure of front sus-
empty/loaded according to load on pension cylinder is measured
machine and compared with standard
value
Anti-roll To prevent the chas- This detects the travel speed
sis from rolling when and steering angle, and
turning at high speed switches the mode according to (When
turning)
certain conditions.
(Not controlled when traveling
empty) (See Fig. 1)
Anti-dive To prevent nose-div- The damping force is made
ing when braking stronger when the brakes are
(Brake (Brake (Brake (Brake
applied. OFF) ON) OFF) ON)
Anti-lift To prevent the front The damping force is made
from lifting up when stronger when the dump control
dumping lever is at any position except (Float) (Other (Float) (Other
than than
FLOAT. Float) Float)
High speed To improve stability Detects travel speed and selects
stability when traveling at damping force. (No control when
high speed traveling empty) (See Fig. 2)
Fig. 1 Fig. 2
HD785-7 29
Auto suspention solenoid valve
2. Solenoid q The automatic suspension solenoid valve is
installed in the circuit between the hydraulic
A: To hydraulic cylinder head pump and the suspension cylinder. The valve
B: To hydraulic cylinder bottom switches oil pressure of the hydraulic cylinder
P: From pump which is installed to the front suspension,
T: To transmission oil pan according to signal from the retarder controller.
Two solenoid valves are combined to select
three modes of Soft, Medium and Hard.
30 HD785-7
Retarder control system 1
HD785-7 31
Retarder controller
Outline braking, etc. sent from various sensors to set

The retarder controller has the following functions. the damping force of the front suspension to 1
1. Retarder control of 3 levels of SOFT, MEDIUM, and HARD.
The solenoid valve is controlled according to 6. ASR Control (if equipped)
the operating angle of the retarder control lever The retarder controller detects slips of the right
and actuates the retarder. and left drive wheels from their speed and
2. Overrun prevention and retarder control when steering angle and controls the ASR solenoid
there is transmission abuse v al v e t o m ai nta in t he s pee d d iff er e n c e
The retarder controller controls the solenoid between both wheels constant.
valve to operate the retarder according to the The wheel slipping at higher speed is braked
command of the transmission controller. and the brake torque is transmitted to the
wheel rotating at lower speed to improve the
3. Hoist control travel performance.
The retarder controller controls the hoist EPC
valve (solenoid valve) and hoist selector valve 7. Transmission of network data
(ON/OFF valve) according to the position of 1) The retarder controller transmits the infor-
the dump control lever and actuates the dump mation of operation of the retarder, float
body. caution, and operation of the parking
brake to the machine monitor.
4. Automatic retarder speed control (ARSC)
2) The retarder controller receives informa-
The retarder controller controls the solenoid
tion of overrun prevention, retarder com-
valve to control the retarder braking force and
mand when there is abuse, etc. from the
keep the downhill travel speed at the speed set
transmission controller.
with the automatic retarder travel speed set
switch. 3) The retarder controller transmits informa-
tion of reverse inhibition, etc. to the trans-
5. Automatic suspension control (if equipped) mission controller.
The retarder controller changes the signals for
the automatic suspension solenoid valve
according to the travel conditions and load
conditions such as the load weight, turning,
32 HD785-7
CN1
Pin No. Signal name Imput/output signal Pin No. Signal name Imput/output signal
1 SUS press sensor (RL) Input 13 ARSC set SW Input
2 Strg potentio Input 14 Retard lever Input
3 Retard oil temp (R) Input 15 Alternator R Input
4 GND (SIG) – 16 Sens PWR Output
5 Retard SW (rear) Input 17 Service brake press SW Input
6 Brake system filter Input 18 Validation SW2 Input
7 SUS press sensor (RR) Input 19 Hoist lever (main) Input
8 Body position sensor Input 20 Hoist lever (SUB) Input
9 Retard oil temp (F) Input 21 GND (Analog GND) –
10 GND (SIG) – 22 Pot PWR Output
11 Retard SW (F) Input 23 Exhaust brake SW Input
12 Memory clear SW Input 24 Validation SW1 Input
CN2
1 – Output 21 – Input/Output
2 Strg hoist filter SW Input 22 CAN0 L Input/Output
3 Strg hoist lever SW Input 23 – Input/Output
4 232C RxD Input 24 PWR CTR EXT Input
5 Brake wear SW (RL) Input 25 Brake wear SW (FL) Input
6 – Input 26 Parking brake sol status Input
7 ENG oil level SW Input 27 – Input
8 – Output 28 TM & Brake oil level SW Input
9 Body float signal Output 29 GND (pulse GND) –
10 Wheel speed (RR) Input 30 T/M output shaft speed Input
11 – Output 31 – –
12 – – 32 CAN0_H Input/Output
13 Eng oil filter Input 33 – Input/Output
14 – Output 34 – –
15 Brake wear SW (FR) Input 35 Key SW C (Engine start) Input
16 – Input 36 Steering speed Input
17 Retard cooling filter Input 37 – Input
18 Stop lamp relay Output 38 Battery requid level SW Input
19 – Output 39 GND (pulse GND) –
20 Wheel speed (RL) Input 40 – Input
CN3
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
SOL_COM SOL_COM
3 Input 23 Input
(solenoid common GND) (solenoid common GND)
4 – Output 24 Key SIG Input
5 Hoist EPC valve Output 25 – Output
6 – Output 26 ASR valve (RL) Output
7 Auto SUS SOL1 Output 27 Lever kick out sol Output
8 +24 V for sensor Output 28 – Output
9 Parking brake press SW Input 29 – Input
10 ASR press SW (RL) Input 30 Shut off valve SW Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
SOL_COM (solenoid com- 33 GND (controller GND) Input
13 Input
mon GND) 34 Power out 5V1 –
14 Key SIG Input 35 – Output
15 ASR shut off valve Output 36 ASR valve (RR) Output
16 Retard valve (R) Output 37 Auto SUS SOL2 Output
17 Hoist change valve Output 38 Exhaust brake valve Output
18 BCV relay Output 39 Secondary brake SW Input
19 – Input 40 ASR check SW Input
20 ASR press SW (RR) Input
HD785-7 33
Retarder controller list of real-time monitoring display contens

The input and output signal states of the retarder controller can be checked with the real-time monitoring
function of the machine monitor.
Real-time monitoring display items related to retarder controller and contents displayed in normal state
are as follows.
No. Item ID number Diplay spec. Data contents
1 Part No. of software 20214 VERSION Mass production software part number is
output
2 Application version 20231 VERSION (APP) Software version No. is output (soft logic part
version No.)
3 Data version 20232 VERSION (DATA) Software version No. is output (soft data part
version No.)
4 ARSC set switch 37701 ARSC SET SP SW A_IN_8
5 Transmission output shaft speed 31403 T/M SPEED:OUT PLS_IN1

Transmission output shaft speed is output
6 Wheel speed (left) 39705 WHEEL SPEED L PLS_IN2
Wheel speed is output.
7 Wheel speed (right) 39704 WHEEL SPEED R PLS_IN3
Wheel speed is output.
8 Retarder cooling oil temperature 30201 BRAKE OIL T F Converted temperature of retarder oil tem-
(front) perature sensor (front) (A_IN_6) is output.
9 Retarder cooling oil temperature 30204 BRAKE OIL T F A_IN_1
(front)
10 Retarder cooling oil temperature 30211 BRAKE OIL T R Converted temperature of retarder oil tem-
(rear) perature sensor (rear) (A_IN_2) is output.
11 Retarder cooling oil temperature 30212 BRAKE OIL T R A_IN_2
(rear)
12 Brake output (front wheel) 33700 BK OUTP DIR F SOL_OUT_6
13 Brake output (rear wheel) 33806 BK OUTP DIR R SOL_OUT_7
14 Retarder lever 33900 RETARD LEVER A_IN_4
15 Body positioner 34602 BODY POSITION A_IN_5
16 Dump lever (hoist lever) potenti- 34304 DUMP LEVER 1 A_IN_3

ometer 1
17 Dump lever (hoist lever) potenti- 34305 DUMP LEVER 2 A_IN_7
ometer 2
18 Hoist EPC output 45600 HOIST EPC DIR SOL_OUT10A
19 Seating control command (Hi) 45102 S CNT DIR H
20 Seating control command (Lo) 45103 S CNT DIR L
21 Seating condition calibration 45201 S CNT A

value ( )
22 Cylinder stopper calibration 45301 S CNT B
value ( )
23 Seating control time (Hi) 45402 S CNT TIME H
24 Seating control time (Lo) 45403 S CNT TIME L
25 Shutoff valve output 45700 SHUT OFF VALVE SOL_OUT10B
34 HD785-7
Data range Remarks

Depending upon software part number
0.00 – 5.00 [V]

---- [ARSC setting OFF or other than above]
0 – 32767 [rpm]
---- [ARSC option setting OFF or other than above]
0 – 32767 [rpm]
0 – 32767 [rpm]
0 – 160 [°C]
0.00 – 5.00 [V]
0 – 160 [°C]
0.00 – 5.00 [V]
0 – 1000 [mA] [command value]
--- -[Other than above]
0 – 1000[mA] [command value]
0.00 – 5.00[V]
----[Other than above]
0.00 – 5.00[V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.00 – 5.00 [V]
0.0 – 10.00 [s] Down to 2 decimal places are displayed.
0.0 – 10.00 [s] Down to 2 decimal places are displayed.
ON [1] Unit is not displayed.
OFF [0]
HD785-7 35
No. Item ID number Diplay spec. Data contents

26 Steering position sensor 35402 STRG ANGLE Converted angle of steering angle sensor
(A_IN_6) is output.
27 Steering position sensor 35400 STRG ANGLE A_IN_6
28 Steering speed 35403 STRG ANG SPEED PLS_IN0

Steering speed is output.
29 Suspension pressure (left) 32814 SUS PRESS (L) Converted pressure of suspension pressure
sensor (A_IN_10) is output.
30 Suspension pressure (left) 32815 SUS PRESS (L) A_IN_10
31 Suspension pressure (right) 32816 SUS PRESS (R) Converted pressure of suspension pressure
sensor (A_IN_9) is output.
32 Suspension pressure (right) 32817 SUS PRESS (R) A_IN_9
33 Judgment of empty/loaded truck 39400 EMPTY OR LOAD Judgment of empty/loaded truck is output.
34 ASR output (L) command 39601 ASR OUTP DIR L Output command value to ASR (L) solenoid
is output.
35 ASR output (R) command 39603 ASR OUTP DIR R Output command value to ASR (R) solenoid
is output.
36 Input signal D_IN_0 – 7 40932 D - IN--0------7 Input signal stats of D_IN_0 – D_IN_7 are
output as they are.
37 Input signal D_IN_8 – 15 40933 D - IN--8-----15 Input signal stats of D_IN_8 – D_IN_15 are
output as they are.
38 Input signal D_IN_16 – 23 40934 D - IN-16-----23 Input signal stats of D_IN_16 – D_IN_23 are
output as they are.
output as they are.
output as they are.
41 Output signal D_OUT_0 – 7 40955 D-OUT-0------7 D_OUT_0 – 7 refer to SOL_OUT_0 – 7 of

CR710.
36 HD785-7
Data range Remarks

-180.0 – +180.0 [° ]
--- [Other than above]
0.00 – 5.00 [V]
0.0 – 99.99 [rad/s] Down to 2 decimal places are displayed.
--- [Other than above]
0.00 – 20.10 [MPa]
--- [Automatic suspension option setting OFF and ARSC
option setting OFF, or other than above]
0.00 – 5.00 [V]
---[Automatic suspension option setting OFF and ARSC
0.00 – 20.10 [MPa]
--- [Automatic suspension option setting OFF and ARSC
0.00 – 5.00 [V]
-- -[Automatic suspension option setting OFF and ARSC
LOAD[1] Unit is not displayed.
EMPTY[0]
---[Other than above]
Command value 0 - 1020[mA][00 - FF]
Command value 0 - 1020[mA][00 - FF]
01010101 [1.0 is displayed under corresponding display Unit is not displayed.
(number)]
Input signal ON [1],
Input signal OFF [0],
0 is displayed on unused part.
(number)]
Input signal ON[1],
Input signal OFF[0],
(number)]
Input signal ON[1],
(number)]
Input signal ON[1],
(number)]
Input signal ON[1],
(number)]
Input signal ON[1],
HD785-7 37

42 Output signal D_OUT_8 – 15 40956 D-OUT-8-----15 D_OUT_8 – 15 refer to SOL_OUT_8, 9, 10A,
10B, 11A, 11B, SIG_OUT_0 and
SIG_OUT_1 of CR710.
43 Output signal D_OUT_16 – 23 40957 D-OUT-16-----23 D_OUT_16 – 23 refer to SIG_OUT_2, 3,

HSW_OUT_0, 1 and BATT_RY_OUT of
CR710. D_OUT_21, 22 and 23 are not
used.
38 HD785-7
Data range Remarks

(number)]
Input signal ON[1],
(number)]
Input signal ON[1],
HD785-7 39
Retarder control function

Retarder control system diagram
Retarder lever control

q The operating angle of the retarder lever is
detected by the potentiometer and a current
corresponding to this is output to the solenoid
valve to actuate the retarder.
q The solenoid valve outputs pressure to control
the retarding action according to the input cur-
rent (retarder lever angle).
Overrun prevention and retarder control when

there is transmission abuse
q The retarder controller controls the solenoid
valve to operate the retarder according to the
command of the transmission controller.
40 HD785-7
Relationship between retarder lever potentiometer and output to solenoid valve
A: To improve the initial response of the solenoid

reducing valve, the output (trigger output) is
set to a high value.
B: To operate the hydraulic equipment smoothly
in the low pressure range, the output is set to a
high value.
C: In the range where the retarder is normally
used, the output is proportional to the angle of
the lever.
D: To release the hydraulic pressure smoothly in
the low pressure range, the output is set to a
low value.
HD785-7 41
Hoist control function

Hoist control system diagram
1. Hoist control function 3. Body seating speed control

When the engine is running, the EPC valve When the body is lowered to near the seat, the
(solenoid valve) and selector valve are con- open area of the EPC valve is reduced to con-
trolled according to the operation of the dump trol the lowering speed of the body and reduce
control lever and operate the dump body. the seating shock.
2. Lever positioner function

The dump control lever has four positions:
RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the
RAISE position, the dump body is raised, and
when the top of the dump body reaches the set
position of the body position sensor, the lever
is returned to the HOLD position.
If the lever is kept at the RAISE position, the
RAISE output continues to be given.
The body stops before the raising stroke end
automatically to reduce the shock at the stroke
end.
42 HD785-7
4. Control when starting switch is turned to

ON, OFF, or START
Starting switch at ON:
The output is set to HOLD, regardless of the
position of the lever.
If the engine is not started, even if the hoist
lever is operated, the condition remains at
HOLD.
Starting switch at OFF:
The hoist valve is closed and the dump body is
held in position regardless of the position of the
lever.
Engine started:
Immediately after the engine is started, the out-
put is set to HOLD, regardless of the position
of the lever.
After the lever is moved to the HOLD position,
it becomes possible to carry out normal opera-
tions.
5. Reverse inhibit function

The retarder controller judges if it is permissi-
ble to travel in reverse or not, and transmits the
result of the judgment through the network to
the transmission controller.
"FLOAT OUTPUT" or "SEATED" and "LEVER
NOT RAISED" o Reverse travel permitted
"NOT FLOAT OUTPUT" and "NOT SEATED"
o r " L E V E R R A I S E D " a n d " S E AT E D " o
Reverse travel prohibited
6. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body
cylinder stopper condition.
After adjusting the installation of the body

potentiometer or replacing the retarder control-
ler, carry out calibration. For the calibration
procedure, see Testing and adjusting.
HD785-7 43
Battery disconnector switch 1
EU spec.
1. Battery disconnect switch
44 HD785-7
KAL spec.

2. Battery jump start connector
3. Starter disconnector switch
Disconnect and jump start electrical circuit diagram

(EU spec.)
HD785-7 45
Disconnect and jump start electrical circuit diagram

(KAL spec.)
Position ON (connected)
Position OFF (cut)
46 HD785-7
HD785-7 47
Dump control lever 1
48 HD785-7
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HD785-7 49
Function
q If lever (1) is operated, rod (18) moves up and
down to rotate potentiometer (16) according to
the operation stroke of the lever.
q The operation angle (stroke) of the control
lever is sensed with the potentiometer and it is
output in the form of signal voltage to the con-
troller.
q One potentiometer is installed to output 2
opposite signal voltages shown in "Output volt-
age characteristics".
Operation
1. When dump control lever is set in "FLOAT"
position
q If rod (2) on the LOWER side is pushed and
moved down with lever (1), ball (14) touches
projection (a) of rod (11) on the stroke. (Before
start of mechanical detent)
q If rods (2) and (11) are pushed further, ball (14)
pushes up retainer (13) held on detent spring
(12) and escapes out to go over projection (a)
of rod (11).
q At this time, rod (18) on the opposite side is
pushed up by spring (4) and ball (14) is moved
to the small diameter side of projection (b) of
rod (19) by retainer (13) held on detent spring
(20).
q Even if the operator releases the lever, rod (18)
is held by projection (b) of rod (19) and ball
pressing force, and consequently the lever is
held in the "FLOAT" position.
50 HD785-7
2. When dump control lever is returned from 4. When dump control lever is set in "RAISE"
"FLOAT" position position
q To return lever (1) from the "FLOAT" position, q If rod (18) on the RAISE side is pushed and
push it down with a force larger than the hold- moved down with lever (1), ball (14) touches
ing force of rod (19), detent spring (20), projection (a) of rod (19) on the stroke. (Before
retainer (13) and ball (14). start of electric detent)
q If rods (18) and (19) are pushed further, ball
3. When dump control lever is set in (14) pushes up retainer (13) held on detent
"LOWER" position spring (20) and escapes out to go over projec-
q If lever (1) is leaned further from the "FLOAT" tion (a) of rod (19).
position, it is set in the "LOWER" position. q At this time, rod (2) on the opposite side is
q Rod (18) is pushed up by spring (4) according pushed up by spring (4).
to the operation stroke of lever (1). q If rod (2) is pushed up while current is flowing
q Since lever (17) and rod (19) installed to the in solenoid (9), nut (10) is attracted by bushing
turning shaft of potentiometer (16) are con- (8).
nected to each other, potentiometer (16) out- q As a result, rod (2) is kept pushed up. Accord-
puts voltages according to the vertical stroke of ingly, even if the operator releases the lever,
the rod. the lever is held in the "RAISE" position.
5. When dump control lever is returned from

"RAISE" position
q To return lever (1) from the "RAISE" position,
push it down with a force larger than the attrac-
tion of the solenoid. It is also returned to the
"HOLD" position when the solenoid power sup-
ply is turned "OFF" and the "RAISE" operation
is reset.
HD785-7 51
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
52 HD785-7
SEN01291-04
DUMP TRUCK
HD785-7

HD785-7 7001 and up

VHMS controller related.................................................................................................................................. 2
ABS/ASR system .......................................................................................................................................... 28
Altitude setting function................................................................................................................................. 46
HD785-7 1
VHMS controller related 1

a For details of basic precautions, outlines, see
"Testing and adjusting".
VHMS controller
a For details of the basic precautions, outlines,
method of sending and receiving data, and the
procedure for the initial setup, see Testing and
adjusting.
Specifications
1. Voltage of power supply: DC20V - DC30V
2. Size (mm): W272 x D169 x H72
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine
controller. It also gives commands for transmitting
the accumulated data through the communications
satellite.
2 HD785-7
Communications (ORB: Orbcomm)

Controller/Antenna
(If equipped)
Controller
Specifications
1. Power supply voltage: DC12V – DC30V
2. Size: W306 x D177 x H50 (mm)
Installation location
Install the controller to rear right bottom of opera-
tor's cab.
Connector portion
CN1: DRC23-40PA
CN2: Communications antenna cable connector
Antenna
Specifications
1. Type : Helical whip antenna
2. Impedance : 50 z
3. Input terminal: M-P type
4. Length : 165 ± 20 mm
a : Communications antenna mount
Installation location
Install pole at right front of machine and set
antenna on top of it.
Function
The antenna transmits the data collected and accu-
mulated by the VHMS controller through the com-
munications satellite to the computer center.
HD785-7 3
Payload meter (having VHMS)

(If equipped)
System configuration
4 HD785-7
Outline Principle of calculation

q A dump truck is supported by 4 suspension 1. Outline
cylinders. By measuring the total of the loads A dump truck is supported by 4 suspension
on each cylinder, it is possible to know the cylinders. By measuring the total of the loads
mass on the springs of the dump truck. on each cylinder, it is possible to know the load
The measurement of the load mass is obtained mass on the springs of the dump truck.
by calculating the difference between the mass The measurement of the load mass is obtained
when empty and the mass when full. by calculating the difference between the mass
Payload meter displays the load mass calcu- when empty and the mass when full.
lated as above on the monitor screen and dis- The load on each cylinder can be calculated
plays the load level on the outside indicator from the internal pressure and sectional area
lamps. of the suspension cylinder.
It also has an estimation display function:
when loading the next load, the new total load
mass is estimated and the appropriate lamp
flashes. This prevents overloading.
q The operation data, including the load mass of

each transportation cycle, can be saved in the
internal memory and downloaded with special
software (if equipped).
The hauled load weight is obtained by statisti-
cally processing the data sampled during travel
from the loading place to the dumping place
and then saved.
q The VHMS controller executes the functions of

the payload meter and saves the data of each
transportation cycle. It displays, sets, and
operates various items through the machine
monitor and network.
When the payload meter is installed for the first
time or the VHMS controller is replaced, the
necessary items of the VHMS controller must
be set again.
q The payload meter (having VHMS) cannot be

installed to a dump truck which is not equipped
with the VHMS controller.
Electric circuit diagram

See Troubleshooting, Troubleshooting of VHMS
controller system.
HD785-7 5
[Load bearing on suspension cylinder]
W = PB SB – PT (SB – ST)
Where
W = Load bearing on suspension cylinder
PB = Bottom pressure
PT = Top pressure
SB = Cross-sectional area of cylinder
ST = Cross-sectional area of rod
Because of the structure of the suspension cyl-

inder,
PB PT
Therefore, the load can be calculated as fol-
lows.
W = PBST
6 HD785-7
2. Measurement of mass when empty

(Calibration)
Drive the empty dump truck at a speed of
about 10 km/h for about 30 seconds, and then
measure the average load and use it as the
mass when empty.
The reason why the mass is measured while
the dump truck is traveling is that the sliding
resistance of the suspension cylinders must be
averaged by extracting and retracting the cylin-
ders by changing the condition of the dump
truck.
The measured mass when empty is saved as a
calibration data in the memory in the controller.
3. Correction on slope
If the dump truck is loaded on a slope, the
measured mass is different from the mass
measured on a level ground. To solve this
problem, the longitudinal inclination of the
dump truck is measured and the measured
mass is corrected according to the inclination
angle. (Correction range of inclination angle: ±
5°)
4. Detecting distance, travel speed

The travel speed and distance are detected
from the travel signal sensor on the truck.
a Travel signal sensor:
Transmission output shaft speed sensor
HD785-7 7
Initial setting of payload meter

In the following cases, carry out "Testing and
adjusting, Setting and adjusting of devices" and
"Testing and adjusting, VHMS controller initial set-
ting procedure" according to the table shown below.
1. When the payload meter (having VHMS) is
installed for the first time
2. When the payload meter (having VHMS) is
removed
3. When the VHMS controller or transmission
controller is replaced
4. When setting of VHMS controller is changed
Setting with VHMS initial setting tool (*2)

Optional Date
VHMS device Time
Setting of payload meter setting of Variation Time
controller machine Model Serial No.
code difference
monitor (*1) Summer
time
Not
NON – – – –
installed
Payload meter function is not installed
Installed VHMS ST
Set
HD785 7
properly
Payload meter function is installed VHMS Installed + PLM PV
(*1) See "Testing and adjusting, Setting and adjusting of devices".

(*2) See "Testing and adjusting, VHMS controller initial setting procedure".
When there is not a problem in installation and wir- Reference

ing of the payload meter but there are the following Testing and adjusting
problems, check the above setting again.
1. Items related to the payload meter are not dis- Setting and adjusting of devices
played on the machine monitor.
"The payload is not displayed when the VHMS controller initial setting procedure
machine is loaded and stopped", "There are
not the menus related to the payload meter on
the machine monitor", etc.
2. While the payload meter (having VHMS) is not
set, there are the menus related to the payload
meter on the machine monitor.
3. Data cannot be downloaded.
a Wrong setting of the model, serial No.,
and variation code with the VHMS initial
setting tool.
4. Date and time of the downloaded data are
wrong.
a Wrong setting of the date and time with
the VHMS initial setting tool.
8 HD785-7
Basic functions of payload meter start of loading will delay and shorter stoppage
For details, see Operation and Maintenance Man- time for loading than actual will be recorded as
ual. the cycle data. Always test the setting by load-
ing the truck with the loader to be used in pro-
Various setting functions duction.
(Service functions)
1. Setting of travel distance to recognize com- 6. Setting of indication range of outside indi-
pletion of loading cator lamp
When the dump truck travels 160 m from the This function is used to change the indication
loading area, the payload meter judges that range of the outside indicator lamp. The condi-
the loading operation is finished. If the dump tion for turning on the red lamp cannot be
truck is unloaded before it travels 160 m, the changed. If it is changed, the red lamp cannot
payload meter does not judge that the dump warn of overloading.
truck is unloaded and the cycle data is not
completed at this time. This function is used to 7. Setting of OFFSET range
change the travel distance to recognize com- This function is used to adjust the calculated
pletion of loading when the distance between load mass by a set amount.
the loading area and dump area is very short.
2. Correction of calculation of load mass

If the load mass indicated by the payload
meter is different from that indicated by the
user's load meter, measure the operating mass
(when the truck is empty) and gross truck
mass (when the truck is loaded with the rated
load mass) with the user's load meter, then
correct the relation table of the suspension
pressure and load mass forcibly with the mea-
sured masses.
3. Correction of level of inclination sensor

This function is used to correct the level of the
inclination sensor.
4. Setting of criterion of maximum travel speed

This function is used to set a criterion of the
maximum travel speed for the machine control
system.
5. Setting of load mass to recognize start of

loading
The payload meter recognizes that the loading
operation has been started when the sprung
weight has changed a certain amount. The
value is set to 10% or less of the rated payload
at the time of shipment from the factory. This
function allows this value to be adjusted. Care
must be exercised when changing this value. If
the value is too small, the payload meter will
recognize an impact due to the bounce of the
truck during empty travel on the uneven road
as the start of loading, and will start displaying
load mass when the truck is stopped even if
the truck has not yet been loaded. This will
cause incorrect recording of the cycle data;
shorter empty travel time than actual, and
longer stoppage time for loading than actual. If
the value is too large, the recognition of the
HD785-7 9
Operating method
Select "PLM" in Service mode 1 on the machine monitor.
For method of selection, see Testing and adjusting, "Special functions of machine monitor (EMMS)".
10 HD785-7
1. Setting of travel distance to recognize com- 2. Correction of calculation of payload

pletion of loading a Since this function affects the accuracy
directly, execute the following procedure
securely.
a Be sure to measure the weight of the empty
dump truck and that of the fully loaded dump
truck "as a set" according to the following pro-
cedure.
a The dump truck must travel for about 3 min-
utes each after the weight of the empty dump
truck and that of the fully loaded dump truck
are measured. Accordingly, secure a road for
this purpose.
a The relationship between the suspension pres-
sure and payload corrected with this function
Input a travel distance to recognize completion cannot be returned to the condition at the time
of loading by pressing the following switches. of shipment. Accordingly, perform the follow-
The setting range is 0 – 255 m (0.0 – 0.158 ing procedure very carefully.
miles). a This function is used to match the calculation
q [>] switch:
result to the indication of the load meter to be
Number at cursor moves forward. used. It does not always heighten the absolute
q [<] switch:
accuracy.
Number at cursor moves backward. 1) Measure the weight of the empty dump
truck with the load meter and record it
q [ ] switch: Enter number at cursor.
(Write it on a sheet of paper, etc.)
q [ ] switch: Stop inputting number.
2) Input the measured weight of the empty
a If the set value is too small, the system may
dump truck and drive the dump truck for
recognize that loading is completed while the
about 3 minutes.
dump truck is still being loaded.
i) Select "EMPTY WEIGHT".
q [>], [<] switchs:

Select "EMPTY WEIGHT" or "LOADED
WEIGHT".
q [ ] switch: Enter the selection.
q [ ] switch:
Return to the previous screen.
If the weight of the empty dump truck has
been input and the dump truck has been
driven for about 3 minutes, "LOADED
WEIGHT" is displayed when the menu is
selected.
Check the unit of the input value. The unit
is indicated in the ( ) on the right side of
WEIGHT.
(METRIC): metric ton
(SHORT): short ton
HD785-7 11
ii) Check that measurement of the iv) Check the input value.
weight of the empty dump truck has
been completed.
q [<] switch: Select "YES".

q [>] switch: Select "NO".
q [] switch: q [ ] switch: Enter.
Check that measurement has
been completed and go to the v) Move the dump truck to a place where
next step. you can drive it for about 3 minutes.
q [ ] switch:
iii) Input the measured weight of the
empty dump truck.
q [ ] switch:
After getting ready for drive,
press this switch and start
driving the dump truck.
q [>] switch: q [ ] switch:
Number at cursor moves for- Return to the screen for input-
ward. ting values.
q [<] switch: Drive the dump truck for about 3 min-
Number at cursor moves back- utes (at a speed higher than 8 km/h)
ward. to enter the relationship between the
q [ ] switch: Enter number at cursor. weight of the dump truck and the sus-
q [ ] switch: pension pressure under that weight.
Return to the largest position
of the number to input the
value again. If this switch is
pressed again, inputting of the
value is stopped and the previ-
ous screen appears.
q Inputtable range
HD785-7:
91 [t] (Operating weight ± 13%)
(metric ton)
12 HD785-7
vi) Display the progress of measurement. i) Select "LOADED WEIGHT".

For the method of displaying the fol-
lowing screen, see the steps up to the
above step.
q [
] switch:
Stop measurement and return
to the previous screen.
As measurement is executed, the q [>], [<] switchs:
number of [ ] increases. When mea- Select "EMPTY WEIGHT" or
surement is finished, the next screen "LOADED WEIGHT".
appears automatically. q [ ] switch: Enter the selection.
3) Load the dump truck to measure the q [ ] switch:
weight of the fully loaded dump truck. Return to the previous screen.
If the weight of the empty dump truck
has been input and the dump truck
has been driven for about 3 minutes,
"LOADED WEIGHT" is displayed
when the menu is selected.
Check the unit of the input value. The
unit is indicated in the ( ) on the right
side of WEIGHT.
(SHORT): short ton
ii) Check that measurement of the weight
of the fully loaded dump truck has
been completed.
q [ ] switch:
Return to the menu screen.
When loading is started, the menu screen
appears automatically. When indicating
the current load for reference while the
dump truck is being loaded, go out of
"Service mode 1" temporarily and return to
"Display of load/integrated odometer". On
this screen, you can check the current
load.
4) Measure the weight of the fully loaded
dump truck with the load meter and record
it (Write it on a sheet of paper, etc.)
5) Input the measured weight of the fully q [ ] switch:
loaded dump truck and drive the dump Check that measurement has
truck for about 3 minutes. been completed and go to the
next step.
q [ ] switch:
HD785-7 13
iii) Input the measured weight of the fully v) Move the dump truck to a place where
loaded dump truck. you can drive it for about 3 minutes.
[>] switch:
q q [] switch:
Number at cursor moves for- After getting ready for drive,
ward. press this switch and start
q [<] switch: driving the dump truck.
Number at cursor moves q [ ] switch:
backward. Return to the screen for input-
q [ ] switch: Enter number at cursor. ting values.
q [ ] switch: Drive the dump truck for about 3 min-
Return to the largest position utes (at a speed higher than 8 km/h)
of the number to input the to enter the relationship between the
value again. If this switch is weight of the dump truck and the sus-
pressed again, inputting of the pension pressure under that weight.
value is stopped and the previ- vi) Display the progress of measure-
ous screen appears. ment.
a Inputtable range
HD785-7: 119.63 – 199.37 (metric ton)
iv) Check the input value.
q [] switch:
Stop measurement and return
to the previous screen.
q [<] switch: Select "YES". As measurement is executed, the
q [>] switch: Select "NO". number of [ ] increases. When mea-
q [ ] switch: Enter. surement is finished, the next screen
appears automatically.
14 HD785-7
6) Dump the load in the dump area. 3. Correction of level of inclination sensor
1) Move the dump truck to a level place.
2) Input the clinometer reading (F) at the cur-
rent position and that (R) after turning 180
degrees (stopping it in the opposite direc-
tion) on the same position and use the
average value as the standard level.
i) Enter value of (F).
q [ ] switch:
If the load is dumped with the dump lever,
the menu screen appears automatically.
If the load is dumped normally, correction
is finished.
q [ ] switch: Enter the flashing value.

q [ ] switch:
The current standard level value is
displayed on the upper line. The cli-
nometer value (F) at the current posi-
tion flashes. Enter it when it is
stabilized.
ii) Turn the dump truck 180 degrees
(Stop it in the opposite direction).
iii) Enter value of (R).
q [ ] switch: Enter the flashing value.

q [ ] switch:
displayed on the upper line. The cli-
nometer value at the current position
flashes. Enter it when it is stabilized.
HD785-7 15
iv) Enter the standard level value. 4. Setting of criterion of maximum travel speed
q [<] switch: Select "YES". Input a criterion of the maximum travel speed
q [>] switch: Select "NO". by pressing the following switches.
q [ ] switch: Enter. q [>] switch:
Number at cursor moves forward.
q [<] switch:
Number at cursor moves backward.
The setting range is 0 – 99 km/h (0 – 62 MPH).
(Default: 99 km/h)
16 HD785-7
5. Setting of payload to recognize start of load- 6. Setting of indication range of outside indi-
ing cator lamps
Input a payload to recognize start of loading by Input an indication range of the outside indica-
pressing the following switches. tor lamps by pressing the following switches.
q [>] switch: q [>] switch:
Number at cursor moves forward. Number at cursor moves forward.
q [<] switch: q [<] switch:
Number at cursor moves backward. Number at cursor moves backward.
q [ ] switch: Enter number at cursor. q [ ] switch: Enter number at cursor.
q [ ] switch: Stop inputting number. q [ ] switch: Stop inputting number.
The setting range is 6 – 25.5%. a The setting range is 0 – 130% of the load
(Default: 15%) capacity.
a This function does not assure the operation Set (A) (Yellow lamp) higher than (G)
because of the contrary phenomena shown (Green lamp) and set (R) (Red lamp)
below. higher than (A) (Yellow lamp), however.
q If the value is reduced, start of loading
may be recognized wrongly.
q If the value is increased and a loader hav-
ing a small-capacity bucket is used, the
forecast function of the outside indicator
lamps and the MMS communication may
not operate normally.
HD785-7 17
7. Setting of OFFSET range
Input an offset range by pressing the following

switches.
q [>] switch:
Number at cursor moves forward.
q [<] switch:
Number at cursor moves backward.
a The setting range is - 5.0 – +5.0 [t].
Check the unit of the input value on the
previous menu screen.
a The unit is indicated in the ( ) on the right
side of the input value [t].
(SHORT): short ton
18 HD785-7
Functions of communicating with external devices for purposes other than downloading
The following 2 functions of communicating with external devices are installed. They use the RS232C com-
munication port which is installed to download the data of the payload meter.
1. Automatic transmission
When dumping is finished, the data of the concerned cycle are transmitted automatically.
The data saved in the payload meter can be made by accumulating the above cycle data with the sys-
tem on the user side.
2. MMS communication
If the mass of a bucketful is recognized, the load mass at that time is transmitted automatically.
If the final load mass (hauled load mass of the concerned cycle) is entered, its value is transmitted auto-
matically.
Upon receiving a request command, the load mass is transmitted in real time.
RS232C is used for only the selected one of data downloading, automatic transmission, and MMS communi-
cation.
q Specifications of RS232C connection
Baud rate: 9,600 bps
Data length: 8 bits
Stop bit: 1 bits
Parity: Not applied
Flow control: Not executed
q Connection of RS232C (communication line) (3-wire method)
q Selecting wiring harness for downloading/automatic transmission/MMS communication
HD785-7 19
q Distinction of communication control codes

The transmitting side transmits data as explained below so that the data in a communication frame
beginning with STX and finishing with EXT and BCC will have permeability.
1) If there is a code which is the same as STX or ETX in the data area of the communication frame,
DLE (10h) is inserted just before that code.
2) If there is a code which is the same as DLE in the data area of the communication frame, DLE (10h)
is inserted just before that code.
3) Calculation of BCC
XOR (Exclusive-or) is checked in order from STX at the head of the frame to ETX just before BCC,
including inserted DLE.
When one of 02h (STX), 03h (ETX), and 10h (DLE) is included in the data
Original frame
STX (02h) ••• STX (02h) ••• ETX (03h) BCC
Transmitted frame
STX (02h) ••• DLE (10h) STX (02h) ••• ETX (03h) BCC
20 HD785-7
q Automatic transmission
(a) Timing of transmission
The operation data of the concerned cycle are transmitted automatically when the concerned cycle
data are entered (when dumping is finished).
(b) Contents of communication
Format (VHMS controller External device)
STX (02h) [1] ETX (03h) BCC
[1]: Cycle data {39 bytes including header (ASCII L)}

Item Unit Range Number of byte Remarks
Header "L" ASCII 1 L (Fixed)
Unused Integer 1 – 65535 2 0 (Fixed)
Month Month (BCD) 1
Day Day (BCD) 1
Time, hour Hour (BCD) 0 – 23 expression 1
Time, minute Minute (BCD) 1
Truck ID Integer 0 – 200 1
Open ID Integer 0 – 200 1
Load mass Metric ton (10-time value) 0 – 6553.5 2
Empty travel time MIN (10-time value) 0 – 6553.5 2
Empty travel distance km (10-time value) 0 – 25.5 1
Empty max. travel speed km/h 0 – 255 1
Empty ave. travel speed km/h 0 – 255 1
Empty stoppage time MIN (10-time value) 0 – 6553.5 2
Stoppage time for loading MIN (10-time value) 0 – 6553.5 2
Loaded travel time MIN (10-time value) 0 – 6553.5 2
Loaded travel distance km (10-time value) 0 – 25.5 1
Loaded max. travel speed km/h 0 – 255 1
Loaded ave. travel speed km/h 0 – 255 1
Loaded stoppage time MIN (10-time value) 0 – 6553.5 2
Dumping time MIN (10-time value) 0 – 25.5 1
Limited speed km/h 0 – 99 1
Cycle warning code 0 – FFFF (HEX) 2
Unused V (10-time value) 0 – 4.0 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
[BCC]: EX-OR of each bit from STX to ETX
Answer (External device VHMS controller)

STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC
Action that VHMS controller takes when answer is abnormal

If "NAK" is returned, the VHMS controller transmits up to 2 more times. If "NAK" is still returned, the
VHMS controller stops transmission.
HD785-7 21
q MMS communication
Transmission of unit distinction setting
After the VHMS controller is started by turning the key to the ON position, it transmits the unit dis-
tinction setting information automatically.
Format (VHMS controller )
STX (02h) [1] [2] ETX (03h) BCC
[1]: K (ASCII) fixed

[2]: 02 (h) fixed (Unit classification [HEX])
The unit classification is the same as one used for PLM2. It is fixed to 02 (h) in the VHMS con-
troller.
Answer ( VHMS controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or

If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller
transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmis-
sion.
Transmission of load mass, estimated load mass, and suspension pressure

When mass of 1 bucketful is recognized.
22 HD785-7

Format (VHMS controller)
STX (02h) [1] [2] [3] [4] [5] [6] ETX (03h) BCC
[1]: M (ASCII) fixed

[2]: 4 (ASCII) fixed
[4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
[5]: Estimated load mass (C) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
[6]: (B) Calculated suspension pressure [HEX] [8 BYTES]
From head
Signal name Position Name HEX
(Lower position)
P FL (Upper position) Front left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P FR (Upper position) Front right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RL (Upper position) Rear left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RR (Upper position) Rear right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5

or

sion.
Transmission of final load mass

When the concerned cycle data are entered (When dumping is finished), the final load mass (= the
load mass to be saved as the hauled load mass of the concerned cycle in the memory) is transmit-
ted automatically.
Format (VHMS controller)
STX (02h) [1] [2] [3] [4] ETX (03h) BCC
[1]:
P (ASCII) fixed
[2]:
4 (ASCII) fixed
[3]:
02h fixed for unit identification
[4]:
Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
Order: Lower position upper position from the head byte of [4]

or
HD785-7 23

sion.
Transmission of real-time data

(a) Outline of communication procedure
1) The VHMS controller receives a request for the real-time data from MMS.
2) After receiving the request for the real-time data, the VHMS controller transmits the real-time
data at intervals of 0.2 seconds.
3) When the VHMS controller receives a request for finishing transmission of the real-time data, it
finishes transmission of the real-time data. When the key is turned to the OFF position, trans-
mission of the real-time data is finished, too.
1) Request for real-time data ( VHMS controller)
Format
STX (02h) [1] [2] ETX (03h) BCC

Answer (VHMS controller )

Transmission of the real-time data from the VHMS controller is used as a substitute for the
answer.
24 HD785-7
2) Transmission of real-time data (VHMS controller )

Format (VHMS controller )
STX (02h) [1] [2] [3] [4] ETX (03h) BCC

[4]: Real-time data (17 BYTES)
From head
Signal name Position Name HEX
(Lower position)
P FL (Upper position) Front left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P FR (Upper position) Front right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RL (Upper position) Rear left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RR (Upper position) Rear right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position) [Complement of 2 of 100-time value]

INC (Upper position) Inclination angle (degree) -9.99 – +9.99
(Lower position)
PAYLD (Upper position) Real-time load mass (Metric ton) [10-time value, to 1 decimal place]
SP (Current) Travel speed (km/h) 0 – 99
DIG STST Status of digital signals See (*1)
ANA 1 Unused 0
ANA 2 Unused 0
VEH STAT Status of dump truck See (*2)
(*1) Status of digital signals [HEX]

bit 0: N signal1: N (OPEN) 0: Other than N (GND)
bit 1: BODY FLOAT signal 1: FLOAT (OPEN) 0: Other than FLOAT N (GND)
bit 2: Unused
bit 3: Unused
bit 4: Unused
bit 5: Unused
bit 6: Unused
bit 7: Unused
(*2) Status of dump truck [HEX]
00 (h): Engine stopped
01 (h): Empty and stopped
02 (h): Empty and traveling
03 (h): Loading
04 (h): Loaded and traveling
05 (h): Loaded and stopped
06 (h): Unloading
HD785-7 25

STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC

Even if "NAK" is returned or any of "ACK", "NAK", and a request for finishing RTM is not
returned in RTM transmission timing, the VHMS controller transmits the real-time data normally
after 0.2 seconds. If this condition is repeated 10 times, the VHMS controller stops transmis-
sion.
3) Request for finishing transmission of real-time data ( VHMS controller)

Format
STX (02h) [1] [2] ETX (03h) BCC
[1]: Q (ASCII) fixed

Answer (VHMS controller )

STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC
26 HD785-7
HD785-7 27
ABS/ASR system 1
(If equipped)
ABS specification
28 HD785-7
1. Brake system tank

cooling) brake control pump
(SDR(30)100+100SA(1)25)
3. ABS control valve
4. ABS ON/OFF valve
HD785-7 29
ASR specification
30 HD785-7

(SDR(30)100+100SA(1)25)
3. ASR control valve
4. ASR shut-off valve
HD785-7 31
ABS and ASR specification
32 HD785-7

(SDR(30)100+100SA(1)25)
3. ABS control valve
4. ABS ON/OFF valve
5. ASR control valve
6. ASR shut-off valve
HD785-7 33
System operation logic
Outline
ABS (Anti-skid Brake System) ASR (Automatic Spin Regulator)
q The ABS automatically controls slippage that is q The ASR prevents the drive wheels from slip-
caused by locking of the wheels when the ping when there is excessive torque. In this
brakes are applied suddenly or on snow or way it improves the starting ability and drive-
other slippery road surfaces. In this way, the through ability on poor or frozen road surfaces.
ABS keeps the machine stable and insures q When the machine starts to move on snow-
that it can be steered. covered or split road surfaces (where the con-
q With the ABS, the ABS controller calculates dition of the road surface is different on the left
the machine travel speed and the speed of and right: such as when one side is snow and
each wheel from the signals sent by the wheel the other side is dry road), if an excessive
speed sensors installed to each wheel. It then torque is applied to the wheels, both or one of
sends a signal to the pressure control valve for the wheels will spin and it may be impossible
the wheel where the brakes may possibly for the machine to start. However, if the
lock, thereby controlling the brakes on the four machine is equipped with an ASR, the brake is
wheels independently. automatically applied to the wheel that is spin-
ning and the torque applied to the wheel is
a When the ABS is actuated on a slippery road controlled, so the machine can move off.
surface, the braking distance becomes slightly
longer. a If both rear wheels slip at the same speed, the
a When traveling at extremely low speed, the ASR function is not actuated, so reduce the
wheels may lock. pressure on the accelerator to control the
engine output.
34 HD785-7
HD785-7 35
Operation
ABS (Anti-skid Brake System)
When not actuated V : Travel speed
(when there is normal braking) V (Ref) : Calculated machine speed
q If the tires do not tend to skid when the brake is V (Rad): Wheel speed
applied normally, the ABS control valve does a0: Acceleration (–)
not operate and the oil pressure is supplied The signal for the condition when the wheel
from the brake valve directly to the slack deceleration speed has exceeded the set limit.
adjuster. a1: Acceleration
The signal for the condition when the wheel
When actuated acceleration speed has exceeded the set limit.
q The oil pressure applied to the brake is con- 1: Slip ratio
trolled as shown in the graph to prevent a skid The signal for the condition where the wheel
of the tires automatically. speed is less than the travel speed and has
exceeded the set limit.
t1: Braking is started and the brakes start to have
effect on the wheels. At the same time, the
wheel speed shows a possibility of locking.
t2: If the wheel acceleration exceeds (a0), the

controller judges that the wheels have started
to be unstable and sets the electric signal con-
stant to check the condition.
t3: If the wheel speed lowers further to slip ratio

( 1), the controller judges that the wheels are
unstable and changes the electric signal to
release the brake.
t4: Since the brake is released, the wheel speed

tends to recover. If the wheel acceleration
passes (a0), the controller judges that the
wheels have entered the stable range and sets
the electric signal constant.
t5, t6: After the wheel acceleration passes (a1), it

lowers and returns to (a1) again since the
brake pressure is held. At this time, the con-
troller judges that the wheel acceleration is
stabilized and changes the electric signal to
apply the brake. The signal is changed
gradually so that the wheel speed will not
change sharply (since the controller has
judged that the road surface is slippery).
t7: Since the brake is applied, the wheels tend to

skid again. If the wheel acceleration passes
(a0), the controller judges that the wheels are
unstable and changes the electric signal to
release the brake.
t8: Since the brake is released, the wheel speed

tends to recover. When the wheel acceleration
returns to (a0) again, the controller judges that
the wheels have entered the stable range and
sets the electric signal constant.
t9: Same as t6
Stages t4 – t9 are repeated.
36 HD785-7
HD785-7 37
ASR (Automatic spin regulator)
When ASR does not operate

q While the vehicle is travelling normally and the
speeds of both rear wheels are not much dif-
ferent from each other, ASR does not operate
and the brake is not applied to the drive
wheels.
q When the vehicle turns, ASR still does not
operate since the condition for starting the con-
trol changes according to the steering angle.
ASR will operate if the vehicle turns on a slip-
pery road and the speeds of the drive wheels
become greater from each other than what
they should at a given steering angle.
When ASR operates (When vehicle starts)

q If the speeds of both drive wheels become dif-
ferent from each other while the accelerator
pedal is depressed as shown in the graph, the
slipping wheel is braked so that the speeds of
both wheels will be the same.
38 HD785-7
HD785-7 39
ABS controller
Outline
q This calculates the wheel speed and dummy
machine speed from the signals sent by the
wheel speed sensors installed to each wheel.
It then sends a control signal to the control
valve for the wheel which is slipping or where
there is a possibility of locking.
If the system becomes abnormal, the ABS
controller displays related error codes and
stops the system and then works as a normal
brake.
40 HD785-7

CN1
1 ABS CONTROL PRESSURE (RL) Input 13 ABS CONTROL PRESSURE (FL) Input
2 NC Input 14 NC Input
3 NC Input 15 R TERMINAL SIGNAL Input
4 GND_SIG_D – 16 PWR_OUT_SENS Output
5 NC Input 17 ABS CUT PRESS SW (R) Input
7 ABS CONTROL PRESSURE (RR) Input 19 ABS CONTROL PRESSURE (FR) Input
9 NC Input 21 GND_SIG_A –
10 GND_SIG_D – 22 POT_PWRO Output
11 NC Input 23 ABS CUT PRESS SW (F) Input
CN2
1 NC Output 21 NC Input/output
2 NC Input 22 COMM_CAN_L_O Input/output
3 NC Input 23 NC Input/output
4 NC Input 24 PER_CTR_EXT Input
8 NC Output 28 NC Input
9 NC Output 29 GND_SIG_P –
10 WHEEL SPEED (RL) Input 30 WHEEL SPEED (FL) Input
11 NC Output 31 GND (S_NET_GND) –
12 NC – 32 COMM_CAN_H_O Input/output
13 NC Input 33 NC Input/output
14 NC Output 34 NC –
15 NC Input 35 KEY SW C (ENGINE START) Input
18 NC Output 38 NC Input
19 NC Output 39 GND_SIG_P Input
20 WHEEL SPEED (RR) Input 40 WHEEL SPEED (FR) Input
CN3
Pin Input/output Pin Input/output
Signal name Signal name
1 PWR_IN_BATT Input 21 GND_PWR Input
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT Input 23 GND_ACT Input
4 NC Output 24 PWR_CTR_KEY Input
5 NC Output 25 NC Output
6 ABS CONTROL VALVE (FR) Output 26 ABS CONTROL VALVE (RR) Output
8 ABS CUT VALVE (F) Output 28 NC Output
11 PWR_IN_BATT Input 31 GND_PWR Input
12 PWR_IN_BRY Input 32 GND_PWR Input
13 GND_ACT Input 33 GND_PWR Input
14 PER_CTR_KEY Input 34 NC Output
16 ABS CONTROL VALVE (FL) Output 36 ABS CONTROL VALVE (RL) Output
18 ABS CUT VALVE (F) Output 38 NC Output
HD785-7 41
ABS control valve
1. Filter Function
2. Connector q The ABS control valve is installed between the
3. Solenid assembly brake valve and slack adjuster. It changes the
discharge oil pressure to control the braking
A: To slack adjuster force according to the electric output from the
P: From brake valve ABS controller.
42 HD785-7
ABS ON/OFF valve
2. Solenid q The ABS ON/OFF valve is installed between
the brake valve and slack adjuster.
A: To slack adjuster q If the ABS switch is turned ON, the solenoid
P: From brake valve valve is energized to make the ABS hydraulic
T: To brake system tank circuit effective.
q If the ABS switch is turned OFF, the solenoid
valve is de-energized and the ABS control
valve output is minimized to make the ABS
hydraulic circuit ineffective.
HD785-7 43
ASR control valve
1. Filter Function
2. Connector q The ASR control valve is installed between the
3. Solenid assembly accumulator and slack adjuster. It changes the
discharge oil pressure to control the braking
A: To slack adjuster force according to the ASR control electric out-
P: From accumulator put from the retarder controller.
44 HD785-7
ASR shut-off valve
2. Solenoid q The ASR shut-off valve is installed between
the accumulator and ASR control valve.
A: To ASR control valve q If the ASR switch is turned ON, the solenoid
P: From accumulator valve is energized to make the ASR hydraulic
T: To brake system tank circuit effective.
q If the ASR switch is turned OFF, the solenoid
valve is de-energized to make the ASR
hydraulic circuit ineffective.
HD785-7 45
Altitude setting function 1

System configuration
Outline
q This function is used to prevent breakage of q The setting changes as follows according to
the pump caused by cavitation which occurs the job site altitude.
when the machine is used at high altitude and q From lowland to altitude of 2,350 m (Stan-
the pump suction pressure lowers below the dard)
cavitation limit. q Above altitude of 2,350 m to 3,000 m
q If the machine is used at a high altitude, the q Above altitude of 3,000 m to 4,500 m.
internal pressure of the hydraulic tank lowers
and the oil level in the hydraulic tank also low- a For the setting method, see "Testing and adjust-
ers when the dump body is raised and conse- ing".
quently the suction pressure of the hydraulic
pumps (steering and hoist) lowers.
Accordingly, while the dump body is not seated
at an altitude of 2,350 m or higher, the engine
speed is lowered to lower the hydraulic pump
speed and prevent cavitation in the hydraulic
pumps.
46 HD785-7
High idle no-load engine speed at each altitude while body is not seated
Unit: rpm
Power mode Economy mode
Loaded Empty Loaded Empty
From lowland to altitude of 2,350 m (Standard) 2,250 ± 50 2,250 ± 50 2,250 ± 50 2,100 ± 50
Above altitude of 2,350 m to 3,000 m 2,220 ± 50 2,220 ± 50 2,220 ± 50 2,100 ± 50
Above altitude of 3,000 m to 4,500 m 1,825 ± 50 1,825 ± 50 1,825 ± 50 1,825 ± 50
q While the body is seated, this function does not control the engine speed and the engine speed is set to
the standard speed (the value of "From lowland to altitude of 2,350 m (Standard)" in the above table),
regardless of the altitude setting.
If the retarder controller CAN communication has an error, however, the engine speed is lowered to the
speed of the set altitude.
Principle of prevention of cavitation

q Occurrence of cavitation in a pump depends q At a low altitude, the pump is used in the lower
on the relationship between the pump speed area of the pump cavitation limit curve and
and pump suction pressure. cavitation does not occur. (Position q in the
Accordingly, when the job site is at a high alti- figure)
tude and reduction of the pump suction pres- If the pump is operated at a high altitude with-
sure is expected, the engine speed is reduced out changing its speed, however, its suction
to reduce the pump speed and prevent cavita- pressure lowers by the increase of the altitude
tion. and it is used in the higher area of the pump
cavitation limit curve and cavitation occurs.
Cavitation occurrence limit curve (Position Q in the figure)
Accordingly, the engine speed is controlled to
lower the pump speed below the cavitation
limit curve and prevent cavitation. (Position T
in the figure)
q : Pump speed and suction pressure at low

altitude
Q : Pump speed and suction pressure expected at
high altitude
T : Pump speed and suction pressure when pump
speed is changed by altitude setting
HD785-7 47
Control flow
<Machine monitor> <Retarder controller>
• Transmits the altitude data. • Transmits the body seating data.
From lowland to altitude of 2,350 m (Standard) Seated
Above altitude of 2,350 m to 3,000 m Not seated
Above altitude of 3,000 m to 4,500 m • Transmits the truck load data.
• Transmits the engine mode data. Empty
Power mode Loaded
Economy mode
O O
<Transmission controller>
Selects the engine speed upper limit according to the information from the machine monitor and retarder
controller.
<When body is not seated>
Depends on the altitude setting.
<When body is seated>

Selects "From lowland to altitude of 2,350 m (Standard)", regardless of the altitude setting.
<When retarder controller CAN communication has error>

Selects the value of the set altitude, regardless of the seating condition.
O
<Engine controller>
Outputs a command value to select the lower one of the high idle no-load engine speed determined by the
input to the engine controller and that determined by the signal from the transmission described above.
O
High idle no-load engine speed
<When body is not seated>
Unit: rpm
Power mode Economy mode
Loaded Empty Loaded Empty
From lowland to altitude of 2,350 m (Standard) 2,250 2,250 2,250 2,100
Above altitude of 2,350 m to 3,000 m 2,220 2,220 2,220 2,100
Above altitude of 3,000 m to 4,500 m 1,825 1,825 1,825 1,825
<When body is seated>

Selects "From lowland to altitude of 2,350 m (Standard)", regardless of the altitude setting.
<When retarder controller CAN communication has error>

Selects the value of the set altitude, regardless of the seating condition.
48 HD785-7
HD785-7 49
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
50 HD785-7
SEN01292-03
DUMP TRUCK
HD785-7

HD785-7 7001 and up

Sensors, switches ........................................................................................................................................... 2
HD785-7 1
Sensors, switches 1
Accelerator sensor
1. Pedal 3. Sensor
2. Connector
Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle Output characteristics
validation signal depending on the accelerator
pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer
inside the sensor is output in variable voltage
from No. 2 pin.
Idle validation signal

q The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator
pedal is released, it outputs the signal being
entered to No. 5 pin from No. 4 pin. And as the
accelerator pedal is pressed, it outputs the sig-
nal being entered to No. 6 pin from No. 4 pin.
2 HD785-7
Retarder oil temperature sensor

Steering oil temperature sensor
1. Thermistor Function
2. Plug q The retarder oil temperature sensor is installed
3. Wiring harness on the retarder pipe. It converts a temperature
4. Connector change into a change of thermistor resistance,
and transmits a signal to the retarder controller.
The retarder controller transmits the signal via
the network to the machine monitor panel, and
the machine monitor panel displays a tempera-
ture level. The temperature level displayed on
the monitor panel reaches a predetermined
position, the lamp flashes and the warning
buzzer sounds.
q The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor
portion detects the temperature, and when the
oil temperature goes above the specified level,
the warning lamps lights up and a message is
displayed on the character display of the mon-
itor panel.
HD785-7 3
Coolant level sensor
1. Float Function
2. Sensor q This sensor is installed to the top of the radia-
3. Connector tor, and when the coolant level goes below the
specified level, the float goes down and the
switch goes OFF. The maintenance caution
lamp lights up and the character display shows
message to warn of abnormality.
4 HD785-7
Fuel level secsor
2. Float q The fuel sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down
4. Body according to the fuel level. This movement of
5. Spring the float is transmitted by the arm and actuates
6. Contact a variable resistance. This sends a signal to
7. Spacer the monitor panel to indicate the remaining fuel
level. When the display of the monitor panel
reaches a certain level, a warning lamp
flashes.
HD785-7 5
Transmission oil filter clogging sensor
1. Body Function
2. Tube q This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A : Low pressure pickup port side and high-pressure side reaches the speci-
B : High pressure pickup port fied pressure, the switch goes OFF. The main-
tenance caution lamp lights up and the
character display shown message to warn of
abnormality.
Actuating pressure: 275 kPa {2.8 kg/cm2}
Principle of switch: Pressure difference sliding pis-

ton type
6 HD785-7
Air cleaner clogging sensor
1. Indicator Function
2. Spring q The air cleaner clogging sensor is installed to
3. Adapter the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
caution lamp lights up and character display
shows message to warn of the abnormality.
HD785-7 7
Body positioner sensor
Steering angle sensor (for ASR)
1. Bearing Function
2. Brush Assembly q The body position sensor is installed to the
3. Connector rear of the chassis. When the angle of the
dump body changes, the shaft rotates through
the link installed to the dump body, and the
dump body angle is detected.
q The steering angle sensor is installed to the
center lever and transmits voltage signals to
the controller according to the center lever
angle.
8 HD785-7
Accumulator oil pressure sensor
1. Sensor Function
2. Connector q The accumulator oil pressure sensor is
installed to the accumulator piping on the right
side of the machine and its sensor section
senses the oil pressure. If the oil pressure low-
ers below the set level, the warning lamp lights
up and the message is indicated on the char-
acter display of the monitor panel.
Steering oil pressure switch (For auto emergency steering system)
1. Piston Function
2. Body q The steering oil pressure switch is installed to
3. Switch the steering and hoist piping. While the engine
4. Connector is running, if the steering circuit oil pressure
lowers below the set level, the steering oil
pressure switch operates the electric pump to
secure the oil pressure for steering.
HD785-7 9
Tilt switch
1. Body Function
2. Connector q When the machine tilts to the left or right and
become into the roll-over danger range, If the
dump lever is operated to the RAISE position
in this condition, the lamp lights up and the
buzzer sounds to warn of the danger.
10 HD785-7
Steering angle sensor (For auto suspension system)
1. Body Principle of operation:

2. Tube Magnetic contactless proximity switch
3. Connector Form of output:
Turning ON when object of sensing approaches.
Function
q A round disc with teeth like a comb is installed
to the steering column. As this disc passes
through the slit in the sensor, the sensor out-
puts a pulse signal. The suspension controller
can obtain the steering speed from the number
of pulses per time.
HD785-7 11
Pressure sensor (For auto suspension system, for ARSC, for ABS)
Suspension oil pressure sensor
1. Sensor Function
2. Tube q The suspension oil pressure switch is installed
3. Connector to the suspension cylinder. If the pressure
supplied through the pressure inlet is applied
to the diaphragm of the pressure sensor sec-
tion, the diaphragm is deflected and deformed.
A bridge consisting of strain gauges is installed
on the opposite side of the diaphragm. If the
diaphragm is deflected, the resistance of the
strain gauges changes. A constant voltage is
applied to the strain gauges and the change of
the resistance of the strain gauges is sent as a
change of voltage to the amplifier. The ampli-
fier amplifies the change of the voltage and
outputs it to the controller.
q The pressure sensor for ABS is installed to the
output line of each ABS control valve. If the
pressure supplied through the pressure inlet is
applied to the diaphragm of the pressure sen-
sor section, the diaphragm is deflected and
deformed. A bridge consisting of strain
gauges is installed on the opposite side of the
diaphragm. If the diaphragm is deflected, the
resistance of the strain gauges changes. A
constant voltage is applied to the strain gauges
and the change of the resistance of the strain
gauges is sent as a change of voltage to the
amplifier. The amplifier amplifies the change
of the voltage and outputs it to the controller.
12 HD785-7
Pressure sensor (For payload meter)
1. Sensor
2. Tube
3. Connector
The pressure sensor is installed at the bottom end

of the suspension cylinder and acts to measure the
pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the

valve (2) installed to the suspension and remove
only pressure sensor (1).
When removing or installing pressure sensor (1),
be careful not to let valve (2) rotate.
When removing pressure sensor (1), the action of
valve core (3) prevents the suspension pressure
from going down.
The output characteristics of the sensor are as

shown in the diagram on the right.
Voltage between pin 1 (GND) and pin 3 (Output) of
each pressure sensor connector or output voltage
of each sensor (1, 2, 7, 8) when pin 9 of VHMS con-
troller connector (CN2B) is grounded.
HD785-7 13
Clinometer (For payload meter) Lamp drive relay (For payload meter )
To carry out compensation on slopes, the clinome- The external display lamps are driven by a signal
ter measures the tilt angle of the chassis in the from the payload meter.
front-to-rear direction.
The output characteristics of the clinometer are as

shown in the diagram.
Voltage between clinometer connector pin 1 (GND)
and pin 2 (output) or voltage of output (pin (3)) of
clinometer when pin (9) of VHMS controller con-
nector (CN2B pin) is grounded
14 HD785-7
Blow-by pressure sensor (For VHMS) Engine oil temperature sensor

(For VHMS)
Specifications
1. Voltage of power supply: DC5V Specifications
2. Output voltage : 0.5V(engine stopped) 1. Type of sensor : Thermistor
or more 2. Range of measurement : 40 – 130 °C
3. Size: Mount (portion a) : R 1/4 : 80 – 130 °C
: Outside diameter of (guaranteed precision
seat receiving pres- ± 2 °C)
sure: 37 mm 3. Max. power consumption: 0.5 mW
: Length of cable: 4. Pressure resistance : 4.9 MPa {50 kg/cm2}
1,110 mm 5. Temperature range : --30 to 140 °C
6. Performance table
Function
The blow-by sensor converts the pressure inside Tempera- Resis- Tempera- Resis- Tempera- Resis-
ture tance ture tance ture tance
the engine crankcase into a voltage and inputs this (°C) (kz) (°C) (kz) (°C) (kz)
into the VHMS controller as the blow-by pressure.
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
Function
The engine oil temperature sensor is installed to
the engine oil filter. It inputs the change in tempera-
ture to the VHMS controller as a change in the
resistance of the thermistor.
a: Heat sensing portion of sensor, outside diame-

ter of mount R 1/4
HD785-7 15
Exhaust temperature sensor Ambient temperature sensor

(For VHMS) (For VHMS)
Specifications Specifications
1. Rated voltage : DC24V 1. Electricity consumption : Max. 0.5 mW
2. Detection temperature range : 100 – 1,000 °C 2. Pressure resistance : 0.98 MPa
: 300 – 800 °C {10 kg/cm2}
(guaranteed accuracy ± 10 °C) 3. Detected temperature range (surrounding)
3. Output voltage characteristics: See table below : --30 to 120°C
4. Actuation temperature range : --40 to 110 °C 4. Retention temperature range : --30 to 140°C
5. Consumption current : Max. 30 mA 5. Performance table below
a: Heat sensing portion of sensor, outside diame-
ter of mount R 1/8 Detection
temperature --20 --10 0 10 20 50
b: Amp (°C)
c: Connector (power source end)
d: Connector (sensor end) Resistance 30.32 18.58 11.74 7.623 5.077 1.712
(kz)
Output voltage characteristics

(ambient temperature: 20 °C) ••• Reference value Function
The ambient temperature sensor inputs the ambi-
Detection ent temperature to the VHMS controller as a
temperature 50 100 400 700 800
(°C) change in the resistance of the thermistor.
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
a: Heat sensing portion of sensor, diameter of

mount 16 x 1.5
16 HD785-7
Wheel speed sensor (For ABS/ASR)
1. Spring spacer Function

2. Tube q This is non-condact sensor. A pulse voltage is
3. Connector generated by rotation of the teeth of the gear
installed to the outside of the pulse wheel, and
a signal is sent to the controller.
Relay (For ABS ON/OFF valve)
1. Body
2. Terminal
HD785-7 17
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
18 HD785-7
SEN01769-01
DUMP TRUCK
HD785-7

HD785-7 7001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 4
HD785-7 1
SEN01769-01 20 Standard value table
Standard value table for engine 1

Engine SAA12V140E-3
Classi- Standard value Permissible

Check item Measurement conditions Unit
fication for new machine value
Power mode
(High load/ 2,250/2,250 ± 50 2,250/2,250 ± 50
Low load) [*2]
Economy mode
(High load/ 2,250/2,100 ± 50 2,250/2,100 ± 50
Low load) [*2]
Reverse (RH)
(High load/ 2,050/2,050 ± 50 2,050/2,050 ± 50
High
Low load) [*2]
idle
Reverse (RL)
Power mode
2,250/2,250 ± 50 2,250/2,250 ± 50
• Coolant (High load/
temperature: Low load) [*2]
Engine speed rpm
Within operat- Reverse (RL)
ing range [*1] Economy mode
2,250/2,100 ± 50 2,250/2,100 ± 50
(High load/
Low load) [*2]
Low High side 945 ± 50 945 ± 50
idle Low side 650 ± 25 650 ± 25
Power mode
(High load/ 1,900/1,900 ± 50 1,900/1,900 ± 50
Rated Low load) [*2]
Engine
speed Economy mode

(High load/ 1,900/1,800 ± 50 1,900/1,800 ± 50
Low load) [*2]
• Engine coolant temperature: Within
operating range
Intake air pressure kPa Min. 165.40 Min. 165.40
(Boost pressure) • Power train oil temperature: Within oper- {mmHg} {Min. 1,250} {Min. 1,250}
ating range
• At rated speed
Exhaust temperature • Whole speed range (Ambient tempera- °C Max. 700 750
ture: 20 °C)
At sudden
acceleration Max. 4.5 5.5
• Engine coolant temper- (Low o High) Bosch
Exhaust gas color ature: Within operat- index
ing range At rated output Max. 1.0 2.0
At high idle Max. 1.0 2.0
Intake valve 0.35 ± 0.02 —
Valve clearance • Normal temperature mm
Exhaust valve 0.57 ± 0.02 —
Compression • Engine oil temperature: 40 – 60 °C MPa Min. 4.1 2.8
pressure • Engine speed: 210 – 250 rpm {kg/cm²} {Min. 42} {29}
Blow-by gas pres- • Engine coolant temperature: Min. 70 °C kPa Max. 2.94 5.88
sure • At rated output {mmH2O} {Max. 300} {600}
*1: If "TO 2350" is not selected in the high altitude setting selection of the optional setting, the high idle speed is
decreased while the body is not seated. (For details, see "Structure and function and maintenance standard".)
*2: High load: The load is recognized high when the rear suspension gas pressure is 10.8 MPa {110 kg/cm2} or
higher.
Low load: The load is recognized low when the rear suspension gas pressure is below 10.8 MPa {110 kg/cm2}.
2 HD785-7
Engine SAA12V140E-3
Classi- Standard value Permissible

fication for new machine value
• SAE0W30E0S, At torque
SAE5W40E0S, 0.29 – 0.44 0.2
converter
SAE10W30DH, {3.0 – 4.5} {2.0}
stalling MPa
Engine oil pressure SAE15W40DH,
{kg/cm²}
SAE30DH oil Min. 0.08 0.07
• Engine oil tempera- At low idle
{Min. 0.8} {0.7}
ture: Min 80 °C
Oil temperature • Whole speed range (Inside oil pan) °C 80 – 110 120
Engine
—
Fan belt tension • Between fan pulley and tension pulley mm (Automatic —
adjustment)
• Between alternator pulley - drive pulley
Alternator belt
• Deflection under finger pressure of 58.8 mm About 20 —
tension
N {6 kg}
• Between compressor pulley - drive pul-
Air conditioner com- ley
mm About 10 —
pressor belt tension • Deflection under finger pressure of 59 N
{6 kg}
HD785-7 3
Standard value table for machine 1

Standard value Permissible

for new machine value
10.9 ± 5 % 10.9 ± 5 %
F1
(9.8 ± 5 %) (9.8 ± 5 %)
15.2 ± 5 % 15.2 ± 5 %
F2
(13.9 ± 5 %) (13.9 ± 5 %)
• On flat, dry road surface 20.4 ± 5 % 20.4 ± 5 %
F3 • Engine coolant tempera- (18.7 ± 5 %) (18.7 ± 5 %)
ture: Within operating
27.2 ± 5 % 27.2 ± 5 %
F4 range
Travel speed
(25.1 ± 5 %) (25.1 ± 5 %)
• Transmission oil tempera-
Max. speed at each ture: 60 – 80 °C 36.2 ± 5 % 36.2 ± 5 %
F5 km/h
gear speed (33.8 ± 5 %) (33.8 ± 5 %)
• Mode: Power mode
(Econormy mode) 48.7 ± 10 % 48.7 ± 10 %
F6
(46.2 ± 10 %) (46.2 ± 10 %)
• Body: When unloaded
• Travel resistance 3.3 % 65.0 ± 10 % 65.0 ± 10 %
F7
(60.6 ± 10 %) (60.6 ± 10 %)
• Standard tire
9.7 ± 5 % 9.7 ± 5 %
RL
(8.8 ± 5 %) (8.8 ± 5 %)
11.7 ± 5 % 11.7 ± 5 %
RH
(11.7 ± 5 %) (11.7 ± 5 %)
2,050 ± 50 2,050 ± 50
F1 o F2
(1,950 ± 50) (1,950 ± 50)
Shift up
F2 o F3
F3 o F4 2,020 ± 50 2,020 ± 50
Accelerator full
F4 o F5 (1,900 ± 50) (1,900 ± 50)

F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4
1,350 ± 50 1,350 ± 50
Power mode (When machine is unloaded: *1)
F4 o F3
F3 o F2
F2 o F1
F1 o F2 2,000 ± 50 2,000 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Automatic shift control
• Engine coolant tempera-

Shift up
F3 o F4 ture: Within operating

Accelerator partial
Engine speed
F4 o F5 range 1,725 ± 50 1,725 ± 50

F5 o F6 • Transmission oil tempera-
F6 o F7 rpm
ture: 60 – 80 °C
F7 o F6 • Hydraulic oil temperature:
F6 o F5
Shift down
45 – 55 °C 1,200 ± 50 1,200 ± 50
F5 o F4 • ( ): At high acceleration
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
F1 o F2
Accelerator OFF (Coasting run)
F2 o F3
Shift up
F3 o F4
2,450 ± 50 2,450 ± 50
F4 o F5
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 50 1,200 ± 50
F5 o F4
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
*1: The dump truck is recognized unloaded when the rear suspension gas pressure is below 10.8 MPa {110 kg/
cm2}.
4 HD785-7

2,080 ± 50 2,080 ± 50
F1 o F2
(1,950 ± 50) (1,950 ± 50)
Shift up
F2 o F3
F3 o F4
Accelerator full
2,030 ± 50 2,030 ± 50
F4 o F5
(1,950 ± 50) (1,950 ± 50)
F5 o F6
F6 o F7
F7 o F6
Shift down
F6 o F5
F5 o F4 1,350 ± 50 1,350 ± 50
F4 o F3
F3 o F2
Power mode (When machine is loaded: *2)
F1 o F2 2,000 ± 50 2,000 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Shift up
F3 o F4 • Engine coolant tempera-

Accelerator partial

Engine speed
range 1,725 ± 50 1,725 ± 50

F5 o F6
rpm
ture: 60 – 80 °C
F7 o F6
Shift down
45 – 55 °C 1,200 ± 50 1,200 ± 50
F5 o F4
F3 o F2
1,250 ± 50 1,330 ± 50
F2 o F1
F1 o F2
F2 o F3
Shift up
F3 o F4
2,450 ± 50 2,450 ± 50
F4 o F5
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 50 1,200 ± 50
F5 o F4
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
*2: The dump truck is recognized loaded when the rear suspension gas pressure is 10.8 MPa {110 kg/cm2} or
higher.
HD785-7 5

1,950 ± 50 1,950 ± 50
F1 o F2
(1,800 ± 50) (1,800 ± 50)
Shift up
F2 o F3
F3 o F4
1,900 ± 50 1,900 ± 50
Accelerator full
F4 o F5
(1,750 ± 50) (1,750 ± 50)
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4 1,250 ± 50 1,250 ± 50
F3 o F2
F2 o F1
Power mode (When machine is unloaded: *3)
F4 o F3 1,280 ± 50 1,280 ± 50
F1 o F2 2,000 ± 50 2,000 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Shift up

Accelerator partial
Engine speed
F4 o F5 range 1,725 ± 50 1,725 ± 50

F6 o F7 rpm
ture: 60 – 80 °C
F6 o F5 45 – 55 °C
Shift down
1,200 ± 35 1,200 ± 35
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
F1 o F2
F2 o F3
Shift up
F3 o F4
2,450 ± 50 2,450 ± 50
F4 o F5
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,200 ± 50 1,200 ± 50
F5 o F4
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
*3: The dump truck is recognized unloaded when the rear suspension gas pressure is below 10.8 MPa {110 kg/
cm2}.
6 HD785-7

2,050 ± 50 2,050 ± 50
F1 o F2
(1,850 ± 50) (1,850 ± 50)
Shift up
F2 o F3
F3 o F4
2,000 ± 50 2,000 ± 50
Accelerator full
F4 o F5
(1,800 ± 50) (1,800 ± 50)
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
F5 o F4
1,300 ± 50 1,300 ± 50
F4 o F3
F3 o F2
Power mode (When machine is loaded: *4)
F2 o F1
F1 o F2 2,000 ± 50 2,000 ± 50
F2 o F3 1,800 ± 50 1,800 ± 50
Shift up
F3 o F4
Accelerator partial
F4 o F5
1,725 ± 50 1,725 ± 50
F5 o F6

Engine speed
F7 o F6 range
Shift down
rpm 1,200 ± 50 1,200 ± 50

F5 o F4 ture: 60 – 80 °C
F3 o F2 45 – 55 °C
• ( ): At high acceleration 1,250 ± 50 1,250 ± 50
F2 o F1
F1 o F2
F2 o F3
Shift up
F3 o F4
2,450 ± 50 2,450 ± 50
F4 o F5
F5 o F6
F6 o F7
F7 o F6
F6 o F5
Shift down
1,250 ± 50 1,250 ± 50
F5 o F4
F4 o F3
F3 o F2
1,250 ± 50 1,250 ± 50
F2 o F1
Braking mode
Shift up 2,450 ± 50 2,450 ± 50
Shift down 1,680 ± 50 1,680 ± 50
*4: The dump truck is recognized loaded when the rear suspension gas pressure is 10.8 MPa {110 kg/cm2} or
higher.
HD785-7 7

F1 – F7 • Engine coolant tempera- 1,250 – 1,475 1,250 – 1,475
Set ture: Within operating
Auto lock-up
RL, RH 1,475 1,475

range
F1, F2 • Transmission oil tempera- 1,100 1,100
Reset F3 – F7 ture: 60 – 80 °C — —
• Hydraulic oil temperature:
RL, RH 45 – 55 °C 1,100 1,100
Engine speed
prevention brake
F1 – F7, RL 2,600 ± 10 2,600 ± 10

Set rpm
Overrun
RH • Engine coolant tempera- 2,150 ± 10 2,150 ± 10

ture: Within operating
F1 – F7, RL range 2,350 ± 10 2,350 ± 10
Reset
RH • Transmission oil tempera- 2,000 ± 10 2,000 ± 10
ture: 60 – 80 °C
• Hydraulic oil temperature: Same as Same as
45 – 55 °C shift-down in shift-down in
Downshift inhibiter
"Automatic shift "Automatic shift
control" control"
8 HD785-7

Low load: *5 • Engine coolant tempera- 1,780 ± 100 1,780 ± 100
Power ture: Within operating
mode range
High load: *6 1,845 ± 100 1,845 ± 100
• Transmission oil tempera-
Low load: *5 ture: 85 – 110 °C 1,695 ± 100 1,695 ± 100
Economy
mode • Hydraulic oil temperature:
High load: *6 45 – 55 °C 1,730 ± 100 1,730 ± 100
• Engine coolant
temperature: A mode
Within operat- 1,800 ± 100 1,800 ± 100
[*7]
ing range
Engine speed
Torque • Torque
converter converter oil
rpm
stall temperature: B mode
speed 75 – 85 °C 1,735 ± 100 1,735 ± 100
[*7]
At inspection with • Transmission
engine mode fixing func- oil temperature:
tion set by machine 70 – 85 °C
monitor • Hydraulic oil C mode
1,685 ± 100 1,685 ± 100
temperature: [*7]
45 – 55 °C
a For details, see
Testing and
adjusting, "Spe- D mode
cial functions of 1,635 ± 100 1,635 ± 100
[*7]
machine moni-
tor (EMMS)".
Starting to 29.3 (+13.0/0) 29.3 (+13.0/0)
Operating depress N {3.0 (+1.4/0)} {3.0 (+1.4/0)}
Operating force and stroke
farce • Point at 150 {kg} 58.7 (0/-13.3) 58.7 (0/-13.3)

Full
Accelerator pedal mm from ful- {6.0 (0/-1.4)} {6.0 (0/-1.4)}
crum of pedal Starting to
Stroke depress mm 45 ± 5 45 ± 5
o Full
Operating N
Max. 29.4 {3.0} Max. 29.4 {3.0}
farce {kg}
Shift lever • At center of knob
Stroke mm 24.5 ± 1 24.5 ± 2
*5: Means that the dump truck is unloaded (Rear suspension gas pressure is below 10.8 MPa {110 kg/cm2}).
*6: Means that the dump truck is loaded (Rear suspension gas pressure is 10.8 MPa {110 kg/cm2} or higher).
*7: Detail of each mode (Setting is changed as follows, depending on selection of modes A – D)
Mode setting Condition (*8) Rated output High idle speed
Mode A Power mode High load (Loaded) 895 kW {1,200 HP} /1,900 rpm 2,250 rpm
Mode B Power mode Low load (Unloaded) 809 kW {1,080 HP} /1,900 rpm 2,250 rpm
Mode C Economy mode High load (Loaded) 750 kW {1,010 HP} /1,900 rpm 2,250 rpm
Mode D Economy mode Low load (Unloaded) 699 kW {937 HP} /1,900 rpm 2,100 rpm
*8: Remarks
q High load (When loaded): The load (dump truck) is judged high (loaded) when the rear suspension gas pres-
sure is confirmed to be 10.8 MPa {110 kg/cm2} or higher.
q Low load (When unloaded): The load (dump truck) is judged low (unloaded) when the rear suspension gas
pressure is confirmed to be below 10.8 MPa {110 kg/cm2}.
HD785-7 9

• Oil temperature: 80 °C
• Brake: OFF
(When oil bypasses brake Max. 0.85 Max. 0.85
Inlet oil pressure
and cooler through BCV) {Max. 8.67} {Max. 8.67}
• Engine speed: 1,900 rpm
(Rated speed)
• Brake: OFF
• (When oil bypasses brake 0.49 ± 0.04 0.49 ± 0.04
and cooler through BCV) {5.0 ± 0.41} {5.0 ± 0.41}
Torque converter
(Rated speed)
Oil pressure
Outlet oil pressure • Oil temperature: 80 °C MPa

• Brake: ON {kg/cm²}
• (When oil does not 0.52 ± 0.07 0.52 ± 0.07
bypass brake and cooler {5.3 ± 0.71} {5.3 ± 0.71}
through BCV)
(Rated speed)
1.52 ± 0.2 1.52 ± 0.2
Lock-up oil pressure • Engine speed: 1,900 rpm {15.5 ± 2.0} {15.5 ± 2.0}
(Rated speed)
N, F1 – F3, 3.53 ± 0.2 3.53 ± 0.2
oil pressure
Main relief
RL, RH • Oil temperature: 80 °C {36.0 ± 2.0} {36.0 ± 2.0}

(Rated speed) 2.16 ± 0.2 2.16 ± 0.2
F4 – F7
{22.0 ± 2.0} {22.0 ± 2.0}
Lo, Hi, 4th 1.61 ± 0.2 1.61 ± 0.2
Control valve set pressure
cluch {16.5 ± 2.0} {16.5 ± 2.0}

2.01 ± 0.2 2.01 ± 0.2
3rd cluch
• Oil temperature: 80 °C {20.5 ± 2.0} {20.5 ± 2.0}
• Engine speed: 1,900 rpm 3.29 ± 0.25 3.29 ± 0.25
2nd cluch (Rated speed) {33.5 ± 2.5} {33.5 ± 2.5}
Transmission
Oil pressure
MPa 3.43 ± 0.2 3.43 ± 0.2

1st, R cluch {kg/cm²} {35.0 ± 2.0} {35.0 ± 2.0}
• Oil temperature: 60 – 80
°C (T010)
Lubricating valve set • Oil temperature: 80 – 100 0.17 ± 0.05 0.17 ± 0.05
pressure °C (T030) {1.7 ± 0.5} {1.7 ± 0.5}
(Rated speed)
27.00-R49
Standard 0.69 0.69
Air pressure
(Front, rear
tire {7.0} {7.0}
wheel) MPa
Tire • Machine unloaded
If 31/90-R49 {kg/cm²}
0.69 0.69
equipped (Front, rear
{7.0} {7.0}
tire wheel)
10 HD785-7

Stop slope angle
• With 91 t payload
Braking capacity • Machine can be stopped % Min. 20 Min. 20
at standard value
Parking brake
• F2
Engine
speed
Starting test • Torque converter stall rpm Min. 1,790 Min. 1,610
• Machine can be stopped
at standard value
MPa
Releasing pressure (See "Brake") (See "Brake")
—
{kg/cm²}
• On flat dry road surface
Front • When unloaded 247 ± 10 247 ± 20
• Dimension see Fig. 1 in
Dimension
Suspension cylinder
Installed "A"
mm
length • On flat dry road surface
Rear • When unloaded 199 ± 10 199 ± 20
• Dimension see Fig. 1 in
"B"
3.56 ± 0.36 3.56 ± 0.36
Front
Pressure
• On flat dry road surface MPa {36.4 ± 3.6} {36.4 ± 3.6}

Pressure
• When unloaded {kg/cm²} 2.77 ± 0.28 2.77 ± 0.28
Rear
{28.2 ± 2.8} {28.2 ± 2.8}
Stationary steering effort • On flat dry road surface
Operating
(If stationary steering

N 14.7 – 29.4 Max. 35.3
effort
is impossible, measure • Steering wheel speed: 30

rpm {kg} {1.5 – 3.0} {Max. 3.6}
steering effort at low
speed) • Engine low idle
• Engine: Stopped
Dimension
Steering wheel
• Dimension on periphery
Play of grip mm Max. 150 Max. 150
• Until front wheel starts
moving
Time Number of
Num-
rotation
Rotation range • Lock o Lock ber of 3.4 3.4 ± 0.34

rotation
• Lock o Lock
Turning time sec. Max. 4 Max. 5
• Engine speed: All range
HD785-7 11

At rated
20.2 – 21.1 20.2 – 21.1
speed
Oil pressure
{206 – 215} {206 – 215}

(1,900 rpm)
Steering
Relief oil • Oil temperature: MPa

valve
pressure At low idle 50 – 80 °C {kg/cm²}

(650 rpm) 18.1 – 19.1 18.1 – 19.1
[Reference {185 – 195} {185 – 195}
value]
Operating Angle Operating Dimension Operating
N 234 ± 29.4 234 ± 29.4

force
Operating force
{kg} {23.8 ± 3.0} {23.8 ± 3.0}
Brake pedal
• Measuring point: Point at

150 mm from fulcrum of
pedal
Stroke mm 40 ± 5 40 ± 10
control lever
N 5.9 – 9.8 3.0 – 14.7

force
Operating force
Retarder
• Measuring point: Point at {kg} {0.6 – 1.0} {0.3 – 1.5}

10 mm from lever end
°
Stroke (Operating range) 0 – 78 (0/-2) 0 – 78 (0/-4)
(degree)
brake pedal
Emergency
• Measuring point: Point at

N 294 ± 29.4 294 ± 29.4
force
Operating force 150 mm from fulcrum of {kg} {30 ± 3.0} {30 ± 3.0}
pedal
For front •
Oil pressure Gas pressure
Accumulator
6.2 ± 0.20 6.2 ± 0.20

Nitrogen rear service • Gas temperature
MPa {63 ± 2.0} {63 ± 2.0}
gas brake (atmosphere tempera- {kg/cm²}
pressure For parking ture): 20 ± 5 °C 6.2 ± 0.20 6.2 ± 0.20
brake {63 ± 2.0} {63 ± 2.0}
11.8 (+0.98/0) 11.8 (+0.98/0)
charge valve
Accumulator
Cut-in pressure
• Oil temperature: {120 (+10/0)} {120 (+10/0)}
MPa
45 – 55 °C
{kg/cm²} 20.6 (+0.98/0) 20.6 (+0.98/0)
Cut-out pressure • High idle
{210 (+10/0)} {210 (+10/0)}
12 HD785-7

• Dry flat road
When
• At max. Max. 16.5 17.5
unloaded
brake opera-
tion pressure
Front:
9.8 MPa {100
Distance
Stopping distance with

kg/cm²}
service brake m
Rear:
[Reference value] With 91 t
9.8 MPa
Max. 20.4 24
{100 kg/cm²} payload
• From check
of sign to stop
• Initial speed:
32 km/h
Front • Rear
9.8 ± 0.69 9.8 ± 0.69
(Service
{100 ± 7} {100 ± 7}
Operating brake) MPa
Oil pressure
pressure • At full stroke {kg/cm²} 6.4 6.4

Front • Rear
(+0.69/-0.59) (+0.69/-0.59)
(Retarder)
{65 (+7/-6)} {65 (+7/-6)}
9.85 9.85
Parking brake releasing MPa
• Stop engine (+0.98/-0.49) (+0.98/-0.49)
pressure {kg/cm²}
{100.4 (+10/-5)} {100.4 (+10/-5)}
Brake
• Dry flat road

Stopping distance
Distance
• From start of braking to

when secondary
stop m Max. 60.9 Max. 60.9
brake is applied
[Reference value] • Initial speed: 25 km/h
• With 91 ton payload
Front • Rear
9.8 ± 0.69 9.8 ± 0.69
Oil pressure
(Service
• Charge accumulator and {100 ± 7} {100 ± 7}
Brake oil brake) MPa
oprate brake first time
pressure {kg/cm²} 6.4 6.4
Front • Rear • At full strake
(+0.69/-0.59) (+0.69/-0.59)
(Retarder)
{65 (+7/-6)} {65 (+7/-6)}
Servise brake • When unloaded 1,760 1,570

• Concrete road
Retarder • At max. brake operation
At brake 1,340 1,200
Engine
brake
speed
starting pressure rpm

test • Gear speed: F2
Parking brake 1,790 1,610
• Machine must not move
Emergency off at torque converter
stall 1,790 1,610
brake
Must be in normal range of wear
inspection
Front • Check with disc wear gauge.

Visual
Wear limit gauge (mounted on —

machine) Must be in normal range of wear
Rear
gauge.
HD785-7 13

Max. 29.4 Max. 35.3
Hold o Raise
{Max. 3.0} {Max. 3.6}
Must return smoothly when engine
Raise o Hold
speed is high idle.
Operating force
Operating force
• Engine: Stopped
Max. 29.4 Max. 35.3
Hold o Float • Measuring point: Center
N {Max. 3.0} {Max. 3.6}
of grip
{kg} Max. 29.4 Max. 35.3
Dump lever
Float o Hold
{Max. 3.0} {Max. 3.6}
Float o Max. 29.4 Max. 35.3
Lower {Max. 3.0} {Max. 3.6}
Lower o • Measuring point: Center Must return smoothly when engine
Float of grip speed is 1,900 rpm (rated speed).
Dimention
Raise o Hold • Engine: Stopped 44.8 ± 1.9 44.8 ± 1.9

Stroke
• Measuring point: Center mm

Hold o
of grip 44.8 ± 1.9 44.8 ± 1.9
Lower
At rated
20.2 – 21.1 20.2 – 21.1
speed
{206 – 215} {206 – 215}
(1,900 rpm)
Hoist Relief
valve pressure At low idle
(650 rpm) 18.1 – 19.1 18.1 – 19.1
Oil pressure
[Reference {185 – 195} {185 – 195}

value] • Oil temperature: MPa
50 – 80 °C {kg/cm²}
At high idle 3.4 ± 0.49 3.4 ± 0.49
Relief (2,250 rpm) {35 ± 5} {35 ± 5}
Dump
pressure At low idle
EPC
(root pres- (650 rpm) 2.6 ± 0.49 2.6 ± 0.49
valve
sure) [Reference {27 ± 5} {27 ± 5}
value]
• Oil temperature: 50 – 80
°C
Lifting speed 13 ± 1.5 13 ± 1.5
(Rated speed)
Time
sec.
• Oil temperature:
50 – 80 °C
Lowering speed 14 ± 1.5 14 ± 1.5
• Engine speed: 650 rpm
Body
• Dump lever: "Float"
• Oil temperature:
50 – 80 °C
Dimension
Hydraulic drift • From 20 mm of extension mm Max. 85 Max. 170

of 2nd cylinder
• Measuring time:
5 minutes
Fig. 1: Installed length (A) of front suspension cylin-

der rod and installed length (B) of rear suspension
cylinder rod
14 HD785-7
HD785-7 15
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
16 HD785-7
SEN01770-03
DUMP TRUCK
HD785-7

HD785-7 7001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting tools list ........................................................................................................................ 3
Sketch of special tool ...................................................................................................................................... 8
Testing engine speed ...................................................................................................................................... 9
Testing air supply pressure (boost pressure) ................................................................................................ 10
Testing exhaust temperature......................................................................................................................... 12
Testing exhaust gas color ............................................................................................................................. 14
Adjustment of valve clearance ...................................................................................................................... 16
Testing compression pressure ...................................................................................................................... 18
Testing blow-by pressure .............................................................................................................................. 20
Testing engine oil pressure ........................................................................................................................... 21
Handling of fuel system devices ................................................................................................................... 22
Releasing residual pressure from fuel system .............................................................................................. 22
Testing fuel pressure..................................................................................................................................... 23
Reduced cylinder mode operation ................................................................................................................ 24
No-injection cranking .................................................................................................................................... 24
Testing leakage-from pressure limiter and return rate from injector.............................................................. 25
HD785-7 1
SEN01770-03 30 Testing and adjusting
Bleeding air from fuel circuit (Standard spec.) .............................................................................................. 28

Bleeding air from fuel circuit (Extra low-grade fuel spec.)............................................................................. 30
Testing the fuel circuit for leakage................................................................................................................. 32
Replacement and adjustment of fan belt....................................................................................................... 33
Testing and adjusting alternator belt tension................................................................................................. 34
Testing and adjusting air conditioner compressor belt .................................................................................. 35
2 HD785-7
Testing and adjusting tools list 1
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Testing air boost pres- 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
A
sure 799-401-2220 Hose 1
799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
Testing exhaust
B 6215-11-8171 Sensor 1 Wire length: 490 mm
temperature
799-201-1110 Wiring harness 1
1 799-201-9001 Handy smoke checker 1
Testing exhaust color C Bosch index: Level 0 – 9
2 795-502-1350 Smoke meter 1
Commercially Intake: 0.35 mm
Adjusting valve clearance D Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
E 795-471-1310 Adapter 1
pressure 2 For 140E-3, 5
6261-71-6150 Gasket 1
1 799-201-1590 Gauge 1 0 – 10 kPa {0 – 1,000 mmH2O}
2 799-201-1450 Adapter 2
Testing blow-by pressure F
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
Oil pressure gauge KIT Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
Testing engine oil 1
G Oil pressure gauge KIT
pressure 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm²}
(Digital)
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Oil pressure gauge KIT
790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm²}
(Digital)
Testing fuel pressure H 2 795-471-1450 Adapter 1 8 x 1.25 (male) – PT1/8 (female)
799-101-5220 Nipple (10 x 1.25 mm) 1
3 Size: 10 x 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 ø 14
2 6141-71-1710 Joint 1 ø 10
Commercially
3 Hose 1 Inside diameter: Approx. 11 mm
available
Testing leakage through Commercially
4 Hose 1 Inside diameter: Approx. 17 mm
pressure limiter and J available
return rate from injector Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
7 07376-70315 Plug 1 Size: 03
HD785-7 3
Sym-
Q'ty
bol
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Testing power train oil Oil pressure gauge KIT
pressure (Digital)
799-101-5220 Nipple 1
2 M10 × 1.25
07002-11023 O-ring 1
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
Testing brake oil pres- 1
sure 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm²}
(Digital)
3 566-35-43561 Nipple 1 18 × 1.5 (Female: PT 1/8)
K Oil pressure gauge KIT Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 1
Testing steering, hoist oil (Analog) {25, 60, 400, 600 kg/cm²}
1
pressure circuit Oil pressure gauge KIT
(Digital)
799-101-5002 1
(Analog) {25, 60, 400, 600 kg/cm²}
1
Testing dump EPC oil (Digital)
pressure circuit 4 799-101-5230 Nipple 1 14 × 1.5
1 Face seal type (# 02)

799-401-3100 Adapter
5 (Female: PT 1/8)
02896-11008 O-ring 1
– 792-610-1000 Suspension tool assembly 1
– 792-610-1100 •Pump Ass'y 1
1 792-610-1130 ••Pump 1
2 792-610-1110 ••Hose 1
• L1 to L3 are inner parts of 792-610-
3 792-610-2200 ••Joint 1 1100.
– 792-610-1200 •Charging tool assembly 1 • L4 to L10 are inner parts of 792-610-
Suspension cylinder of 1200.
L 4 07020-21732 ••Fitting 1
adjustment • 792-610-1100 and 792-610-1200 are
5 792-610-1140 ••Joint 1 inner parts of 792-610-1000.
6 792-610-1250 ••Valve Ass'y 1 • 792-610-1000 includes tool box 792-
610-1290.
7 792-610-1260 ••Nipple 1
8 792-610-1270 ••Hose 2
9 792-610-1280 ••Valve 2
10 792-610-1400 ••Regulator 1
At raise of emergency
M 792T-691-1110 Plug 1 Refer to the skech
dump body
1 799-608-3211 Discket
Initial set up of VHMS
2 799-608-3220 Harness
controller and, at repair N
set up Commercially Lap top type personal com- OS: Windows 98/2000/Me/XP
3
available puter Terminal "RS232C" is with it
4 HD785-7
Sym-
Q'ty
bol
1 792-610-1701 Gas charge tool 1
– 07000-11009 •O-ring 1
792-610-1310 Nipple (For Russia) GOST
792-610-1320 Nipple (For USA) CGA No. 351
Gas pressure check and
P 792-610-1330 Nipple (For USA) ASA B-571-1965
filling of the accumulator
2 1 DIN 477-1963
792-610-1350 Nipple (For Germany) NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS341 Part 1-1962
799-601-4101
or T-adapter Ass'y 1
799-601-4201
799-601-4130 •T-adapter 1 For Ne sensor
799-601-4330 •Socket 1 For G (Bkup) sensor
799-601-4240 •Socket 1 For Atmospheric sensor
799-601-4250 •Socket 1 For boost pressure sensor
799-601-9420 •T-adapter 1 For common rail pressure sensor
799-601-4150 •T-adapter 1 For oil pressure sensor
799-601-9430 •Socket 1 For supply pump PCV
799-601-9020 •T-adapter 1 For injector
799-601-4260 •T-adapter 1 For controller (4-pole)
For controller (50-pole)
799-601-4211 •T-adapter 1
Engine related controller, (799-601-4101 only)
sensor and actuator diag- For controller (60-pole)
nosis 799-601-4220 •T-adapter 1
(799-601-4101 only)
For 60-pole
799-601-4350 •T-adapter 1
(799-601-4101 only)
For boost temperature sensor
Q 795-799-5540 •Socket 1
For intake-air temperature sensor
For water temperature sensor
795-799-5530 •Socket 1 For fuel temperature sensor
For oil temperature sensor
799-601-9000
or
799-601-9100 T-adapter Ass'y
or
799-601-9300
799-601-9320 •T-adapter 1 For 24-pole
799-601-9310 •Plate 1
799-601-2500
or
799-601-2700
or
799-601-2800
Chassis related control-
ler, sensor and harness
799-601-7100
or
799-601-7400
or
799-601-8000
HD785-7 5
Sym-
Q'ty
bol
For Econo (799-601-2700 is not
799-601-2600 •T-box 1
include)
799-601-2740 •For MIC adapter 1 For MIC-5P
799-601-4101 T-adapter Ass'y 1
799-601-4211 •For DRC adapter 1 For DRC50
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 •For X adapter 1 For X2P
For SW8P (799-601-8000 is not
799-601-7060 •For SWP adapter 1
include)
For M1P (799-601-7000 and 799-601-
799-601-7080 •For M adapter 1
7100 are not include)
799-601-7090 •For M adapter 1 For M2P
799-601-7180 •For AMP040 adapter 1 For A8P (799-601-7400 only)
For A12P (799-601-7000 and 799-
799-601-7190 •For AMP040 adapter 1
Chassis related control- 601-7100 are not include)
Q
ler, sensor and harness 799-601-7330 •For S adapter 1 For S16PW
799-601-7320 For AMP040 adapter 1 For SW16P (799-601-8000 only)
799-601-7360 For relay adapter 1 For REL-5P
799-601-7370 For relay adapter 1 For REL-6P
799-601-7520 •For 070 adapter 1 For 07-12P
799-601-7540 •For 070 adapter 1 For 07-18P
799-601-7550 •For 070 adapter 1 For 07-20P
799-601-9000
799-601-9200
For DT2P (Include 799-601-4101 and
799-601-9020 •For DT adapter 1
799-601-4201)
799-601-9030 •For DT adapter 1 For DT3P
For DT4P (Include 799-601-4101 and
799-601-9040 •For DT adapter 1
799-601-4201)
799-601-9050 •For DT adapter 1 For DT6P
799-601-9060 •For DT adapter (Gray) 1 For DT8PGR
799-601-9070 •For DT adapter (Black) 1 For DT8PB
799-601-9080 •For DT adapter (Green) 1 For DT8PG
799-601-9110 •For DT adapter (Gray) 1 For DT12PGR
799-601-9120 •For DT adapter (Black) 1 For DT12PB
799-601-9130 •For DT adapter (Green) 1 For DT12PG
799-601-9140 •For DT adapter (Brown) 1 For DT12P
6 HD785-7
Sym-
Q'ty
bol
Chassis related control-
Q 799-601-9350 •For DRC adapter 1 For DRC-40
ler, sensor and harness
799-601-9360 •For DRC adapter 1 For DRC-24
Testing coolant tempera-
– 799-101-1502 Digital temperature gauge 1 -99. 9 – 1,299 °C
ture and oil temperature
Testing operation force – 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
and pedal force – 79A-264-0091 Push-pull scale 1 0 – 500 N {0 – 50 kg}
Testing stroke and Commercially
– Scale 1
hydraulic drift available
Testing work equipment Commercially
– Stopwatch 1
speed available
Testing voltage and Commercially
– Circuit tester 1
resistance available
HD785-7 7
Sketch of special tool 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these draw-
ings.
M Plug
8 HD785-7
Testing engine speed 1

k Stop the machine on flat ground, turn the
parking brake switch PARKING, and block
the tires.
a Test the engine speed under the following con-
dition.
q Engine coolant temperature:
Within operating range
q Torque converter oil temperature:
q Hydraulic oil temperature: 45 – 55 °C
a If "TO 2350" is not selected in the high alti-
tude setting selection of the optional set-
ting, the high idle speed is decreased
while the body is not seated. Accordingly,
perform the test with the body seated.
1. Preparation work
Turn the starting switch ON and set the
machine monitor (EMMS) in the "Monitoring
function of service mode" to prepare for testing
of the engine speed.
q Monitoring system: ENGINE
q Monitoring code: 01002 (ENG SPEED)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
2. Testing low idle speed

1) Set the shift lever "N" and dump lever in
HOLD.
2) Start the engine and measure the engine
speed without pressing the accelerator
pedal.
3. Testing high idle speed

1) Set the shift lever "N" and dump lever in
HOLD.
2) Start the engine and set the accelerator
pedal in the high idle position and mea-
sure the engine speed.
4. Testing torque converter stall speed

See "Testing of torque converter stall speed"
(in "Testing and adjusting (Part 2)".
HD785-7 9
Testing air supply pressure (Method with testing instruments)

(boost pressure) 1 1. Open the engine hood.
a Testing instrument 2. Remove air boost pressure pickup plug ((L1)

Symbol Part No. Part name on left bank or (R1) on right bank) from the bot-
tom of the air intake connector.
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Stop the machine on the level ground, turn

the parking brake switch PARKING, and set
chocks to the tires.
k Be careful not to touch any hot parts when
removing or installing the testing tools.
a Test the air supply pressure (boost pressure)
under the following conditions.
q Coolant temperature:
q Torque converter oil temperature:
3. Install nipple [1] of boost gauge kit A and con-
(Testing with monitor panel) nect it to gauge [2].
a Example of (L1) on the left bank
1. Change the machine monitor to "Service
mode" and display the following 2 items simul-
taneously with the "Monitoring function".
q Monitoring system: 2 ITEMS
q Monitoring code: 36500 (CHG PRESS-A)
4. Run the engine at a mid-range speed or above

to bleed the oil from the hose.
a Insert the connection of the hose and
pressure gauge about half way, repeat the
action to open the self-seal portion at the
hose end, and bleed the oil.
a If Pm kit is available, the air bleed coupling
a For the method of testing, see "Method
(790-261-1130) inside the kit can be used.
with testing instruments".
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
10 HD785-7
5. Run the engine at high idle to stall the torque

converter, and test the air supply pressure
(boost pressure).
a For details of the procedure for stalling the
torque converter, see "Testing torque con-
verter stall speed".
6. After completing the testing, rermove the test-

ing equipment and set to the original condition.
HD785-7 11
Testing exhaust temperature 1

a Testing instrument
Symbol Part No. Part name
799-101-1502 Digital temperature gauge
B 6215-11-8171 Sensor
799-201-1110 Wiring harness

k Wait for the temperature of the exhaust
manifold to go down before removing or
installing the testing equipment. a For engines mounted with the exhaust
a Test the exhaust temperature under the follow- temperature sensor, connect temperature
ing conditions. gauge [2] to the sensor on machine.
Within operating range 4. Run the engine and test the exhaust tempera-
q Torque converter oil temperature: ture in the whole speed range.
(Method with testing instruments)

1. Open the engine hood.
2. Remove an exhaust temperature pickup plug
(1) of the subject section for measuring from
the top of the exhaust manifold.
a Subject section for measuring includes
front left, rear left, front right and rear right
(4 points in total).
5. Method of periodic testing for preventive main-

tenance service.
a To prevent the torque converter from over-
heating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the
exhaust temperature, then stall only the
torque converter and test the temperature.
1) Turn the power mode switch to the HIGH
POWER position.
2) Start the engine and raise the temperature
of the coolant to the operating range.
3. Install sensor [1] of digital thermometer B and 3) Depress the parking brake pedal, turn the
connect it to thermometer [2]. parking brake switch OFF, then set the
a Installation example to the rear right-hand gearshift lever to the D position.
side (RR)
k If the gearshift lever is operated to
any position other than the D posi-
tion, the machine may move off
ev e n i f t h e b r ak e i s b ei ng d e -
pressed, so always test at the D
position.
12 HD785-7
4) Depress the accelerator pedal gradually, (Method using monitoring)

run the engine at high idle and stall the 1. Switch the machine monitor display to "Service
torque converter. At the same time, oper- mode" and use the "Monitoring function" to dis-
ate the dump lever to the LOWER position play the following two items at the same time.
and relieve the oil pressure (full stall). q Monitoring system: 2 ITEMS
a If "TO 2350" is not selected in the q Monitoring code: 01002 (ENG SPEED)
high altitude setting selection of the q Monitoring code:
optional setting, the high idle speed is 42600 (EXHAUST TEMP FL)
decreased while the body is not 42601 (EXHAUST TEMP RR)
seated. Accordingly, perform the test 42602 (EXHAUST TEMP FR)
with the body seated. 42606 (EXHAUST TEMP RL)
a Continue the above operation until a For the operating method, see "Special
the exhaust temperature is stabilized. functions of machine monitor (EMMS)".
k If the torque converter is stalled
while the gearshift indicator is indi-
cating "F1", the inside of the trans-
mission may be broken.
Accordingly, when stalling the
torque converter, seat the body
securely and check that the body
pilot lamp is turned OFF, and then
set the gearshift lever in the D
position and check that the gear-
shift indicator is indicating "F2".
5) When the temperature stabilizes at near
the target temperature, return the dump
lever to FLOAT and test the temperature
with only the torque converter stalled. a For other testing methods, see "Methods
a The exhaust temperature will start to with testing tools".
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
go down but rises, make the set tem-
perature at full stall higher.
a After completing the testing, lower the
engine speed to low idle, then return
the gearshift lever to the N position.
6. When testing the maximum value for the ex-

haust temperature during troubleshooting, do
as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
a Use the PEAK mode of the digital temper-
ature gauge. (Set the temperature gauge
to the PEAK mode. The maximum tem-
perature automatically recorded.)
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q Corrected value [°C] = Tested value
+ 2 × (20 – ambient temperature)
7. After completing the testing, remove the test-

ing equipment and set to the original condition.
HD785-7 13
Testing exhaust gas color 1 2. Testing with smoke meter C2

1) Raise the body and fix it with the lock pin
a Testing instrument securely.
Symbol Part No. Part name 2) Insert probe [1] of smoke meter C2 in the
1 799-201-9001 Handy smoke checker outlet of exhaust pipe (1) and fix it to the
C exhaust pipe with a clip.
2 795-502-1350 Smoke meter

k When installing and removing the testing
instrument, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
1. Testing with handy smoke checker C1

1) Raise the body and fix it with the lock pin
securely. 3) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
2) Attach a sheet of filter paper to handy
meter C2.
smoke checker C1.
a Restrict the supplied air pressure
3) Insert the exhaust gas intake pipe in below 1.5 MPa {15 kg/cm²}.
exhaust pipe (1).
4) Connect the power cable to a receptacle
4) Start the engine and raise the temperature of power source.
of the engine to the operating range. a Before connecting the cable, check
5) As increasing the engine speed rapidly or that the power switch of the smoke
running it at high idle, operate the handle meter is turned off.
of handy smoke checker C1 so that the fil- 5) Loosen the cap nut of the suction pump
ter paper absorbs the exhaust gas. and fit the filter paper.
a If "TO 2350" is not selected in the a Fit the filter paper securely so that the
high altitude setting selection of the exhaust gas does not leak.
optional setting, the high idle speed is
6) Turn on the power switch of smoke meter
decreased while the body is not
C2.
seated. Accordingly, perform the test
while accelerating the engine quickly.
6) Remove the filter paper and compare it with

the attached scale to make a judgment.
7) When the testing is completed, remove
the instruments and set to the original
condition.
14 HD785-7
7) Start the engine and raise the coolant

temperature of the engine to the operating
range.
8) As increasing the engine speed rapidly or
running it at high idle, press the accelera-
tor pedal of smoke meter C2 and collect
the exhaust gas with the filter paper.
9) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
10) When the testing is completed, remove
the instruments and set to the original
condition.
HD785-7 15
Adjustment of valve clearance 1

Commercially
D Thickness gauge
available

1. Remove cylinder head cover.
2. Rotate the crankshaft forward and match

stamped line of R1.6 TOP on vibration damper 3. Loosen locknut (6) of RH No. 1 cylinder adjust
(1) to pointer (2), by setting RH No. 1 cylinder screw (5). Insert a clearance gauge D of speci-
to the compression top dead center while fied clearance between the crosshead (4) and
watching the movement of the intake valve of rocker arm (3) and adjust the adjustment
RH No. 6 cylinder. screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Intake valve: 0.35 mm
Exhaust valve: 0.57 mm
a Crank the engine using the barring tool (B)

mounted to the front right-hand side of the
flywheel housing.
4. Tighten locknut (6) to secure adjustment

screw.
3 Locknut tightening torque:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
a At near the compression top dead center

of the RH No. 1 cylinder, the intake valve
of RH No. 6 cylinder moves.(opens).
16 HD785-7
5. Hereafter crank the engine similar way in the

firing order. Match the stamped line of the
damper to the pointer and adjust the valve
clearance of each cylinder.
a Firing order
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6
–R2 – L2 – R4 – L4
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
HD785-7 17
Testing compression pressure 1

a Testing instruments
1 795-502-1590 Compression gauge
E 795-471-1310 Adapter
2
6261-71-6150 Gasket

k When measuring the compression pres-
sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part. 4. Install adapter E2 to the mounting hole on the
a Measure the compression pressure after the injector and compression gauge E1.
engine is warmed up. a Fit the gasket to the adapter E2 end with-
(Engine oil temperature: 40 – 60?). out fail
a Fix the adapter with the injector holder.
1. Remove cylinder head cover (1) of the cylinder 3 Holder mounting bolt:
to be tested for compression pressure. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance“.
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance“.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s s
(Loosen the 2 terminal nuts alternately)
from the injector.
a Pass injector under the fuel path projected
sideways and pull up the injector through
wire (Do not pry the injector top up).
18 HD785-7
6. Set the engine in the reduced cylinder mode

(cylinder cut-out).
k If the engine is not set in the reduced
cylinder mode (cylinder cut-out), it will
start and will be dangerous. Accord-
ingly, be sure to set the engine in this
mode.
a For the setting method, see "Special func-
tions of machine monitor (EMMS).
a Install the injector wiring harness accord-

ing to the following procedure
1) Install the injector wiring harness to the
cylinder head and fix the connector side
with the plate.Install O-ring (16).
2) Install cap (17) with clip on the injector
side of wiring harness.
Press wiring harness (18) between the
injector top and cap to the injector main
body without slack.
7. Rotate the engine with the starting motor and 3) Tighten nut (19) on the injector side.
measure the compression pressure. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Read the pressure gauge pointer when it
is stabilized.
a Check the engine speed with the monitor.
8. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) tempo-
rarily.
2 Spherical part of washer: Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently. 4) Tighten the clamp and spacer with the
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
bolt.
5) Tighten sleeve nut (15) permanently. 5) Install rocker arm assembly.
3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm}
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details,
see “Adjusting valve clearance“.
6) Install head cover.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
HD785-7 19
Testing blow-by pressure 1 3. Run the engine at the rated output and test the
blow-by pressure.
a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
1 799-201-1590 Gauge described in the shop manual for the
machine.
2 799-201-1450 Adapter
F
3 799-201-1511 Nozzle
4 799-201-1571 Tube

a The test point is subject to machine models.
a Measure blow-by pressure after the engine is
warmed up.
(Engine coolant temperature: Min. 70?)
a Breather is provided to each RH and LH
banks. Test the breather on either one of the
banks.
1. Install adaptor F2 and nozzle F3 to the tip of and return the removed parts.
each breather hose on the RH and LH.
(Method using monitoring)
2. Connect tube F4 and gauge F1 to either one of 1. Switch the machine monitor display to "Service
the nozzles.Close the tube connecting mate of mode 1" and use the "Monitoring function" to
other nozzle with a piece of short cut tube, etc. display the following two items at the same
time.
q Monitoring code: 42801 (BLOWBY PRESS)
a For details of the method of testing, see

"Method using testing equipment".
20 HD785-7
Testing engine oil pressure 1 2. Install nipples [1] and [2] of hydraulic tester G1
and connect them to hydraulic tester G2.
a Testing instruments a Since the screw size of the sensor mount
Symbol Part No. Part name is 14 x P1.5, nipple (799-101-5230) may
be used.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

a Test the engine oil pressure under the follow-
ing conditions.
q Engine oil temperature: Min. 80 °C
1. Remove oil temperature sensor (1) on the LH

side of the cylinder block.
Keep the removed oil temperature sensor and 3. Run the engine at the rated output and low idle
the wiring harness connector connected.to and test the oil pressure.
each other. a When testing with the engine mounted on
a Don't remove the oil pressure sensor right the machine, test on the condition
side from the block because the engine described in the shop manual for the
controller detects abnormal low pressure machine.
error of the oil pressure sensor.

HD785-7 21
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low pressure cir-
The common rail fuel injection system (CRI) cuit and high pressure circuit of the fuel system
consists of more precise parts than the con- while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause Feed pump – Fuel filter – Fuel supply
trouble. When testing and maintaining the fuel pump
system, take care more than the past. If dust, High pressure circuit:
etc, sticks to any part, wash that part thor- Fuel supply pump – Common rail –
oughly with clean fuel. Fuel injector
a Precaution for replacing fuel filter cartridge. a The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level
tridge. Since the common rail fuel injection automatically 30 seconds after the engine is
system (CRI) consists of more precise parts stopped.
than the conventional fuel injection pump and a Before the fuel circuit is tested and its parts are
nozzle, it employs a high-efficiency special fil- removed, the residual pressure in the fuel cir-
ter to prevent foreign matter from entering it. If cuit must be released completely. Accordingly
a filter other than the genuine one is used, the observe the following.
fuel system may have trouble. Accordingly, k When testing the fuel line or removing or
never use such a filter. installing equipment of fuel system, wait for
at least 30 seconds after the engine is
stopped to release the remaining pressure
in the fuel circuit before starting operation.
(There is still pressure remaining in the cir-
cuit, so do not start operations immediately
after the engine is stopped.)
22 HD785-7
Testing fuel pressure 1 2. Install adapter H2 and connect to gauge H4.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 795-471-1450 Adapter
H
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply 3. Run the engine at high idle and measure the
pump. fuel pressure.
k Stop the machine on the level ground, turn a If "TO 2350" is not selected in the high alti-
the parking brake switch PARKING, and set tude setting selection of the optional set-
chocks to the tires. ting, the high idle speed is decreased
k Since the pressure in the high-pressure cir- while the body is not seated. Accordingly,
cuit from the supply pump through the perform the test with the body seated.
common rail to the injector is very high, it a If the fuel pressure is in the following
cannot be measured. range, it is normal.
Engine speed Fuel pressure
1. Remove air bleeder plug (1) on the top of fuel
filter. 0.15 – 0.3 MPa
High idle
{1.5 – 3 kg/cm2}
4. Since the fuel circuits on the LH and RH banks

after the priming pump are independent, test
each circuit.

HD785-7 23
Reduced cylinder mode operation1 No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the en-
run the engine with the fuel injectors of 1 or gine with the starting motor while all the injec-
more cylinders disabled electrically to reduce tions are stopped electrically. The purpose
the number of effective cylinders. The purpos- and effect of this operation are as follows.
es and effects of this operation are as follows. q Before the engine is started after it or the ma-
chine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
a For the setting method, see "Special functions
2. When a cylinder is selected for the reduced of machine monitor (EMMS)".
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring or cylinder lin-
er
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a For the setting method, see "Special func-
tions of machine monitor (EMMS)".
24 HD785-7
Testing leakage-from pressure 1. Preparation work

limiter and return rate from 1) Remove tube (3) between common rail (1)
and fuel block (2). (Standard spec.)
injector 1
1 6151-51-8490 Spacer
2 6141-71-1710 Joint
Commercially Inside diameter of the
3
available hose: Approx. 11 mm
Commercially Inside diameter of the
4
J available hose: Approx. 17 mm
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available 2) Insert spacer J1 on fuel block (2) side and
7 07376-70315 Plug tighten the removed joint bolt again. (Stan-
dard spec.)
a If the engine is of a type that returns the fuel

spilling from the injector from the return block
installed to the front of intake manifold, check
the engine according to the following.
a The above figure and procedure are for the left
bank.
a Prepare an oil pan of about 20 l to receive the
fuel flowing out during the test.
a For the extra low-grade fuel specifica-

tion, remove tube (3) between com-
mon rail (1) and fuel block (2) and
install spacer J1 to the arrowed part.
(For the procedure, see the standard
specification.)
a Connect the return pipe to the fuel

tank again, too.
a Be sure to provide a gasket to both
ends of the spacer.
HD785-7 25
3) Insert joint J2 on common rail (3) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect test hose J3 to the end of joint
J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injec-
tor.
1) Disconnect return hose (2) of return block
(1) and connect test hose J4.
a Apply plug J7 to the return hose side
to stop oil, and fix it to the fuel tank.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
2. Testing leakage from pressure limiter
from coming off.
1) Lay test hose J3 so that it will not slacken
2) Lay test hose J4 so that it will not slacken
and put its end in the oil pan.
and put its end in the oil pan.
2) Referring to "Measurement of engine
speed", prepare for measurement of the
engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage 3) Referring to "Measurement of engine
(rpm) (cc/min) speed", prepare for measurement of the
1,600 Max. 10 engine speed.
4) Run the engine at the rated output.
a If "TO 2350" is not selected in the
high altitude setting selection of the
optional setting, the high idle speed is
decreased while the body is not
seated. Accordingly, perform the test
with the body seated.
26 HD785-7
5) After the engine speed is stabilized, test

the return rate in 1 minute with measuring
cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Engine speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
6) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
5. Check the RH bank following the identical pro-

cedure.
HD785-7 27
Bleeding air from fuel circuit

(Standard spec.) 1
a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
a Work similarly on the right and left side (The
figure shows the left side).
1. Remove cover (1).
3. Install fuel pre-filter (2) to the pre-filter head.

a Apply engine oil thinly over the packing on
the fuel pre-filter side.
a After the packing of the fuel pre-filter
touches the sealing face of the filter head,
tighten the fuel filter 1/2 – 3/4 turns.
2. Remove fuel pre-filter (2) and fill it with fuel.
4. Loosen air bleed plugs (5) of the fuel main filter

and operate priming pump (3).
a Fill the fuel filter with clean fuel and take

care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter (2), and
then add fuel through part (b) (holes
around the central hole).
a After filling the fuel pre-filter (2) with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the filter but fill it with the fuel by
operating priming pump (3).
a Don't fill fuel directly after removing main a Operate the priming pump until the fuel
filter (4). flows out of the hole of plug (5). When
bubbles stop coming out, tighten plug.
3 Air bleeding plug:
2.0 – 3.9 Nm {0.2 – 0.4 kgm}
28 HD785-7
5. Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
a Operate the priming pump until the fuel

flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
6. Work on the opposite side similarly according

to steps 1 – 5.
7. Crank the engine with the starting motor to

start engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 4.
HD785-7 29
Bleeding air from fuel circuit a The electric priming pump has a timer in it
to start and stop itself automatically (See
(Extra low-grade fuel spec.) 1 the following figure).
a The electric priming pump stops while the
a Bleed air from the fuel circuit in the following
lamp is blinking. This phenomenon is not
cases according to this procedure.
abnormal, however.
q When the fuel filter is replaced
a If the switch is turned to the "OFF" position
q When fuel is used up
while the lamp is blinking, the lamp goes
q When the engine is started for the first
off and the electric priming pump stops.
k
time after the fuel piping or supply pump is
While the electric priming pump is op-
replaced
eration, pressure is applied to the fuel
a If the fuel filter was replaced, do not fill the
circuit. Do not loosen the air bleeding
main filter and prefilter with the fuel.
plug at this time, since the fuel may
spout out.
1. Turn the starting switch to the "OFF" position.
2. Check that the fuel valve on the fuel tank side

is open.
3. Turn lever (1) of the air bleeding piping to the

horizontal position to open the circuit valve.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or

4. Turn "ON" switch (3) of electric priming pump supply pump was replaced and there is not fuel
(2) installed in the left front fender. in the fuel circuit, turn switch (3) "ON" after the
a The electric priming pump operates and electric priming pump stops automatically.
lamp (4) blinks.
7. When lamp (4) goes off, the air bleeding work
is completed.
8. Turn lever (1) of the air bleeding piping to the

vertical position to close the circuit valve.
30 HD785-7
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously for more than 20 seconds.
q After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q Stop the engine and check that the air
bleeding valve is closed.
10. If the engine does not start, try to start it again
according to the following procedure.
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
ing valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continu-
ously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.
HD785-7 31
Testing the fuel circuit for leakage1 9. Check the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the a Check the high-pressure circuit parts con-
high-pressure circuit of the fuel system. If centrating on the areas coated with the
fuel leaks while the engine is running, it is color checker, for fuel leakage.
dangerous since it can catch fire. a If any fuel leakage is detected, repair it
a After testing the fuel system or removing and and test again from step 1.
installing its components, check for fuel leak- a If any fuel leakage is not detected, inspec-
age according to the following procedure. tion is completed.
1. Spray color checker (developer) over the sup-
ply pump, common rail, injector, and joints of
the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Check the fuel piping and the devices for fuel

leakage.
a Check the high-pressure circuit parts con-
centrating on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and test again from step 1.
4. Run the engine at low idle.

leakage.
centrating on the areas coated with the
6. Run the engine at high idle.


leakage.
centration on the areas coated with the
8. While keeping the engine speed at high idle,

apply a load to the engine by stalling the
torque converter.
32 HD785-7
Replacement and adjustment of

fan belt 1
a The fan belt tension usually does not need to
be adjusted, since the auto-tensioner is
installed.
a The procedures for replacing the belt and
adjusting the auto-tensioner after replacing the
belt are described here.
1. Loosen locknut (1).
2. Remove adjustment bolt (2) from yoke (3) with-

out removing locknut (1). 5. Install adjustment bolt (2) to yoke (3) in the
a Keep adjustment bolt (2) installed to reverse order to removal.
bracket (4) so that it will not be lost.
6. After the clearance between slot end face (a)
3. Insert a bar about 50 cm long in tension brack- of yoke (3) and side of pin (7) is eliminated,
et hole (6) (ø 24) and pull it strongly to move tighten adjustment bolt (2) 1.5 more turns and
tension pulley (5) inward and hold it. then tighten locknut (1).
a Take care that the bar will not come off.
4. Replace the fan belts.

a Replace all the belts as a set.
k Do not put your hands or fingers be-
tween the pulley and belts. If the bar
comes off, your hands or fingers will
be caught between the pulleys and
belts.
HD785-7 33
Testing and adjusting alternator

belt tension 1
Testing
Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and
measure deflection (a) of the belt.
a Pressing force: Approx. 59 N {Approx. 6 kg}
a Deflection (a): approx. 20 mm (1 piece)
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Loosen nut (B) and bolt (2) alternately.
2. Adjust belt tension using nut (A).
3. Tighten bolt (2) to have adjust bolt (1) and

plate (3) made orthogonal to each other.
4. Tighten nut (B) to fix plate (3).

a After adjusting, test the belt tension again.
34 HD785-7
Testing and adjusting air Adjusting

conditioner compressor belt 1 1. Loosen bolt (1), and then loosen adjustment
nuts (3).
Testing
Press the intermediate point of the belt between air 2. Turn adjustment nuts (3) to set the tension of
conditioner compressor pulley and drive pulley with belt (2) to the standard value.
a finger and measure deflection (a) of the belt.
a Pressing force: Approx. 59 N {Approx. 6 kg} 3. Tighten adjustment nuts (3) and bolt (1).
3 Bolt (1): 98 – 123 Nm {10 – 12.5 kgm}
a Deflection (a): Approx. 10 mm
a After adjusting, check the belt tension
again.
HD785-7 35
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
36 HD785-7
SEN01771-05
HD785-7
SEN01771-03
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Testing torque converter stall speed ............................................................................................................... 3

Testing power train oil pressure ...................................................................................................................... 5
Adjusting transmission speed sensor ........................................................................................................... 13
Testing and adjusting brake oil pressure....................................................................................................... 14
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas . 17
Testing brake performance ........................................................................................................................... 22
Bleeding air from brake circuit ...................................................................................................................... 24
Bleeding air from ASR circuit (if equipped) ................................................................................................... 26
Testing wear of front brake disc .................................................................................................................... 27
Testing wear of rear brake disc ..................................................................................................................... 28
Method of releasing parking brake in an emergency .................................................................................... 29
Testing and adjusting front suspension cylinder ........................................................................................... 30
Testing and adjusting rear suspension cylinder ............................................................................................ 34
Testing and adjusting front suspension cylinder (Automatic suspension specification) ................................ 38
Testing and adjusting hydraulic pressure in steering, hoist circuit ................................................................ 39
Testing and adjusting oil pressure in dump EPC circuit ................................................................................ 42
Air bleeding from steering cylinder................................................................................................................ 43
Procedure for raising dump body in emergency ........................................................................................... 44
Adjusting body positioner sensor .................................................................................................................. 45
Handling of high voltage circuit of engine controller ..................................................................................... 47
HD785-7 1
Adjusting transmission controller .................................................................................................................. 47

Method for emergency escape at electrical system failure ........................................................................... 48
2 HD785-7
Testing torque converter stall 4. Turn the parking brake switch ON, depress the
speed brake pedal, then set the gear shift lever to the D
position.
k Stop the machine on the level ground, turn k If the gearshift lever is operated to any posi-
the parking brake switch PARKING, and set tion other than the D position, the machine
chocks to the tires. may move off even if the brake is being de-
pressed, so always inspect at the D position.
1. Turn the starting switch ON and set the monitor k If the torque converter is stalled while the
panel in the real-time monitoring function gearshift indicator is indicating "F1", the
(REAL-TIME MONITOR) of the service mode. inside of the transmission may be broken.
q Monitoring functions: 2 ITEMS Accordingly, when stalling the torque
q Monitoring code 1: 32500 (T/M OIL TEMP) converter, seat the body securely and
q Monitoring code 2: 30100 (T/C OIL TEMP) check that the body pilot lamp is turned
a For the operation method, see "Special func- OFF, and then set the gearshift lever in
tions of machine monitor". the D position and check that the gear-
shift indicator is indicating "F2".
5. Depress the accelerator pedal gradually, run the

engine at high idle and stall the torque converter
to raise the torque converter oil temperature.
tude setting selection of the optional setting,
the high idle speed is decreased while the
body is not seated. Accordingly, perform the
test with the body seated.
k There is danger of damage to the internal
parts of the transmission, so never oper-
ate the gear shift lever to any position oth-
er than the D position during the stall
2. Start the engine and raise the temperature of the operation.
torque converter oil, transmission oil, hydraulic
oil, and coolant. 6. When the torque converter oil temperature goes
q Torque converter oil temperature: above 90 °C, run the engine immediately at low
75 – 85 °C idle and return the gear shift lever to the N posi-
q Transmission oil temperature: 70 – 85 °C tion.
k Never operate the gear shift lever with the ac-
celerator pedal depressed. Otherwise it may
create a large shock and may also become the
Within operation range cause of shortening the machine's service life.
3. Change the machine monitor to display of the 7. Run the engine at a medium speed, and when
engine mode fixing function (FIX POWER the torque converter oil temperature goes down
MODE) in the service mode. to approx. 80 °C, run at low idle.
a For the operation method, see "Special func- a Keep the gear shift lever at the "N" position.
tions of machine monitor (EMMS)".
8. Repeat Steps 4 – 7 and equalize the oil temper-
ature in the torque converter and transmission.
HD785-7 3
9. At the same time as repeating Steps 4 and 7,

inspect the stall speed when the torque
converter oil temperature is 85 – 100 °C.
a The torque converter oil temperature must
not exceed 110 °C.
a Inspect the stall speed 2 or 3 times.
a The stall speed may vary according to the fol-
lowing conditions, so always inspect the stall
speed at the time of delivery.
1] Variations according to the engine serial
number
2] Variations due to atmospheric pressure
and temperature
3] Variations due to the torque consumed by
accessories
4] Variations due to characteristics of the
torque converter
5] Variations due to the method of inspec-
tion
4 HD785-7
Testing power train oil pressure
a Testing instrument a Table of oil pressure testing port positions and

Symbol Part No. Part name gauges to use
799-101-5002 Analog hydraulic meter Use a gauge
1 No. Testing location
790-261-1204 Digital hydraulic meter (MPa {kg/cm2})
K
799-101-5220 Nipple 1 Main relief pressure 6 {60}
2
07002-11023 O-ring 2 Flow selector valve inlet pressure 6 {60}
Torque converter inlet port pres-
3 2.5 {25}
sure
Torque converter outlet port pres-
4 2.5 {25}
sure
Torque converter lock-up clutch
5 6 {60}
pressure
6 Transmission Lo clutch pressure 6 {60}
7 Transmission Hi clutch pressure 6 {60}
8 Transmission 1st clutch pressure 6 {60}
9 Transmission 2nd clutch pressure 6 {60}
10 Transmission 3rd clutch pressure 6 {60}
11 Transmission 4th clutch pressure 6 {60}
12 Transmission R clutch pressure 6 {60}
a The transmission lubrication pressure is repre-
sented by the torque converter outlet port pres-
sure, so there is no need to test it.
HD785-7 5
k Stop the machine on a flat place, turn the a If "TO 2350" is not selected in the high al-
parking brake switch to the "PARK" position titude setting selection of the optional set-
and lock the tires with chocks. ting, the high idle speed is decreased
k When the body is raised, fix it with the lock while the body is not seated. Accordingly,
pin securely. measure with the body seated after in-
k When the body is raised, fix it with the lock stalling the hydraulic tester.
pin securely. 5) After finishing testing, remove the testing
k When removing and installing a plug or a instruments and return the removed parts.
testing instrument, stop the engine and wait
until the oil temperature lowers thoroughly. 2. Testing of flow selector valve inlet pressure
k When testing the oil pressure during travel, 1) Raise the body and fix it with the lock pin.
secure a wide travel area and take extreme 2) Heighten the transmission oil temperature
care of the safety around the machine. a Oil leak tester for testing: 60 – 80 °C
3) Remove plug (2), install nipple K2 and
Items related to whole power train
connect oil pressure gauge [1] (6 MPa {60
1. Testing of main relief pressure
kg/cm²}) of hydraulic tester K1 by hose [2].
1) Raise the body and fix it with the lock pin.
2) Heighten the transmission oil temperature.
a Oil leak tester for testing: 60 – 80 °C
4) Start the engine, set the gearshift lever in the

"N" position and test the oil pressure at rated
speed (1,900 rpm), low idle and high idle.
a If "TO 2350" is not selected in the high al-
titude setting selection of the optional set-
4) Start the engine, set the gearshift lever in the while the body is not seated. Accordingly,
"N" position and test the oil pressure at rated measure with the body seated after in-
speed (1,900 rpm), low idle and high idle stalling the hydraulic tester.
5) After finishing testing, remove the testing
instruments and return the removed parts.
6 HD785-7
Items related to torque converter 4. Testing of torque converter outlet pressure

3. Testing of torque converter inlet pressure 1) Raise the body and fix it with the lock pin.
1) Raise the body and fix it with the lock pin. 2) Referring to "Testing of main relief pressure",
2) Referring to "Testing of main relief pressure", check that there is no abnormality.
check that there is no abnormality. 3) Remove plug (4), install nipple K2 and
3) Remove plug (3), install nipple K2 and connect oil pressure gauge [1] (2.5 MPa {25
connect oil pressure gauge [1] (2.5 MPa {25 kg/cm²}) of hydraulic tester K1 by hose [2].
4) Start the engine and test the oil pressure at

4) Start the engine and test the oil pressure at rated speed (1,900 rpm) and high idle.
rated speed (1,900 rpm) and high idle. a If "TO 2350" is not selected in the high al-
a If "TO 2350" is not selected in the high altitude setting selection of the optional set-
titude setting selection of the optional setting, the high idle speed is decreased
ting, the high idle speed is decreased while the body is not seated. Accordingly,
while the body is not seated. Accordingly, measure with the body seated after in-
measure with the body seated after installing the hydraulic tester.
stalling the hydraulic tester. 5) After finishing testing, remove the testing
5) After finishing testing, remove the testing instruments and return the removed parts.
HD785-7 7
5. Testing of torque converter lockup clutch pressure Transmission related

1) Raise the body and fix it with the lock pin. a Table of gearshift lever positions, speed ranges,
2) Remove plug (5), install nipple K2 and and clutches actuated
connect oil pressure gauge [1] (6 MPa {60 Gearshift lever Speed Clutches
kg/cm²}) of hydraulic tester K1 by hose [2]. R N D 5 6 6 4 3 L engine Lo Hi 1st 2nd 3rd 4th R
QQQQQQ F1 w q
QQQQQQ F2 q q
QQQQQ F3 q w
QQQQ F4 w q
QQQ F5 w w
QQ F6 w q
Q F7 w w
Q N
Q RH w q
Q RL w w
a The Q mark indicates the speed ranges that are
actuated for each position of the gearshift lever.
a The w mark and q mark indicate the clutches
that are actuated for each travel speed.
a The q mark indicates the speed range when
testing the oil pressure for each clutch.
3) Lower the body to the normal position.

4) Start the engine and raise the temperature of
the torque converter oil to the operating
range.
5) Turn the parking brake switch to the "OFF"
position. While pressing the brake pedal, set
the gearshift lever in the "L" position.
6) Release the brake, drive the machine at
rated speed (1,900 rpm) and high idle and
test the oil pressure when the lockup pilot
lamp lights up.
measure with the body seated after in-
stalling the hydraulic tester.
k Since the F1 speed reaches about 10.9
km/h, take extreme care of the safety
around the machine.
7) After finishing testing, remove the testing
8 HD785-7
6. Testing of transmission low clutch pressure 7. Testing transmission Hi clutch

1) Raise the body and fix it with the lock pin. 1) Raise the body and fix it with the lock pin.
2) Remove plug (6), install nipple K2 and 2) Remove plug (7), install nipple K2 and
connect oil pressure gauge [1] (6 MPa {60 connect oil pressure gauge [1] (6 MPa {60
kg/cm²}) of hydraulic tester K1 by hose [2]. kg/cm²}) of hydraulic tester K1 by hose [2].
3) Lower the dump body and set to the original 3) Lower the dump body and set to the original
condition. condition.
4) Lower the dump body and set to the original 4) Start the engine and raise the temperature of
condition. the torque converter oil to the operating
5) Turn the parking brake switch TRAVEL, range.
depress the parking brake pedal, then set the 5) Turn the parking brake switch OFF, depress
gearshift lever to position "L". the parking brake pedal, then set the gear-
6) Release the brake and measure the oil pres- shift lever to position "3".
sure when traveling at rated speed (1,900 6) Release the brake, travel at rated speed
rpm) and high idle. (1,900 rpm) and high idle, and test the oil
a If "TO 2350" is not selected in the high al- pressure when the shift indicator shows "F3".
titude setting selection of the optional set- a If "TO 2350" is not selected in the high al-
ting, the high idle speed is decreased titude setting selection of the optional set-
while the body is not seated. Accordingly, ting, the high idle speed is decreased
measure with the body seated after in- while the body is not seated. Accordingly,
stalling the hydraulic tester. measure with the body seated after in-
k In F2, a maximum travel speed of ap- stalling the hydraulic tester.
prox. 15.2 km/h is reached, so check k In F3, a maximum travel speed of ap-
carefully that the surrounding area is prox. 20.4 km/h is reached, so check
safe. carefully that the surrounding area is
7) After completing the testing, remove the safe.
testing equipment and set to the original 7) After completing the measurement, remove
condition. the testing equipment and set to the original
condition.
HD785-7 9
8. Testing transmission 1st clutch 9. Testing transmission 2nd clutch and pilot pressure
1) Raise the body and fix it with the lock pin. 1) Raise the body and fix it with the lock pin.
2) Remove plug (8), install nipple K2 and 2) Remove plug (9), install nipple K2 and
connect oil pressure gauge [1] (6 MPa {60 connect oil pressure gauge [1] (6 MPa {60
kg/cm²}) of hydraulic tester K1 by hose [2]. kg/cm²}) of hydraulic tester K1 by hose [2]
3) Lower the dump body and set to the original 3) Lower the dump body and set to the original
4) Start the engine and raise the temperature of 4) Start the engine and raise the temperature of
the torque converter oil to the operating the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF depress
the parking brake pedal, then set the gear- the parking brake pedal, then set the gear-
shift lever to position "L". shift lever to position 2.
6) Release the brake and test the oil pressure 6) Release the brake, travel at rated speed
when traveling at rated speed (1,900 rpm) (1,900 rpm) and high idle, and test the oil
and high idle. pressure when the shift indicator shows "F2".
a If "TO 2350" is not selected in the high al- a If "TO 2350" is not selected in the high al-
titude setting selection of the optional set- titude setting selection of the optional set-
ting, the high idle speed is decreased ting, the high idle speed is decreased
while the body is not seated. Accordingly, while the body is not seated. Accordingly,
measure with the body seated after in- measure with the body seated after in-
stalling the hydraulic tester. stalling the hydraulic tester.
k In F1, a maximum travel speed of ap- k In F2, a maximum travel speed of ap-
prox. 10.9 km/h is reached, so check prox. 15.2 km/h is reached, so check
carefully that the surrounding area is carefully that the surrounding area is
safe. safe.
7) After completing the testing, remove the 7) After completing the testing, remove the
testing equipment and set to the original testing equipment and set to the original
10 HD785-7
10. Testing transmission 3rd clutch and pilot pres- 11. Testing transmission 4th clutch
sure 1) Raise the body and fix it with the lock pin.
1) Raise the body and fix it with the lock pin. 2) Remove plug (11), install nipple K2 and
2) Remove plug (10), install nipple K2 and connect oil pressure gauge [1] (6 MPa {60
connect oil pressure gauge [1] (6 MPa {60 kg/cm²}) of hydraulic tester K1 by hose [2].
kg/cm²}) of hydraulic tester K1 by hose [2]
3) Lower the dump body and set to the original

3) Lower the dump body and set to the original condition.
condition. 4) Start the engine and raise the temperature of
4) Start the engine and raise the temperature of the torque converter oil to the operating
the torque converter oil to the operating range.
range. 5) Turn the parking brake switch OFF, depress
5) Turn the parking brake switch OFF, depress the parking brake pedal, then set the gear-
the parking brake pedal, then set the gearshift lever to position "6".
shift lever to position "4". 6) Release the brake, travel at rated speed
6) Release the brake, travel at rated speed (1,900 rpm) and high idle, and test the oil
(1,900 rpm) and high idle, and test the oil pressure when the shift indicator shows "F6".
pressure when the shift indicator shows "F4". a If "TO 2350" is not selected in the high al-
a If "TO 2350" is not selected in the high altitude setting selection of the optional set-
titude setting selection of the optional setting, the high idle speed is decreased
ting, the high idle speed is decreased while the body is not seated. Accordingly,
while the body is not seated. Accordingly, measure with the body seated after in-
measure with the body seated after installing the hydraulic tester.
stalling the hydraulic tester. k In F6, a maximum travel speed of ap-
k In F4, a maximum travel speed of approx. 48.7 km/h is reached, so check
prox. 27.2 km/h is reached, so check carefully that the surrounding area is
carefully that the surrounding area is safe.
safe. 7) After completing the testing, remove the
7) After completing the testing, remove the testing equipment and set to the original
testing equipment and set to the original condition.
condition.
HD785-7 11
12. Testing transmission R clutch

1) Raise the body and fix it with the lock pin.
3) Lower the dump body and set to the original

condition.
4) Start the engine and raise the temperature of
the torque converter oil to the operating
range.
5) Turn the parking brake switch OFF, depress
the parking brake pedal, then set the gear-
shift lever to position "R".
6) Release the brake and test the oil pressure
when traveling at rated speed (1,900 rpm)
and high idle.
measure with the body seated after in-
stalling the hydraulic tester.
k In R, a maximum travel speed of ap-
prox. 9.7 km/h is reached, so check
carefully that the surrounding area is
safe.
7) After completing the testing, remove the
testing equipment and set to the original
condition.
12 HD785-7
Adjusting transmission speed sensor
a Adjust the 3 speed sensors installed to the trans- 3. Secure sensor (1) with lock nut (3).
mission according to the following procedure. 3 Lock nut: 49.0 – 68.6 Nm {5 – 7 kgm}
a Adjust all of the 3 speed sensors similarly.
(N1): Input shaft speed sensor
(N2): Intermediate shaft speed sensor
(N3): Output shaft speed sensor
1. Screw in sensor (1) until its tip lightly touches

tooth end face of gear (2).
a Check that the sensor tip is free from iron
dust and flaws before installing.
2 Threaded part: Gasket sealant (LG-5)
2. Return sensor (1) by 1/2 – 1 turn.

a At this time, clearance (a) between the sen-
sor tip and tooth tip or tooth end face of the
gear is 0.75 – 1.0 mm. 4. After finishing adjustment, check with the moni-
toring function of the machine monitor that each
transmission shaft speed is displayed normally.
a For details of the method of operation, see
"Special functions of machine monitor
(EMMS)".
HD785-7 13
Testing and adjusting brake oil 4) Test the cut-out pressure at high idle.
pressure a If "TO 2350" is not selected in the high al-
a Testing instrument ting, the high idle speed is decreased
Symbol Part No. Part name while the body is not seated. Accordingly,
799-101-5002 Analog hydraulic meter perform the test with the body seated.
K1
790-261-1204 Digital hydraulic meter
q Read the ACC oil pressure (front or rear)
K3 566-35-43561 Nipple
when it stops rising at the highest point af-
ter the cut-in pressure.
the parking brake switch PARKING, and set (Testing with diagnosing devices)
chocks to the tires. 1) Remove cover.
2) Stop the engine and remove plug (1) (18, P:
1. Testing ACC (accumulator) charge oil pressure 1.5). Connect nippleK3 and hose [1] and
(Method using monitoring) install oil pressure gauge K1 (Oil pressure
1) Set the machine monitor in service mode and gauge: 40 MPa {400 kg/cm²}).
display the following 2 items simultaneously
with the monitoring function.
q Monitoring code: 35500(ACC OIL PRESS
F)
q Monitoring code: 35501(ACC OIL PRESS
R)
2) Start the engine.

3) Test the cut-in pressure at high idle.
ting, the high idle speed is decreased a For the method of testing, see "Method using
while the body is not seated. Accordingly, monitoring, 2) – 4)". (Read the pointer of the
perform the test with the body seated. oil pressure gauge, however.)
1] Press and release the brake pedal
repeatedly to lower the oil pressure in the 2. Testing rear brake operating pressure
accumulator.. 1) Remove air bleeder (1) and install oil pres-
2] Read the lower one of the ACC oil pressure gauge K1 [40 MPa {400 kg/cm²}].
sures (front or rear) when it starts rising a The figure shows the left side.
after it reaches the bottom. 2) Operate the brake pedal and retarder control
lever and measure the oil pressure.
a After finishing testing, bleed air, referring
to "Bleeding air from brake circuit" to see
page 22.
14 HD785-7
3. Testing parking brake on rear brake side releasing 5. Testing front brake operating pressure
pressure 1) Remove air bleeder (3) and install Oil pres-
1) Remove air bleeder (2) and install Oil pressure gauge (C1) [40 MPa {400 kg/cm²}].
sure gauge K1 [40 MPa {400 kg/cm²}]. a The figure shows the left side.
a The figure shows the left side. 2) Operate the brake pedal and retarder control
2) Turn OFF the parking brake switch (Release lever and measure the oil pressure.
the parking brake) and measure the oil pres- a After finishing esting, bleed air, referring
sure. to "Bleeding air from brake circuit".
to "Bleeding air from brake circuit".
4. Testing parking brake on front brake side

releasing pressure
1) Remove air bleeder (4) and install Oil pres-
sure gauge K1 [40 MPa {400 kg/cm²}].
a The figure shows the left side.
2) Turn OFF the parking brake switch (Release
the parking brake) and measure the oil pres-
sure.
to "Bleeding air from brake circuit".
HD785-7 15
Adjusting 4. While holding adjustment screw (2), tighten

Adjusting charge valve cut-in pressure and locknut (3).
cut-out pressure 3 Locknut: 10.2 Nm {1 kgm}
a If the charge valve cut-in pressure or cut-out a After completing the adjustment, check the
pressure is not normal, adjust the R1 relief valve oil pressure again following the procedure for
of charge valve (1) according to the following the above test.
procedures.
q The R1 relief valve is on the frame-side face
of charge valve (1).
a Both cut-in pressure and cut-out pressure
change by adjusting the R1 relief valve.
1. Remove the cover.
2. While holding adjustment screw (2), loosen

locknut (3).
3. Turn adjustment screw (2) to adjust the oil pres-

sure.
q Adjust while checking the oil pressure.
a Adjustment screw:
q When turned clockwise, the oil pressure
is heightened.
q When turned counterclockwise, the oil
pressure is lowered.
16 HD785-7
Testing of accumulator nitrogen When connecting the gas charging tool P1, fit
gas pressure and procedure for the attached O-ring (7) (part number:
07000-11009) to gas valve (8), and confirm that
charging accumulator with gas does not leak.
nitrogen gas
Sym-
Part No. Part name Remarks
bol
1 792-610-1701 Gas charge tool —
– 07000-11009 q O-ring —
Nipple
792-610-1310 GOST
(For Russia)
Nipple
792-610-1320 CGA No. 351
(For USA)
Nipple ASA
P 792-610-1330
(For USA) B-571-1965
2
DIN 477-1963
Nipple NEN 3268-1966
792-610-1350
(For Germany) SIS-SMS
2235/2238
BS 341 Part Testing of accumulator nitrogen gas pressure
792-610-1360 Nipple (For UK) a The nitrogen gas pressure in the accumulator
1-1962
disconnected from the machine can be mea-
sured according to the following procedure, too.
k Put on proper protection gear (goggles,
1. Stop the engine and press the brake pedal
leather gloves and protective clothes) so that
repeatedly to lower the oil pressure in the brake
the leaking nitrogen gas will not touch your
circuit to zero.
skin or clothes and work on the windward
a Generally, if the brake pedal is pressed 30
side as long as possible.
k
times, the reaction force to the brake pedal is
When handling nitrogen gas in a room or an-
lost and the oil pressure is lowered to zero.
other place which is not ventilated well, ven-
tilate the work place forcibly and observe the 2. Remove valve guard (2) and cap (3) from accu-
Oxygen Deficiency Prevention Rules of the mulator (1).
Labor Safety and Sanitation Law.
k Since the accumulator is charged with
high-pressure nitrogen gas, wrong handling
of it can cause an explosion and injury or
death. When handling the accumulator, ob-
serve the following strictly.
q Do not bring fire near the accumulator or put
the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it of
the nitrogen gas.
Precaution when connecting the gas charging 3. Connect gas charge tool P1 to valve (4) of accu-
tool P1 mulator (1) according to the following procedure.
a The threaded portion of the adapter (5) of the 1) Turn handle (a) of gas charge tool P1 to the
gas charging tool P1 is coated with sealant. If the left until it stops.
adapter is removed unnecessarily, gas may q Nitrogen gas cylinder (c) must be con-
leak. Never remove it. nected even when you measure only the
a The threaded portion height (B) of gas valve (8) gas pressure.
may be shorter than the depth (A) of packing (6) q Close the valve of nitrogen gas cylinder
from the end of adapter (5) of gas charging tool (c) and handle (b).
P1 and gas may leak through the threaded por- q For connection of nitrogen gas cylinder
tion of gas valve (8). (c) and gas charge tool P1, see "Proce-
dure for charging accumulator with nitro-
gen gas".
HD785-7 17
2) Fit the attached O-ring (7) (part number: 4. Slowly rotate handle (a) of gas charge tool P1
07000-11009) to gas valve (8). clockwise and read the gauge.
a Since the indicated gas pressure varies with
the atmospheric temperature, check it with
the following table.
Accumulator charge gas pressure table

Atmospheric Gas pressure
temperature Remarks
Mpa kg/cm2
°C
15 6.09 61.9
16 6.12 62.1
17 6.14 62.4
18 6.16 62.6
19 6.18 62.8
3) Connect gas charge tool P1 to valve (4) of Standard gas
accumulator (1). 20 6.20 63.0
pressure
21 6.22 63.2
22 6.24 63.4
23 6.26 63.6
24 6.28 63.9
25 6.31 64.1
26 6.33 64.3
27 6.35 64.5
28 6.37 64.7
29 6.39 64.9
30 6.41 65.2
31 6.43 65.4
32 6.45 65.6
33 6.48 65.8
34 6.50 66.0
35 6.52 66.2
36 6.54 66.4
37 6.56 66.7
38 6.58 66.9
39 6.60 67.1
40 6.62 67.3
41 6.64 67.5
42 6.67 67.7
43 6.69 67.9
44 6.71 68.2
45 6.73 68.4
18 HD785-7
Indicated gas pressure = 3. Connect gas charge tool P1 and nitrogen gas
Standard gas pressure x ((273 + t)/(273 + 20)) cylinder (c) to valve (4) of accumulator (1)
t = Gas temperature at time of charge (°C) according to the following procedure.
Reference: 1) Turn handle (a) of gas charge tool P1 to the
q t may be assumed to be ambient temper-
left until it stops.
ature.
2) Turn handle (b) to the left to open.
q The unit of each value in the formula is °
C. 3) Fit the attached O-ring (7) (part number:
07000-11009) to gas valve (8).
5. If the gas pressure is too high or too low, adjust
it referring to "Procedure for charging accumu-
lator with nitrogen gas".
a Each time the pressure is measured, some
nitrogen gas is discharged and the pressure
lowers. Add nitrogen gas by the loss.
6. Remove gas charge tool P1 from accumulator

(1) and return the removed parts. See "Proce-
dure for charging accumulator with nitrogen
gas".
Procedure for charging accumulator with nitro-

gen gas
a The disconnected from the machine can be 4) Connect gas charge tool P1 to valve (4) of
charged with nitrogen gas according to the fol- accumulator (1).
lowing procedure, too. 5) Connect gas charge tool P1 and nitrogen gas
1. Stop the engine and press the brake pedal cylinder (c).
repeatedly to lower the oil pressure in the brake q Use nipple P2 to connect the hose, de-
circuit to zero. pending on the specification of the nitro-
a Generally, if the brake pedal is pressed 30 gen gas cylinder.
times, the reaction force to the brake pedal is
lost and the oil pressure is lowered to zero.
2. Remove valve guard (2) and cap (3) from accu-

mulator (1).
HD785-7 19
4. Open nitrogen gas cylinder (c) slightly to Atmospheric Gas pressure

discharge nitrogen gas at pressure of 0.19 – temperature Remarks
0.29 MPa {2 – 3 kg/cm²}. °C Mpa kg/cm2
34 6.50 66.0
5. After nitrogen gas starts flowing out of handle
35 6.52 66.2
(b), close handle (b).
36 6.54 66.4
6. Turn handle (a) slowly to the right to open valve 37 6.56 66.7
(4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve 38 6.58 66.9
core of the accumulator will be damaged and 39 6.60 67.1
gas will leak. Accordingly, operate handle (a)
40 6.62 67.3
carefully.
41 6.64 67.5
7. Open the valve of nitrogen gas cylinder (c) 42 6.67 67.7
further to charge the accumulator with nitrogen
gas. 43 6.69 67.9
44 6.71 68.2
8. During the work, close the valve of nitrogen gas 45 6.73 68.4
cylinder (c) and check the nitrogen gas pressure
in the accumulator. Standard gas pressure =
a Since the indicated gas pressure varies with Indicated gas pressure/((273 + t)/(273 + 20))
the atmospheric temperature, correct it with t = Gas temperature at time of charge (°C)
the following table. Reference:
q t may be assumed to be ambient tempera-
Accumulator charge gas pressure table ture.

q The unit of each value in the formula is °C.
Atmospheric Gas pressure
temperature Remarks
°C Mpa kg/cm2 9. After the accumulator is charged to the standard
pressure, close the valve of nitrogen gas
15 6.09 61.9
cylinder (c).
16 6.12 62.1 q If the accumulator is charged too much, turn
17 6.14 62.4 handle (b) to the left slowly with the valve of
nitrogen gas cylinder (c) closed to release
18 6.16 62.6 the nitrogen gas gradually to adjust.
19 6.18 62.8
Standard gas 10. Remove gas charge tool P1 from valve (4) of
20 6.20 63.0 accumulator (1) according to the following
pressure
21 6.22 63.2 procedure.
1) Turn handle (a) to the left to close the valve
22 6.24 63.4
of the accumulator.
23 6.26 63.6 2) Turn handle (b) to the left to open and
24 6.28 63.9 discharge nitrogen gas remaining in gas
charge tool P1 and hoses.
25 6.31 64.1 3) Remove gas charge tool P1 from valve (4) of
26 6.33 64.3 the accumulator.
27 6.35 64.5
28 6.37 64.7
29 6.39 64.9
30 6.41 65.2
31 6.43 65.4
32 6.45 65.6
33 6.48 65.8
20 HD785-7
11. Apply soap water to valve (4) of the accumulator

to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumulator

(1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
13. In a week after charging the accumulator with

nitrogen gas, check that the nitrogen gas pres-
sure has not lowered.
a Check the functions in 5 minutes after stop-
ping the engine. (If the engine is stopped for
more than 5 minutes, the brake circuit pres-
sure lowers and the functions cannot be
checked accurately.)
1) Stop the machine on a level place and set the
parking brake switch in the "PARK" position.
2) Start the engine and run it at medium speed
for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly. Count
the number of presses until the brake oil
pressure caution lamp lights up.
q If number of presses is less than 5: Accu-
mulator gas pressure may have lowered.
q If number of presses is 5 or more: Accu-
mulator gas pressure is normal.
HD785-7 21
Testing brake performance 2. Testing braking performance of retarder brake

k
1) Start the engine and turn the parking brake
Stop the machine on the level ground and
switch OFF.
turn the parking brake switch PARKING.
k If the machine starts to move, it can cause a 2) Pull the retarder lever fully, then set the gear
serious personal injury. Should the machine shift lever to the D position.
k If the torque converter is stalled while
start moving during the performance test, re-
duce the engine speed immediately, move the gearshift indicator is indicating
the gear shift lever to the N position and de- "F1", the inside of the transmission
press the foot brake. may be broken.
Accordingly, when stalling the torque
converter, seat the body securely and
1. Testing braking performance of foot brake
(service brake)
check that the body pilot lamp is
turned OFF, and then set the gearshift
1) Start the engine and turn the parking brake
lever in the D position and check that
switch OFF.
the gearshift indicator is indicating
2) Depress the brake pedal fully, then set the
"F2".
gear shift lever to the D position.
3) Depress the accelerator pedal gradually and
check that the machine does not move when
the torque converter is stalled at the specified
"F1", the inside of the transmission
speed.
may be broken.
Accordingly, when stalling the torque
converter, seat the body securely and
"F2".
speed.
4) After completing the testing, run the engine

at low idle and set the gear shift lever to the
"N" position.
3. Testing braking performance of parking brake

1) Turn the parking brake switch PARKING and
start the engine.
2) Set the gear shift lever to the D position.
"F1", the inside of the transmission
4) After completing the test, run the engine at may be broken.
low idle and set the gear shift lever to the "N" Accordingly, when stalling the torque
position. converter, seat the body securely and
"F2".
22 HD785-7

speed.
a If the machine moves while the engine
speed is below the specified speed, per-
form "Check of wear of rear brake disc"
described later.
4) After completing the testing, run the engine

at low idle and set the gear shift lever to the
"N" position.
HD785-7 23
Bleeding air from brake circuit 3) Bleed air from bleeder (3) on the wheel side
similarly to step 1) above.
a If any brake circuit device was removed and in-
3 Bleeder:
stalled or if the transmission and brake cooling
oil was replaced, bleed air from the brake circuit
7– 9 Nm {0.7 – 0.9 kgm}
according to the following procedure.
a After finishing bleeding air, tighten (close)
a If the machine is equipped with ASR, see
the bleeder and put the cap.
"Bleeding air from ASR circuit", too.
a Brake oil temperature during work: Min. 40 °C
k Stop the machine on a flat place, turn the
parking brake switch to the "PARKING" posi-
tion and lock the tires with chocks.
1. Rear brake
a Bleed air from the slack adjuster side first and
then bleed from the wheel brake side.
1) Using a vinyl tube for bleeding air, depress
the brake pedal and loosen air bleeder screw
(1) or (2) by 3/4 turns. Keep depressing the
brake pedal until bubbles do not come out of
the bleeder any more. When bubbles do not
come out any more, tighten (close) the
bleeder and release the pedal. 2. Parking brake on rear brake side
a Bleed air from the differential top block side
2) Pull the retarder control lever and loosen air
first, then bleed air from the wheel brake
bleeder screw (1) or (2) by 3/4 turns. Keep
side..
pulling the retarder control lever until bubbles
1) Using a vinyl tube for bleeding air, turn OFF
do not come out of the bleeder any more.
the parking brake switch (release the parking
When bubbles do not come out any more,
brake) and loosen air bleeder screw (4) by
tighten (close) the bleeder and release the
3/4 turns.
retarder control lever.
2) When bubbles do not come out of the bleeder
(4) any more, tighten (close) the bleeder and
turn PARKING the parking brake switch.
24 HD785-7
3) Bleed air through bleeder (5) for the parking 4. Parking brake on front brake side
brake on the wheel side according to step 1). a Bleed air from the cab rear block side first,
then bleed air from the wheel brake side.
1) Using a vinyl tube for bleeding air, turn OFF
the parking brake switch (release the parking
brake) and loosen air bleeder screw (7) by
3/4 turns.
2) When bubbles do not come out of the bleeder
(7) any more, tighten (close) the bleeder and
turn PARKING the parking brake switch.

3 Bleeder:
7– 9 Nm {0.7– 0.9 kgm}
3. Front brake
1) Loosen air bleeder (6) by 3/4 turns and bleed
air similarly to step 1) for the rear brake.
3) Bleed air through bleeder (8) for the parking

brake on the wheel side according to step 1).

3 Bleeder:
7– 9 Nm {0.7– 0.9 kgm}
HD785-7 25
Bleeding air from ASR circuit

(if equipped)
a ASR:Automatic Spin Regulator
a Brake oil temperature during work: Min. 40 °C
k Stop the machine on a level ground, turn the
parking brake switch in the "Park" position,
and lock the tires with chocks.
1. Start the engine and check that the brake sub

tank is filled with oil and the brake oil pressure
caution lamp is turned OFF.
2. Turn the ASR switch ON.
3. Remove the cover at the rear of the operator's

seat and connect "TEST" connector (1).
a The valve opens and oil pressure is applied
to the ASR circuit.
4. Referring to "Bleeding air from brake circuit",

bleed air from the wheel brake and parking
brake.
a Bleed air from the ASR circuit, too.
5. After bleeding air from the wheel brake and

parking brake, disconnect "TEST" connector (1)
and install the cover.
26 HD785-7
Testing wear of front brake disc

k Stop the machine on level ground, turn the
parking brake switch PARKING, and put
chocks under the tires.
k Carry out the inspection when the brake oil
temperature is less than 60 °C.
k When the disk comes close to the wear limit,
carry out the inspection more frequently. Be
sure to carry out inspection of the retarder
braking performance at the same time.
1. Check that the brakes other than parking brake

are not being actuated.
2. Stop the engine.
3. Remove cap nut (1) of the gauge.

a The figure shows the left side as an example.
5. Install cap nut (1) of the gauge.

3 Cap nut: 128 – 186 Nm {13 – 19 kgm}
4. Push in the rod (2) of the gauge until it contacts

the piston and judge the amount of wear.
a With a new machine, adjust so that inner
(deeper) end (a) of groove (D) on the rod (2)
is aligned with the end face of guide (3).
The adjustment position will move out of
alignment, so do not loosen locknut (4) of
guide (3) except when replacing the disc.
a Outer end (b) of groove (D) is the wear limit
of the disc. If it is fully on the inside of guide
(3) (it reaches the end face), the disc is worn
to the limit. Replace the disc in this case.
HD785-7 27
Testing wear of rear brake disc

k Carry out the inspection when the brake oil
temperature is less than 60 °C.
k When the disk comes close to the wear limit,
carry out the inspection more frequently. Be
sure to carry out inspection of the retarder
braking performance at the same time.
1. Check that the brakes other than parking brake

are not being actuated.
2. Stop the engine.
3. Remove cap nut (1) of the gauge.

a The figure shows the left side as an exam-
ple..
5. Install cap nut (1) of the gauge.

3 Cap nut: 128 – 186 Nm {13 – 19 kgm}
4. Push in the rod (2) of the gauge until it contacts

the piston and judge the amount of wear.
a With a new machine, adjust so that inner
(deeper) end (a) of groove (D) on the rod (2)
is aligned with the end face of guide (3).
The adjustment position will move out of
alignment, so do not loosen locknut (4) of
guide (3) except when replacing the disc.
a Outer end (b) of groove (D) is the wear limit
of the disc. If it is fully on the inside of guide
(3) (it reaches the end face), the disc is worn
to the limit. Replace the disc in this case.
28 HD785-7
Method of releasing parking brake

in an emergency
a If the parking brake cannot be released because
of a trouble in its electric or hydraulic system, re-
lease it tentatively according to the following pro-
cedure.
k If the hydraulic system has a trouble, the
wheel brake probably does not work normal-
ly. Accordingly, be sure to tow the machine
at low speed after releasing the parking
brake.
k When releasing the parking brake, stop the
machine on a level place and make sure of
the safety around it. If it is obliged to release
3. Prepare bolt (3) (01017-51630), washer (4), and
the parking brake on a slope in an emergen-
nut (5) (01580-1-1613) for releasing the parking
cy, put chocks under the tires securely.
k When releasing the parking brake, stop the
brake manually and tighten the bolts alternately
and evenly to release the parking brake.
engine.
a The figure shows the rear side.
a Tighten nuts (5) to pull piston (6) and release
1. Remove front brake plugs (1) (8 places on each the parking brake.
side)
a Prepare a container to receive the oil flowing
out of the plug holes.
4. After moving the machine, remove the parking

brake manual reset bolts and install plugs (1)
and (2).
3 Tightening torque of plug:
2. Remove rear brake plugs (2) (9 places on each 44.1 – 53.9 Nm {4.5 – 5.5 kgm }
side)
a Remove the oil catch tank (2A) before hand.
a Prepare a container to receive the oil flowing
out of the plug holes.
HD785-7 29
Testing and adjusting front 2) Before adjusting the oil level, check the
suspension cylinder condition of the variable damper valve.
(For only automatic suspension specifica-
a Testing instrument tion)
Sym- (S) posision: soft mode
Part No. Part name
bol (H) posision: hard mode
– 792-610-1000 Suspension tool assembly
(M) posision: medium mode
– 792-610-1100 q Pump assembly
1 792-610-1130 qq Pump
2 792-610-1110 qq Hose
3 792-610-2200 qq Joint
– 792-610-1200 q Charging tool assembly
L 4 07020-21732 qq Fitting
5 792-610-1140 qq Joint
6 792-610-1250 qq Valve Ass'y
7 792-610-1260 qq Nipple
8 792-610-1270 qq Hose
9 792-610-1280 qq Valve
10 792-610-1400 qq Regulator
"–" : Kit tool Nos
1. Testing length of cylinder

1) Check that the bottom of the cylinder cover is
within the range (e) marked by arrows for the
cylinder level.
a With the truck empty, starting switch ON,

parking brake OFF, and hoist control le-
ver at the FLOAT position, check that the
cylinder of the variable damper valve is in
the soft mode.
a If the cylinder of the variable damper
valve is not in the soft mode when check-
ing, operate as follows to switch to the
soft mode.
1] Use the retarder brake (Note 1) and
drive the machine several times
repeatedly forward and in reverse to
set to the soft mode.
(*1)If the foot brake pedal is used, the
automatic suspension is automatically
set to the medium mode, and the
resistance of the cylinder increases,
so it takes time to adjust.
30 HD785-7
2. Bleeding nitrogen gas 3. Adjusting of oil level

1) Set hydraulic jack [1] (490 kN {50 t}) under a Release the nitrogen gas before adjusting
the main frame. the oil level.
2) Remove the cover from the suspension 1) Remove feed vavle (3), and install joint L5.
cylinder. 2) Install fitting L4 to joint L3, then connect hose
3) Disconnect pressure sensor connector (2) of L2 and volume pump L1.
oil level valve (1) and loosen oil level valve 3) Loosen air bleeding valve (4), then operate
(1) by 2 – 3 turns. volume pump L1 until no more bubbles come
a The machine equipped with the pressure out with the oil from air bleed side hole (b).
sensor is shown in the figure. If your ma- 4) When no more bubbles come out with the oil,
chine is not equipped with the pressure tighten air bleeding valve (4).
sensor, ignore the description on the 3 Tightening torque of air bleeding
pressure sensor. valve: 39.2 – 49.0 Nm {4 – 5 kgm}
a If the nitrogen gas is bled through intake 5) Remove valve (1), then operate volume
valve (3), the valve core may be dam- pump L1 until no more bubbles come out with
aged. Accordingly, bleed through oil level the oil from the valve (1) mount.
valve (1). 6) When no more bubbles come out with the oil,
a Loosen only the oil level valve. Do not tighten the valve (1).
3 Tightening torque of oil level valve:
loosen the pressure sensor and nipple.
a When the oil level valve is loosened, if 39.2 – 49.0 Nm {4 – 5 kgm}
both of the oil and gas spout out, close the 7) After completion of supplying the oil, remove
valve a little to bleed the gas slowly. the volume pump, then install feed valve (3).
4) Operate the hydraulic jack so that dimension 3 Tightening torque of feed valve:
(a) of the cylinder is the specified dimension 39.2 – 49.0 Nm {4 – 5 kgm}
for the oil level.
Dimension(a): 82 ± 3 mm
HD785-7 31
4. Filling suspension cylinder with gas

leather gloves and protective clothes) so
that the leaking nitrogen gas will not
touch your skin or clothes and work on
the windward side as long as possible.
k When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate the work place forcibly and ob-
serve the Oxygen Deficiency Prevention
Rules of the Labor Safety and Sanitation
Law.
1) Remove feed valve (3).
2) Set tool Las shown in the diagram.
a Before installing regulator L10 , blow the
connector filter with nitrogen gas at 0.98
MPa {10 kg/cm²} or more to blow out all
dirt or dust. (Dirt or dust in the system
causes failures.)
3) Open valve [2] of the gas cylinder [1], and
check the pressure reading of gauge (c)
(internal pressure of gas cylinder).
a The pressure indicated must be at least
0.98 MPa {10 kg/cm²} higher than the
pressure inside the suspension cylinder
(max. pressure inside suspension cylin-
der: 3.9 MPa {40 kg/cm²}).
4) Turn handle (d) of regulator L10 slowly clock-
wise, set the pressure reading of gauge (e) to
0.98 MPa {10 kg/cm²} above the internal
pressure of the suspension cylinder, then
operate valves L6 and L9 to fill the suspen-
sion cylinder with nitrogen gas.
a Fill the left and right cylinders in the same
way.
5) When dimension (a) of the left and right cylin-
ders reaches the standard value, turn handle
(d) of regulator L10 counterclockwise to stop
the flow of nitrogen gas.
a Standard dimension (a): 247 – 10 mm
6)Turn handle (c) of L9 fully back counterclock-
wise, loosen air bleeding plug (f) of valve L6
release the gas inside the hose, then remove
tool L.
a Be careful not to lose the O-ring of air
supply valve.
32 HD785-7
5. Adjusting installed length of cylinder a If there is any leakage of gas from the
a Carry out adjustment of the installed length of valve core, use tool [3] and replace the
the cylinder with the machine-empty and on valve core.
level ground.
1) Drive the machine forward about 15 m and
stop it sharply and then drive it in reverse and
stop it sharply at the former position. Repeat
this cycle 3 - 4 times and then stop the
machine slowly without pressing the brake
pedal to eliminate the sliding resistance of
the cylinder (hitch of the packing and
bushing). Under this condition, measure the
installed length.
a Do not use the foot brake but use the re-
tarder control lever to stop the machine.
After the machine stops, check that the
suspension is in the soft mode.
2) If the result of the check shows that the Note:
installed length is too long, release nitrogen 1. Check after replacement of oil or gas
gas to adjust the length. When the machine operates after the oil or gas
a Loosen the valve (1) slightly to release is replaced, gas is dissolved in the new oil in the
the nitrogen gas. When doing this, re- replaced cylinder until the oil is saturated. As a
lease only a small amount of gas; do not result, the gas volume is reduced and the
make the cylinder move. installed length of the suspension may be
a If the nitrogen gas is bled so much that reduced to below the limit. Accordingly,
the cylinder will move, the installed length measure the installed length of the suspension
may be less than the specified length. again 48 hours after the oil or gas is replaced. If
a Do not press the tip of the valve core. If it is less than the specification value, adjust the
the tip of the valve core is pressed, the gas.
valve core may be damaged.
3) After releasing nitrogen gas and adjusting 2. Checking for changes in installed length caused
the installed length, repeat Step 1) to check by variation in ambient temperature.
the installed length again. Depending on the ambient temperature when
4) Repeat the above Steps 1) – 3) to adjust the the machine is working, the gas in the suspen-
cylinder to the specified length. sion may expand or contract, so the installed
5) Finally, check that there is no leakage of gas length will also change. In territories where there
from the valve core (6), valve (1), and piston are big differences in temperature throughout
rod gland. the year, inspect daily and adjust to keep the
a Use soapy water to check for leakage of installed length within the specified range.
gas.
HD785-7 33
Testing and adjusting rear 2. Releasing nitrogen gas

suspension cylinder 1) Set block [2] between the stopper and axle
housing.
a Testing instrument a Thickness of block: 19 mm
Symbol Part No. Part name Dimension (a) : 124 ± 3 mm
– 792-610-1000 Suspension tool assembly
– 792-610-1100 q Pump assembly
1 792-610-1130 qq Pump
2 792-610-1110 qq Hose
3 792-610-2200 qq Joint
– 792-610-1200 q Charging tool assembly
L 4 07020-21732 qq Fitting
5 792-610-1140 qq Joint
6 792-610-1250 qq Valve Ass'y
7 792-610-1260 qq Nipple
8 792-610-1270 qq Hose
9 792-610-1280 qq Valve
10 792-610-1400 qq Regulator
"–" : Kit tool Nos

parking brake switch PARKING, and put 2) Disconnect pressure sensor connector (2) of
chocks under the tires. valve (1), then loosen the valve 2 – 3 turns.
a When checking, stop the empty machine on a a When releasing the nitrogen gas, there is
flat place. danger that releasing the gas from the
1. Testing length of cylinder valve core of feed valve (3) will damage
1) Remove dust cover. the valve core, so remove the gas at the
valve (1).
2) Check that dimension (a) of the rear suspen-
a Loosen only the oil level valve. Do not
sion cylinder is within the specified value.
loosen the pressure sensor and nipple.
Specified value for dimension (a) :
k When loosening the valve (1), loosen
199 ± 10 mm
only the valve itself. Do not loosen the
pressure sensor or nipple.
k If the nitrogen gas has not all been re-
leased, pressure sensor (5) are still un-
der high pressure, so do not loosen
them under any circumstances.
a When the valve (1) is loosened, and oil
and gas spurt out together, tighten the
valve slightly, and allow time for the gas to
escape slowly.
a The standard dimension is described on

the decal stuck on the cylinder, too.
34 HD785-7
4. Filling suspension cylinder with gas

leather gloves and protective clothes) so
that the leaking nitrogen gas will not
touch your skin or clothes and work on
the windward side as long as possible.
k When handling nitrogen gas in a room or
another place which is not ventilated well,
ventilate the work place forcibly and ob-
serve the Oxygen Deficiency Prevention
Rules of the Labor Safety and Sanitation
Law.
1) Remove cap (5) from feed valve (3).
2) Set tool Lto the feed valve supply as shown
3. Adjusting oil level in the diagram
a Release the nitrogen gas before adjusting a Before installing regulator L10, blow the
the oil level. filter in the connector with nitrogen gas at
1) Remove feed valve (3), and install joint L5. 0.98 MPa {10 kg/cm²} or more to blow out
2) Install fitting L4 to joint L3, then connect hose all dirt or dust. (Dirt or dust in the system
L2 and volume pump L1. causes failures.)
3) Loosen air bleeding valve (1), then operate 3) Open valve [2] of the gas cylinder [1], and
volume pump L1 until no more bubbles come check the pressure reading of gauge (c)
out with the oil from air bleeding valve (1). (internal pressure of gas cylinder).
4) When no more bubbles come out with the oil, a The pressure indicated must be at least
tighten air bleeding valve (1). 0.98 MPa {10kg/cm²} higher than the
pressure inside the cylinder (max. pres-
5) After adding oil, remove the volume pump,
sure inside cylinder: 3.9 MPa {40
then install feed valve (3).
kg/cm²}).
4) Turn handle (d) of regulator L10 slowly clock-
wise, set the pressure reading of gauge (e) to
0.98 MPa {10kg/cm²} above the internal
pressure of the cylinder, then operate valves
L6 and L9 to fill the cylinder with nitrogen gas.
a Fill the left and right cylinders in the same
way.
5) When dimension (a) of the left and right cylin-
ders reaches the standard value, turn handle
(d) of regulator L10 counterclockwise to stop
the flow of nitrogen gas.
a Standard dimension (a) :
199 ± 10 mm
HD785-7 35
6) Turn handle L10 a of L10 fully back counter- 1) Drive the machine forward about 15 m and
clockwise, loosen air bleeding plug L7a of stop it sharply and then drive it in reverse and
valve L7, release the gas inside the hose, stop it sharply at the former position. Repeat
then remove tool L. this cycle 3 – 4 times and then stop the
a Be careful not to lose the O-ring of the machine slowly without pressing the brake
feed valve. pedal to eliminate the sliding resistance of
the cylinder (hitch ofthe packing and
bushing). Under this condition, measure the
installed length.
a Do not use the foot brake when braking
the machine. Use the retarder control le-
ver to brake, the machine, then check that
the suspension is in the soft mode.
2) If the result of the check shows that the
installed length is too long, release nitrogen
gas to adjust the length.
a Loosen the valve slightly to release the ni-
trogen gas. When doing this, release only
a small amount of gas; do not make the
cylinder move.
a If the nitrogen gas is bled so much that
the cylinder will move, the installed length
may be less than the specified length.
a Do not press the tip of the valve core. If
the tip of the valve core is pressed, the
valve core may be damaged.
3) After releasing nitrogen gas and adjusting
the installed length, repeat Step 1) to check
the installed length again.
4) Repeat the above Steps 1) – 3) to adjust the
cylinder to the specified length.
5) Finally, check that there is no leakage of gas
from the valve core (6), valve, and piston rod
gland.
a Use soapy water to check for leakage of
gas.
a If the gas leaks through the valve core, re-
place the valve core with tool [3]..
2 Valve core: Adhesive
3 Valve core:
16.7 – 34.3 Nm {1.7 – 3.5 kgm}
5. Adjusting installed length of cylinder

a Carry out adjustment of the installed length
of the cylinder with the machine empty and
on level ground.
36 HD785-7
6. Testing and adjusting dust cover

a Check the cover for damage caused by
stones etc. scattered by the tires during trav-
el and repair or replace it, if necessary.
1) Check visually that there are no cracks or
breaks in cover (1).
a If the cover is damaged, replace it with a
new part.
2) Check that hooks (2) are not missing.
a If any hooks are missing, remove all mud
and dirt, then install hooks.
3) Check that band (3) is not loose or missing.
a If the band is loose or missing, tighten to
the following torque.
3 Band:
6.8 ± 0.49 Nm {0.7 ± 0.05 kgm}
HD785-7 37
Testing and adjusting front

suspension cylinder (Automatic
suspension specification)
1. Testing
1) Check that length (a) of hydraulic cylinder (1)
is as specified under the following condition.
a Condition (Mode Soft)
1] Machine is empty.
2]: Starting switch is ON.
3] Parking brake switch is PARKING.
4] Work equipment control lever is at
FLOAT.
a Specified length (a): 351.8 mm
2) Shift the hoist lever from the FLOAT position
to another position and check that hydraulic
cylinder length (a) is not (is longer minimum)
351.8 mm.
2. Adjusting
1) Remove mounting bolt (2) of hydraulic
cylinder (1) and disconnect hydraulic cylinder
(1).
2) Loosen locknut (3) and adjust mounting
length (a) with rod end.
a Specified length (a): 352 ± 1 mm
3) Install (Return) hydraulic cylinder (1) with
mounting bolt (2).
4) Turn the starting switch to the ON position 5) Check that the hole (5) of bracket is in the slit
and shift the hoist lever from the FLOAT posi- (part (f)) in modes Soft (position (d)) and
tion to another position and check that length Medium (position (e)).
(a) of hydraulic cylinder (1) is not (is longer
minimum) 352 ± 1 mm.
(Reference)
q (b) in hard mode: 382.8 mm
q (c) in medium mode: 413.8 mm
38 HD785-7
Testing and adjusting hydraulic

pressure in steering, hoist circuit
799-101-5002 Analog hydraulic meter
K1
k Stop the machine on a flat place, turn the
parking brake switch to the "PARKING" posi-
tion and lock the tires with chocks.
k When testing and adjusting, lower and seat
the body to the frame, stop the engine and re-
move the hydraulic tank cap to release the re-
sidual pressure in the cylinder circuit.
k When operating the steering wheel, check
2. Adjusting hydraulic pressure in steering circuit
that there is nobody around the front tires.
If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
Steering circuit
q Steering pressure (adjust with demand
1. Measuring hydraulic pressure in steering circuit valve)
1) Raise the hydraulic oil temperature. 1) Loosen locknut (4) of relief valve (5) and turn
a Oil temperature when measuring : adjustment screw (5) to adjust.
45 –55°C a To INCREASE pressure, turn CLOCK-
2) Remove plug (2) of the outlet piping of WISE
steering demand valve (1) and install tool K1 To DECREASE pressure, turn COUN-
(40 MPa {400 kg/cm²}). TERCLOCKWISE
3) Start the engine, turn the steering wheel fully a One turn of the adjustment screw adjusts
to the right or left to relieve the oil and by 12.55 MPa {128 kg/cm²}.
measure the oil pressure at this time.
2) After adjusting, tighten locknut (4), holding

adjustment screw (5) with a screwdriver.
HD785-7 39
3) Check again so that the hydraulic pressure is Hoist circuit

within the specified value. 1. Testing hydraulic pressure in hoist circuit
For details, see "Measuring hydraulic pres- 1) Raise the hydraulic oil temperature.
sure in steering circuit". a Oil temperature when measuring :
a The pressure of crossover relief valve (6) 45 – 55°C
cannot be adjusted when it is installed on 2) Remove oil pressure pickup plug (10) at the
the machine, so do not adjust the pres- hoist cylinder bottom and install tool K1 (40
sure. MPa {400 kg/cm²}).
3) Operate the hoist control lever, and move the
dump body to the maximum dump position to
relieve the circuit, then measure the
hydraulic pressure with the engine at full
throttle.
3. Testing steering valve charge pressure

1) Remove plug (7) and install tool K1 (40 MPa
{400 kg/cm²}).
2) Test in the same way as when measuring the
hydraulic pressure in the steering circuit.
4. Testing hydraulic pressure in steering cylinder

1) Remove pressure testing plug (8) (when
turning the steering to the left) or pressure
testing plug (9) (when turning the steering to
the right), and install tool K1 (40 MPa {400
kg/cm²}).
2) Test in the same way as when measuring the
hydraulic pressure in the steering circuit.
40 HD785-7
2. Adjusting hydraulic pressure in hoist circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
1) Loosen locknut (12) of the relief valve of hoist
valve (11) and turn adjustment screw (13) to
adjust.
a To INCREASE pressure, turn CLOCK-
WISE
When turned counterclockwise, the oil
pressure is lowered.
a To DECREASE pressure, turn COUN-
TERCLOCKWISE
2) After adjusting, hold the adjustment screw
(13) with a screwdriver to prevent it from
turning, then tighten the locknut (12).
3 Tightening torque of lock nut:
29.4 – 39.2 Nm {3 – 4 kgm}
3) Check again so that the hydraulic pressure is
within the specified value.
For details, see "Testing hydraulic pressure
in hoist circuit".
HD785-7 41
Testing and adjusting oil pressure 2. Testing dump EPC valve output pressure
in dump EPC circuit 1) Disconnect EPC hose (3) or (4) to be
measured.
a Testing instrument (3): Dump raise side (Port PB)
Symbol Part No. Part name (4): Dump lower side (Port PA)
799-101-5002 Analog hydraulic meter
1
K 4 799-101-5230 Nipple
799-401-3100 Adapter
5
02896-11008 O-ring
k Loosen the oil filler cap of the hydraulic tank slow-
ly to release the residual pressure from the tank.
Testing
1. Testing dump EPC valve main pressure
1) Remove oil pressure testing plug (2) (M14 ×
1.5) from dump EPC valve (1) inside the
hydraulic tank (inside the machine).
2) Install adapter (K5) to hoist valve and

connect the hose.
3) Install nipple [1] and hose [2] and connect oil
pressure gauge K1 [6 MPa {60 kg/cm²}].
4) Start the engine, set the dump lever to the
RAISE, FLOAT or lower position and test the
circuit oil pressure at this time.
2) Install nipple K4 and hose [2] and connect oil

pressure gauge K1 [6 MPa {60 kg/cm²}].
3) Start the engine and test the oil pressure
when the dump lever is in neutral.
42 HD785-7
Air bleeding from steering

cylinder
k Stop the machine on a flat place, turn the parking
brake switch to the "PARKING" position and lock
the tires with chocks.
k Before operating the steering wheel, be sure
to check that there is no one around the front
tires.
a If the hydraulic cylinder was removed and in-
stalled or its hydraulic piping was removed,
breed air from the hydraulic cylinder according to
the following procedure.
1) Start engine, run engine at low idle for 5
minutes.
2) Turn the steering wheel at 30 rpm (2 seconds
for one turn) to the left and right to a point
approx. 50 mm from the end of the steering
cylinder stroke.
Repeat this action ten times.
(This action is to prevent damage to the
piston seal caused in the steering cylinder.)
3) Turn the steering wheel at a speed of about
30 rpm to the right and left steering cylinder
stroke ends repeatedly.
4) Turn the steering wheel as quickly as
possible to the left and right to the end of the
steering cylinder stroke.
When reaching the end of the stroke at the
left and right, turn the steering wheel immedi-
ately in the opposite direction, and carry out
this action continuously.
Repeat this action ten times in both direction.
HD785-7 43
Procedure for raising dump body 5. When lowering the body, operate the manual
in emergency lowering valve according to the following proce-
dure.
a Testing instrument k Be sure to work from the ground and do not
Symbol Part No. Part name put your body under the body.
M 792T-691-1110 Plug 1) Remove the hydraulic tank cap and release
a If the dump body cannot be raised because of a the residual pressure in the hoist circuit.
failure in the controller or electric system, raise it 2) Loosen locknut (1) of manual lowering valve
to dump the load according to the following pro- (2).
cedure. 3) Turn grip (1) of manual lowering valve (3)
1. Stop the engine and remove the hydraulic tank counterclockwise to oven the valve.
cap to release the residual pressure from the q The hydraulic oil in the hoist cylinder is
hoist circuit. drained and the body lowers.
2. Remove plug (1) and tighten tool M fully. a The body lowers by itself. Adjust its low-
a If tool M is tightened in fully, the spool is ering speed to a safe level with the valve.
moved to the rising stroke end. 4) After the body lowers to a desired position,
turn grip (3) clockwise to close the valve and
tighten locknut (2).
3. Start the engine under this condition, and the

dump body rises.
4. Stop the engine and remove tool M and install
plug (1).
3 Tightening torque of plug:
29 – 39 Nm {3 – 4 kgm}
44 HD785-7
Adjusting body positioner sensor 2. Adjusting link length

a If the monitoring voltage is not within the nor-
mal range, adjust the length of the link as fol-
lows.
1) Check that lever hole (a) is not shifted more
than 1 mm from the positioning hole on the
a If the body positioner rod has been disconnected
sensor side.
and connected again or the body positioner sen-
sor has been removed and installed again, in- 2) Loosen locknut (1).
spect and adjust the body positioner sensor as 3) Remove mounting bolt (2).
follows. 4) Turn rod end (3) to adjust the length of the
link (4).
1. Checking sensor input voltage a Standard installed length (b) of link: 484
1) Switch the machine monitor display to the mm
monitoring function of service mode and a Do not reduce length (b) to below 480
display the body positioner sensor input mm.
voltage. a Adjust the input voltage as follows.
q INCREASE link length to
q Monitoring system: BRAKE
q Monitoring code:
DE-CREASE voltage
q DECREASE link length to
34602 (BODY POSITION)
a For the operating method, see "Special IN-CREASE voltage
functions of machine monitor (EMMS)". 5) Install mounting bolt (2).
6) Tighten locknut (1).
7) Check that the sensor input voltage is
normal.

3) Operate the dump lever and check the moni-
toring voltage when the dump lever is oper-
ated fully to the LOWER position and RAISE
position.
a When operated fully to LOWER:
0.46 – 0.54 V
a When operated fully to RAISE:
4.26 – 4.59 V
HD785-7 45
3. Caribrating system
k Stop the machine on the level ground, turn the
parking brake switch PARKING, and set
a Hydraulic oil temperature: 80 – 90 °C
1) Run the engine and raise the hydraulic oil

temperature to 80 – 90 °C.
2) Lower the dump body to the stroke end and
keep the control lever in the "Float" position
for 5 seconds.
a Check that body pilot lamp is turned OFF.
3) Raise the dump body to the stroke end and
keep the control lever in the "Raise" position
for 5 seconds while running the engine at low
idle.
4) Lower the body. Raise the body while
running the engine at high idle and then lower
and seat it with the lever in the "Float" posi-
tion while running the engine at low idle.
Repeat this operation 5 – 10 times.
a Move the body to the raise stroke end and
float stroke end.
5) Raise the body while running the engine at
high idle and then lower and seat it with the
control lever in the "Float" position while
keeping the engine speed at high idle.
Repeat this operation 5 – 10 times.
a Move the control lever to the raise stroke
end and float stroke end.
while the body is not seated. However,
this makes no difference to the calibration
work.
a When the high altitude setting selection is
changed, perform this calibration work.
46 HD785-7
Handling of high voltage circuit of Adjusting transmission controller

engine controller a After any of the following operations, adjust the
1. Disconnecting or connecting operation of the transmission in order to tune the feeling of trans-
connector between the engine controller and the mission and its controller.
engine shall be performed only when the starting q The transmission has been overhauled or re-
switch is in the OFF position. placed.

q The transmission control valve has been re-
2. Do not start the engine while the T adapter is paired or replaced.

q The transmission controller has been replaced.
inserted or connected to the connector between
q Power train speed sensor has been repaired or
the engine controller and the engine for diag-
nosis. replaced
q The transmission oil temperature sensor has
a You may turn the starting switch to the OFF
or ON position but must not turn it to the been repaired or replaced.
q The transmission oil filter has been clogged ab-
START position.
normally and repaired.
a For the adjusting operation of the transmission,
use the service function of the machine monitor.
a For the details of the operation method, see
"Special functions of machine monitor
(EMMS)"..
HD785-7 47
Method for emergency escape at electrical system failure

If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the ma-
chine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor (EMMS)" for the method of checking the failure code.
Note: If the engine cannot be started and the machine is towed, release the parking brake temporarily
refer ring to "Method for emergency release of parking brake", since it cannot be released by oper-
ating the switch.
48 HD785-7
2. When transmission control system has a trouble and machine cannot start
a Check the failure code and select a proper escape procedure from the following table.
a For the method of checking the failure code, see "Special functions of machine monitor".
Failure Condition Starting gear speed set with lever
Escape method Remarks
code whentrouble occurred position after escape operation
1500LO Occurrence condition 2 Escape procedure 2 — ccurrence condition 1
Gear speed is kept fixed
15GOMW Occurrence condition 2 Escape procedure 3 D – L: F2 and gear is not shifted
from fixed gear after
15HOMW Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL
machine restarts. If
15JOMW Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH lever is set to N position,
gear is set in neutral.
15KOMW Occurrence condition 7 Escape procedure 3 D – L: F2, R: RH
15LOMW Occurrence condition 7 Escape procedure 3 D – L: F2, R: RH Occurrence condition 2
Gear is set in neutral
15MOMW Occurrence condition 7 Escape procedure 3 D – L: F2, R: RH suddenly during travel.
Once machine stops
15NOMW Occurrence condition 7 Escape procedure 3 D – L: F2, R: RH
travel, gear is kept in
15SBL1 Occurrence condition 7 Escape procedure 1 R: RH neutral and machine
does start when lever is
15SBMA Occurrence condition 2 Escape procedure 1 D – L: F2 operated.
15SCL1 Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH
Occurrence condition 3
15SCMA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL Gear is set in neutral
15SDL1 Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL suddenly during travel.
15SDMA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH Occurrence condition 4

After engine is started,
15SEL1 Occurrence condition 7 Escape procedure 1 D – L: F1 gear is kept in neutral
15SEMA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH and machine does not
start when lever is oper-
15SFL1 Occurrence condition 7 Escape procedure 1 D – L: F2 ated.
15SFMA Occurrence condition 7 Escape procedure 1 D – L: F1, R: RH
Occurrence condition 5
15SGL1 Occurrence condition 7 Escape procedure 1 D – L: F4 Lever responds abnor-
mally and does not work.
15SGMA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH
If lever is operated, gear
15SHL1 Occurrence condition 7 Escape procedure 1 D – L: F6 is set in neutral.
15SHMA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH Occurrence condition 6

15SJMA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH Gear speed is kept fixed
and gear is not shifted
If display becomes normal, machine from fixed gear after
DAQOKK Occurrence condition 1 Escape procedure 5
can travel normally (Note 1). machine restarts. If
If display becomes normal, machine lever is set to N position,
DAQ2KK Occurrence condition 1 Escape procedure 4
can travel normally (Note 1). gear is set in neutral but
DAQ9KQ Occurrence condition 4 Escape procedure 6 — cannot be shifted any
more.
If display becomes normal, machine
DAQRKR Occurrence condition 2 Escape procedure 5
can travel normally (Note 1). Occurrence condition 7
DAQRMA Occurrence condition 4 Escape procedure 1 D – L: F2, R: RH Proper clutch for travel is
used and gear speed is
DB2RKR Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
fixed. If there is not
DDTHKA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH proper clutch, gear is set
in neutral. If lever is set
DDTJKA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RL to N position, gear is set
DDTKKA Occurrence condition 1 Escape procedure 1 D – L: F1 in neutral.
DDTLKA Occurrence condition 1 Escape procedure 1 D – L: F2

Note 1
DDTMKA Occurrence condition 1 Escape procedure 1 D – L: F4
Even if trouble disap-
DDTNKA Occurrence condition 1 Escape procedure 1 R: RH pears, gear is kept in
neutral until lever is set
DDTPKA Occurrence condition 1 Escape procedure 1 D – L: F6 to N position once
HD785-7 49
Failure Condition Starting gear speed set with lever

Escape method Remarks
code whentrouble occurred position after escape operation
If display becomes normal, machine
DF10KA Occurrence condition 5 Escape procedure 7
can travel normally (Note 1). See the "Remarks" of
If display becomes normal, machine a front page
DF10KB Occurrence condition 5 Escape procedure 7
can travel normally (Note 1).
DLF1KA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DLF1LC Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DLF2KA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DLF2LC Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DLT3KA Occurrence condition 6 Escape procedure 3 D – L: F2, R: RH
DXH1KA Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DXH1KB Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DXH1KY Occurrence condition 1 Escape procedure 1 D – L: F2, R: RH
DXH2KA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL
DXH2KB Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL
DXH2KY Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH
DXH3KY Occurrence condition 7 Escape procedure 1 D – L: F2, R: RL
DXH4KY Occurrence condition 7 Escape procedure 1 D – L: F1
DXH7KA Occurrence condition 7 Escape procedure 1 D – L: F2
DXH7KB Occurrence condition 7 Escape procedure 1 D – L: F2
DXH7KY Occurrence condition 7 Escape procedure 1 R: RH
DXHHKA Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH
DXHHKB Occurrence condition 7 Escape procedure 1 D – L: F2, R: RH
DXHHKY Occurrence condition 7 Escape procedure 1 D – L: F6
50 HD785-7
Escape procedure 1:
1. Stop traveling and return the gearshift lever to
the "N" position.
2. Operate the gearshift lever again and move the
machine OFF.
a When operating the gearshift lever, release
the accelerator pedal.
a N o D – L or N o R
Escape procedure 2:
Tow the machine.
a If the engine cannot be started and the machine
is towed, the parking brake cannot be released
by operating the switch, so carry out the opera-
tion to release it temporarily. For details, see
"Method for emergency release of parking
brake"
Escape procedure 3:
1. Stop traveling and return the gearshift lever to
the "N" position.
2. Disconnect and connect emergency escape
connector A1 (female and male), and switch to
the emergency escape mode.
a Connector A1 (female and male) is installed
to near the fuse box.
a Connect and disconnect the connectors with
the starting switch at ON or with the engine
started.
3. Operate the gearshift lever again and move the
machine OFF.
a When operating the gearshift lever, release
the accelerator pedal.
a N o D – L or N o R
a The emergency escape mode is maintained
until the starting switch is turned OFF.
Escape procedure 4:
Check the circuit breaker and fuse. If they are nor-
mal, replace the transmission controller.
q Circuit breaker: No. 64 "FUB2" No. 65 (80 A)
q Fuse: BT3-No. 14 (10 A)
Escape procedure 5:
Check the circuit breaker and fuse. If they are nor-
mal, replace the transmission controller.
q Circuit breaker: "FUA2" (30 A)
Escape procedure 6:
Check the model selection setting. If it is normal,
see adjustment of transmission controller.
Escape procedure 7:
Check the fuse. If it is normal, replace the gearshift
lever.
HD785-7 51
HD785-7 Dump truck
©2010 KOMATSU
All Rights Reserved
52 HD785-7
SEN01772-03
HD785-7
SEN01772-02
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Setting and adjusting of devices ................................................................................................................. 2
HD785-7 1
Setting and adjusting of devices

Items to be set or adjusted after replacement, disassembly, assembly or additional installation of con-
trollers or sensors
a If any of the following devices or parts is replaced, disassembled, assembled or installed additionally, carry
out the necessary setting and adjusting.
Device/Option replaced,
disassembled,
Necessary setting/adjusting
assembled or installed
additionally
Setting of model selection (See 1-1 of this section)
Setting of option selection (See 1-2 of this section)
Setting of machine monitor (corrosion resistor) in OFF (See 1-3 of this section)
Machine monitor
Deletion of information of electrical equipment system fault history (See *2-1)
Setting of service meter (See *3-1)
Setting of reverse odometer (See *3-2)
Adjusting of transmission ECMV current (See *2-2)
Transmission
Resetting and execution of transmission initial learning (See *2-2)
Transmission controller Adjusting of transmission ECMV current (See *2-2)
Adjusting of transmission ECMV current (See *2-2)
Transmission ECMV solenoid
Retarder controller Setting of option selection (See 1-2 of this section)
Body positioner sensor
Adjusting of body positioner sensor (See *2-3)
Body positioner rod
VHMS Initialization procedure for VHMS controller
ORBCOMM controller Setting of ORBCOMM
Payload meter in VHMS
Initialization procedure for VHMS controller
Optional device Setting of option selection
*2-1: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([10] Elec-
trical equipment system fault history display function).
*2-2: For the setting and adjusting procedure, see "Special functions of machine monitor (EMMS)" ([15] Ad-
justing function).
*2-3: For the setting and adjusting procedure, see "Adjusting of body positioner".
*3-1: For the setting and adjusting procedure, see Service News (AT06310).
*3-2: For the setting and adjusting procedure, see Service News (AT06310).
2 HD785-7
1-1. Setting of model selection 4) Displaying service menu selection screen

1. Switching to service mode After confirming all ID’s of 4 digits, display the
1) Confirming the screen display service menu selection screen in the service
Check that the machine monitor is in oper- mode.
ator mode and the screen is displaying either a By inputting and determining the ID once,
the "service meter and integrated odometer", it will be effective until the starting switch
"action code" or "failure code". is turned OFF.
2) Displaying ID input screen
Press the following 2 switches at the same
time for longer than 5 seconds to display the
ID input screen.
q [t] switch and [<] switch
a If the switch is pressed for longer than 5
seconds, the character display section
becomes blank. After confirming this on-
dition, release the switch.
2. Selecting and determining service menu

1) When pressing the [>] switch or [<] switch in
the service menu selection screen, the
service menu is displayed endlessly in the
order shown in the below table, so select the
model selection function (MACHINE).
q [>]: To proceed to next service menu.
q [<]: To return to previous service menu.
3) Input and determination of ID a Displayed service menu:
After displaying ID input screen, operate [>], Display Function
[<], [U], and [t] switch to input 4 digits ID. ELECTRIC Electrical system failure history dis-
a ID: 6491 FAULT play function
q [>]: Number at the cursor increases. MACHINE Mechanical system failure history dis-
q [<]: Number at the cursor decreases FAULT play function
REAL-TIME
q [U]: Number at the cursor is determined Real-time monitoring function
MONITOR
q [t]: Cursor moves to left end or the dis-
CYLINDER
play returns to operator mode screen. Reduced cylinder mode function
CUT-OUT
a If the ID input screen is left without switch NO INJECTION No injection cranking function
operation for longer than 60 seconds, it TUNING Adjusting function
automatically returns to the operator MAINTENANCE Filter and oil replacement time setting
mode screen. MONITOR function
OPERATION Operation information display func-
INFO tion
FIX POWER
Engine mode fixing function
MODE
SNAPSHOT Manual snap shot function
PLM PLM (Payload meter) setting function
OPTIONAL
Option selection function
SELECT
MACHINE Model selection function
Initialize function
INITIALIZE
(exclusive function for factory)
HD785-7 3
a As for the use of the service menu, be- 3. Selecting and setting of model
sides model selection function, option se- 1) When pressing the [>] switch or [<] switch in
lection function, and filter and oil the model selection setting screen, the model
replacement time setting function (part of which can be set is displayed endlessly in the
function), refer to the section of "Special order shown in the below table, so select the
function of machine monitor". applied model.
a In the "*" part, the model presently set is q [>] switch: To proceed to next model
displayed. q [<] switch: To return to previous model
a Even if the model presently set is correct, a Displayed model:
be sure to carry out the setting newly. Display Model
HD785 HD785-7
HD605 HD605-7E0
HD465 HD465-7E0
HD405 HD405-7
HD325 HD325-7
2) After selecting the model in the model

selecting screen, determine the model by
pressing the [U] switch.
q [U]: Determine the setting.
q [t]: To cancel the setting
a The below figure shows the example that
HD785-7 has been selected.
2) After selecting the model selection function,

press [U] switch for longer than 5 seconds
and display the model selection setting
screen.
q [U]: Conduct the service menu.
a Press [U] switch for longer than 5 sec-
onds, otherwise it will not change to mod-
el selection setting screen.
a In the model selection setting screen, dis-
play only the model to be set at the [*]
part.
4 HD785-7
4. Storing data in controller

1) After determining the model selection setting,
check that the display automatically returned
to the service menu screen and the selected
model is surely displayed.
2) Turn the starting switch OFF and keep that

condition for longer than 15 seconds.
a Unless the starting switch is turned off for
longer than 15 seconds, the new data is
not memorized in the controller.
3) Turn the starting switch ON again.
a After this operation the model setting be-
comes effective.
5. Carrying out option setting

If once carrying out the model selection setting,
all setting of option selection is reset, so continue
to carry out the setting of option selection.
a Refer to section "1-2. Setting of option selec-
tion".
HD785-7 5
1-2. Setting of option selection

a Item list of option selection function
Item Display Code Default setting Contents of selection
Exhaust brake EXH BRAKE 01 Not added (NO ADD) If exhaust brake is installed, select ADD.
ARSC ARSC 02 Added (ADD) If ARSC is installed, select ADD.
ASR ASR 03 Not added (NO ADD) If ASR is installed, select ADD.
ABS ABS 04 Not added (NO ADD) If ABS is installed, select ADD.
Auto-suspension AURTO SUS 05 Added (ADD) If auto-suspension is installed, select ADD.
Select from following.
q VHMS is not installed: [NON]
VHMS/PLM VHMS/PLM 07 VHMS+PLM
q Only VHMS: [VHMS]
q VHMS + Built-in PLM: [+PLM]
― ― 09 E1 Selecting operation is prohibited (Fixed to E1).
― ― 10 Not added (NO ADD) Selecting operation is prohibited (Fixed to NO ADD).
Set speed correction quantity for tire size.
HD785-7 (27.00R49aa) : 0 %
HD785-7 (31/90R49-E4) : -1 %
Tire size correction TIER SIZE 12 0% q If speedometer reading is not correct, adjust it
with this item.
q If setting is increased by 1%, reading is increased
by 1% at 0%.
If inclinometer (machine lateral inclination sensor) is
Inclinometer INCLINOMET 13 Added (ADD)
installed, select ADD.
Set unit of speed as follows.
q When MPH is used: MPH
Unit selection
SPEED (UNIT) 15 MPH q When km/h is used: km/h
(MPH/km/h)
a This item is not displayed for SI specification.
a Do not change this setting, basically.
Maintenance
SENSOR 19 Not added (NO ADD) If maintenance sensor is installed, select ADD.
sensor
Prelube PRELUBE 20 Not added (NO ADD) If pre-lubrication controller is installed, select ADD.
High altitude set- Selection operation is prohibited.
ALTITUDE (M) 21 TO 2350
ting selection (TO 2350 is selected for standard specification)
1. Switching to service mode

Switch to the service mode by referring to "1-1.
Setting of model selection".
2. Selecting and carrying out service menu

1) Select the optional selection function
(OPTIONAL SELECTION) in the service
menu selection screen by referring to "1-1.
Setting of model selection".
6 HD785-7
2) After selecting the optional selection func- a Perform after checking that the model has
tion, press [U] switch for longer than 5 been set.
seconds and display the setting screen for a Always check all the items.
the optional item selection. a Settle the first item by pressing the [U]
q [U]: Conduct the service menu. switch twice, even if the current setting is
a Press [U] switch for longer than 5 sec- correct (to transmit the information to the
onds, otherwise it will not change to op- other controllers).
tional item selection screen. a After setting, be sure to turn the starting
a The setting status of that optional item is switch OFF and wait for 15 seconds to
displayed at the left of the lower row. settle the memory of each controller.
q ADD: Option is set.
q NO ADD: Option is not set. 3. Setting of ARSC (02: ARSC)
1) While the optional item selection screen is
displayed, select ARSC (02: ARSC).
a The current setting condition is displayed
on the left side of the lower line.
q ADD: ARSC is set.
q NO ADD: ARSC is not set.
3) When pressing the [>] switch or [<] switch in

the option item selection screen, the optional
item is displayed endlessly in the order
shown in the below table, so select the
necessary item.
a Be sure to start setting of optional func-
tions from code No. 01. 2) Check the installation condition of ARSC and
q [>]: To proceed to next option item. setting condition on the screen and press the
q [>]: To return to previous option item. [U] switch to settle the setting.
a Displayed option items: q [U]: Change setting (Display changes).
Display Check item q [t]: Return to optional item selection
01: EXH BRAKE Exhaust brake screen.
02: ARSC ARSC q ADD: Set option.
03: ASR ASR
q NO ADD: Set no option.
04: ABS ABS
05: AUTO SUS Auto-suspension a If the setting is settled with the [U] switch,
07: VHMS/PLM VHMS/PLM it is effective even after this screen is
09: ― ― turned OFF.
10: ― ―
11: ― ―
12: TIRE SIZE Tire size correction
13: INCLINOMET. Inclinometer
Speed unit selection
15: SPEED (UNIT)
(Do not change, basically)
16: ― ―
19: SENSOR Maintenance sensor
20: PRELUBE Prelube
21: ALTITUDE (M) High altitude setting selection
HD785-7 7
4. Setting of ASR (03: ASR) 5. Setting of ABS (04: ABS)

1) While the optional item selection screen is 1) While the optional item selection screen is
displayed, select ASR (03: ASR). displayed, select ABS (04: ABS).
a The current setting condition is displayed a The current setting condition is displayed
on the left side of the lower line. on the left side of the lower line.
q ADD: ASR is set. q ADD: ABS is set.
q NO ADD: ASR is not set. q NO ADD: ABS is not set.
2) Check the installation condition of ASR and 2) Check the installation condition of ABS and
setting condition on the screen and press the setting condition on the screen and press the
[U] switch to settle the setting. [U] switch to settle the setting.
q [U]: Change setting (Display changes). q [U]: Change setting (Display changes).
q [t]: Return to optional item selection q [t]: Return to optional item selection
screen. screen.
q ADD: Set option. q ADD: Set option.
q NO ADD: Set no option. q NO ADD: Set no option.
a If the setting is settled with the [U] switch, a If the setting is settled with the [U] switch,
it is effective even after this screen is it is effective even after this screen is
turned OFF. turned OFF.
8 HD785-7
6. Setting of auto-suspension (05: AUTO SUS) 7. Setting of VHMS/PLM (07: VHMS/PLM)

displayed, select the auto-suspension (05: displayed, select VHMS/PLM (07: VHMS/
AUTO SUS). PLM).
q ADD: Auto-suspension is set. q NON: VHMS/PLM is not set.
q NO ADD: Auto-suspension is not set. q VHMS: Only VHMS is set.
q +PLM: VHMS + PLM are set.
2) Check the installation condition of the

auto-suspension and setting condition on the 2) Check the installation condition of VHMS/
screen and press the [U] switch to settle the PLM and setting condition on the screen and
setting. press the [U] switch to settle the setting.
screen. screen.
q ADD: Set option. q NON: Set no option.
q NO ADD: Set no option. q VHMS: Set VHMS.
a If the setting is settled with the [U] switch, q +PLM: Set VHMS + PLM.
it is effective even after this screen is a If the setting is settled with the [U] switch,
turned OFF. it is effective even after this screen is
turned OFF.
HD785-7 9
8. Setting of tire size compensation (12: TIRE 9. Setting of inclinometer (13: INCLINOMET.)
SIZE) 1) While the optional item selection screen is
1) Select the tire size compensation (12: TIRE displayed, select the inclinometer (13: INCLI-
SIZE) in the option item selection screen. NOMET.).
a The present compensation value is dis- a The current setting condition is displayed
played at the left of the lower row. on the left side of the lower line.
***%: Rate of change from standard tire q ADD: Inclinometer is set.
q NO ADD: Inclinometer is not set.
2) For changing the compensation value, press

the [U] switch to display the compensation 2) Check the installation condition of the incli-
value input screen. nometer and setting condition on the screen
q [U]: To change compensation value. and press the [U] switch to settle the setting.
3) After displaying the compensation value q [U]: Change setting (Display changes).
input screen, operate each of the switches q [t]: Return to optional item selection
[>], [<], [U] and [t] to input the compensa- screen.
tion value directly. q ADD: Set option.
q [>]: To switch the cursor symbol (+/-); To q NO ADD: Set no option.
increase number. a If the setting is settled with the [U] switch,
q [<]: To switch the cursor symbol (+/-); To it is effective even after this screen is
decrease number. turned OFF.
q [U]: To determine compensation value.
q [t]: Cursor moves to left end/To return to
optional item selection screen.
a The compensation value at the plant be-
fore shipment is [+/- 00%] (In case of in-
putting 00, +/- does not matter.)
a The compensation value can be input
within the range of [-10 % ― +10 %].
10 HD785-7
10. Setting of maintenance sensor (19: SENSOR.) 11. Setting of prelube (20: PRELUBE)
displayed, select themaintenance sensor displayed, select the prelube (20:
(19: SENSOR.). PRELUBE).
q ADD: Maintenance sensor is set. q ADD: Auto-suspension is set.
q NO ADD: Maintenance sensor is not set. q NO ADD: Auto-suspension is not set.
2) Check the installation condition of the mait- 2) Check the installation condition of the
enance sensor function and setting condition prelube controller and setting condition on
on the screen and press the [U] witch to the screen and press the [U] switch to settle
settle the setting. the setting.
screen. screen.
q ADD: Set option. q ADD: Set option.
q NO ADD: Set no option. q NO ADD: Set no option.
a If the setting is settled with the [U] switch, a If the setting is settled with the [U] switch,
it is effective even after this screen is it is effective even after this screen is
turned OFF. turned OFF.
HD785-7 11
12. Storing data in controller

1) Check that the setting for all items has been
completed in the sub menu screen for the
optional item selection function.
2) Turn the starting switch OFF and keep that
condition for longer than 15 seconds.
a Unless the starting switch is turned off for
longer than 15 seconds, the new data is
not memorized in the controller.
3) Turn the starting switch ON again.
a After this operation the option setting be-
comes effective.
1-3. OFF setting of maintenance monitor (corro-

sion resistor) 2) When pressing the [>] switch or [<] switch in
1. Switching to service mode the maintenance item selection screen, the
Switch to the service mode by referring to "1-1. maintenance item is displayed endlessly in
Setting of model selection". the order shown in the below table, so select
the corrosion register (06: CORR RES).
2. Selecting and carrying out service menu q [>]: To proceed to next maintenance item.
1) Select the filter and oil replacement time q [<]: To return to previous maintenance
setting function (MAINTENANCE item.

MONITOR) in the service menu selection a Displayed maintenance items:
screen referring to "1-1. Setting of model Display Maintenance items and functions
selection". 41: FUEL P FILT Fuel pre filter
01: ENG OIL Engine oil
02: ENG FILT Engine oil filter
13: TM FILT Transmission oil filter
03: FUEL FILT Fuel main filter
06: CORR RES Corrosion resistor
Torque convertor/Transmission/
24: TC/TM/BK OIL
Brake oil
14: BK OIL FILT Brake oil filter
16: BK C FILT Brake cooling oil filter
04: HYD FILT Hydraulic oil filter
11: DIFF OIL Differential oil
08: FNL OIL Final drive oil
10: HYD OIL Hydraulic oil
INTIALIZE Setting default value for all items
Setting validity or invalidity for all
ALL ITEMS
items
3. Displaying and selecting of maintenance item a As for the use of maintenance items be-
sides the corrosion register, refer to the
1) While the filter and oil replacement time
section "Special function of machine
setting function is selected, display the main-
monitor".
tenance item selection screen by pressing
the [U] switch.
12 HD785-7
4. OFF setting of corrosion register item 4) After displaying the setting change screen,
1) With the corrosion register selected, press operate [>], [<], and [t] switch to determine
the [U] switch and display the interval OFF setting.
change screen. q [<]: Select YES (move cursor)
q [U]: To carry out interval change. q [>]: Select NO (move cursor)
q [t]: To determine selection.
2) After displaying the interval change screen,

press the [>] or [<] switch further and display
the setting screen for validity or invalidity.
q [>]: Change the displayed screen
q [<]: Change the displayed screen
a If the present setting is ON, the screen
displays as above, and if the present set-
ting is OFF, it displays as below.
a The default setting of the machine moni-
tor is ON (above).
a If the present setting is ON (above), carry
out the further operation to change the
setting to OFF.
a If the present setting is OFF (below),
press the [t] switch to complete the set-
ting.
3) In order to change the present setting from

ON to OFF, press the [U] switch to display
the setting change screen.
q [U]: Change setting.
HD785-7 13
HD785-7 Dump truck
©2009 KOMATSU
All Rights Reserved
14
SEN01773-03
HD785-7
SEN01773-02
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Special functions of machine monitor (EMMS) ........................................................................................... 2
HD785-7 1
Special functions of machine monitor (EMMS)

a EMMS: Equipment Management Monitoring System
Normal functions and the special functions of machine monitor (EMMS)

The machine monitor is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the machine monitor. The display items are divided by the
internal setting of the machine monitor (EMMS), into automatic display items and items displayed when the
machine monitor switches are operated.
1. Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the oper-
ator operating the switches.
2. Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
2 HD785-7
Operator mode Service mode

Service meter, odometer display function (default)
1 11 Electric system fault history display function
(*1)
Dump counter display function (when option is
2 12 Mechanical system fault history display function
selected)
3 Reverse travel distance display function 13 Real-time monitoring function
Filter replacement, oil change interval display func-
4 14 Reduced cylinder mode
tion
5 Telephone number input function 15 No-injection cranking function
6 Language selection function io 16 Adjustment function
7 Reverse RL, RH switching function 17 Filter replacement, oil change interval display function
8 PLM setup function 18 Operation information display function
9 Action code display function 19 Engine mode fixing function
10 Failure code display function 20 Manual snapshot function
*1: PLM (payload meter) display function when receiv- 21 PLM setting function (when option is selected)
ing VHMS data
22 Option selection function
23 Model selection function
24 Initialize function (factory use only)
HD785-7 3
Function and flow of each mode
*1: Applicable only when VHMS is installed.

*2: Applicable only when PLM built in VHMS is installed.
4 HD785-7
Operator mode Character display portion

a No. 2 – No. 8 is displayed endlessly by following 16 characters can be displayed on each upper and
the switch operation. lower row of the character display section, and de-
a When a failure occurs, the screen changes auto- pending on the contents displays the combination of
matically to No. 9 regardless of the displayed the next figures, letters, and symbols.
screen. 1. Arabic numbers: 1, 2, 3, . . .
a If the switch is not operated for over 30 seconds 2. Small letters: a, b, c, . . .
regardless of the display screen, the screen au- 3. Capital letters: A, B, C, . . .
tomatically;
4. Katakana: A, I, U, . . . (Only for Japanese
q Changes to No. 1.
display)
(If malfunction has not occurred.)
5. Symbols: @, ?, $, . . .
q Changes to No. 9.
(If malfunction has occurred.) 6. Special letters:
a After moving from No. 10 to No. 1 by the switch
operation, if no switch operation is performed for
longer than 10 seconds, then it automatically
moves to No. 9.
Service mode
a No. 11 – No. 14 is displayed endlessly by follow-
ing the switch operation.
a By inputting and determining the ID once, it will
be effective until the starting switch is turned off.
Control switch section

All the display operation of the machine monitor is
operated by the machine monitor mode selector
switches (1) and (2).
Each switch of [U], [t], [>], [<] is assigned to the fol-
lowing function.
1. U: Determine and execute
2. t: To cancel, release, and determine
(only YES and NO screen)
3. >: To right, to next, to proceed, to increase
(only when inputting Arabic numbers)
4. <: To left, to previous, to return, to decrease
(only when inputting Arabic numbers)
HD785-7 5
tOperator mode (Outline) [3] Integrated reverse travel odometer display

function
[1] Service meter and integrated odometer dis- Machine monitor displays the integrated reverse
play function travel odometer by operating the switch.
When turning the starting switch ON, the speed me- a For details, see operation manual.
ter and integrated odometer are displayed in the up-
per and lower row respectively.
a For details, see operation manual.
[4] Filter and oil replacement time display func-

tion
1. Replacement time display of filter and oil
[2] Dump counter display function (displayed automatically)
(When option is selected) When the replacement interval for the various
Display the dump counter by operating the machine filters or oils approaches, the machine monitor
monitor switch. automatically displays the information to remind
a Dump counter is displayed only when the option an operator of maintenance.
selection is set to be effective in the service
mode.
6 HD785-7
2. Reset of replacement time (selection menu) [6] Language selection function

The machine monitor can reset the interval time Display language of the machine monitor can be se-
by operating the switch, if various filters and oils lected with the switch operation.
maintenances are finished. a The Service mode function is not included in the
a For details, see operation manual. display selection function, therefore always dis-
a Replacement interval time setting can be op- played in English.
erated by the filter and oil replacement time a For details, see operation manual.
setting function in the service mode.
[7] Reverse RL, RH switching function

[5] Phone No. input function Reverse RL or RH can be switched with the switch
Phone No. set in the machine monitor can be input- operation.
ted, corrected, and released by the switch opera- a For details, see operation manual.
tion.
a Phone No. is displayed together with "CALL"
when action code "E03" is displayed.
[8] PLM setting function (when option is select-

ed)
This function sets and displays the payload meter.
a For details, see Operation and Maintenance
Manual.
HD785-7 7
[9] Action code display function [10] Failure code display function
When abnormal situations occur, the machine mon- By pressing the [>] switch once while the action
itor automatically displays the action code depend- code is displayed on the machine monitor, the pres-
ing on the extent of the abnormality in order to ent failure code is displayed.
remind the operator of proper remedy. q [>]: To display failure code.
a Below figure shows the example of displaying
action code "E03" and "CALL + phone No." alter-
nately.
a "CALL + phone No." is not displayed if the action
code "E01" or "E02" is displayed.
a The failure codes which have been detected in

the past are separated into electrical and me-
chanical systems and recorded as failure history
(refer to service mode for a detail).
a If there are several failures, other failure codes
are displayed by pressing the [>] switch.
a Action code and remedy requested for an oper- a After displaying all the failure codes by pressing
ator the [>] switch, press [>] switch further to return to
Action CALL + the service meter and integrated odometer dis-
Remedy requested for operator
code phone No. play screen.
q Carry out test and mainte- Press the [>] switch again, and the failure code
E01 None nance when operation is fin- is displayed from the beginning.
ished or operator is changed. a If there is no switch operation for longer than 10
q If related to an over run is dis-
seconds in the service meter and integrated
played: Travel keeping the en-
gine speed and machine odometer display screen, it automatically switch-
speed down. es to the action code display screen.
E02 None
q If related to an overheat is dis- a The following information is displayed in the ser-
played: Stop machine and vice code display function.
keep engine with no-load me- A: Failure code (4-digits device code + 2-digits
dium speed running. symptom code)
q Stop the engine and machine B: Controller code
E03 Yes immediately and contact the MON: Machine monitor
service personnel. ENG: Engine controller
TM: Transmission controller
BK: Retarder controller
PLM: PLM function system of VHMS
controller (when option is selected)
ABS: ABS controller
(when option is selected)
C: Trouble occurring system
8 HD785-7
a Refer to "Failure code table" for details of dis-

played failure codes.
a Be careful of the partial difference in the dis-
played information for the failure code display
function and the failure history display function
(service mode).
HD785-7 9
Failure code table

Failure Applicable Action History
Failure contents
codes equipment code classification
1500L0 Detection of double engagement TM E03 Mechanical system
15B0NX Clogging of transmission oil filter TM E01 Mechanical system
15F0KM Abuse 1 of gear shifting from reverse to forward TM — Mechanical system
15F0MB Abuse 2 of gear shifting from reverse to forward TM — Mechanical system
15F7KM Abuse of transmission forward clutch disk TM — Mechanical system

Trouble in reverse clutch system
15G0MW TM E03 Electrical system
(command holding pressure, fill ON, detection of slip)
15G7KM Abuse of transmission reverse clutch disk TM — Mechanical system
Trouble in high clutch system
15H0MW TM E03 Electrical system
Trouble in low clutch system
15J0MW TM E03 Electrical system
Trouble in 1st clutch system
15K0MW TM E03 Electrical system
Trouble in 2nd clutch system
15L0MW TM E03 Electrical system
Trouble in 3rd clutch system
15M0MW TM E03 Electrical system
Trouble in 4th clutch system
15N0MW TM E03 Electrical system
Trouble I in reverse clutch pressure control valve
15SBL1 TM E03 Electrical system
(command OFF, fill ON)
Trouble II in reverse clutch pressure control valve
15SBMA TM E03 Electrical system
(command holding pressure, fill OFF, detection of slip)
Trouble I in high clutch pressure control valve
15SCL1 TM E03 Electrical system
Trouble II in high clutch pressure control valve
15SCMA TM E03 Electrical system
Trouble I in low clutch pressure control valve
15SDL1 TM E03 Electrical system
Trouble II in low clutch pressure control valve
15SDMA TM E03 Electrical system
Trouble I in 1st clutch pressure control valve
15SEL1 TM E03 Electrical system
Trouble II in 1st clutch pressure control valve
15SEMA TM E03 Electrical system
Trouble I in 2nd clutch pressure control valve
15SFL1 TM E03 Electrical system
Trouble II in 2nd clutch pressure control valve
15SFMA TM E03 Electrical system
Trouble I in 3rd clutch pressure control valve
15SGL1 TM E03 Electrical system
Trouble II in 3rd clutch pressure control valve
15SGMA TM E03 Electrical system
Trouble I in 4th clutch pressure control valve
15SHL1 TM E03 Electrical system
Trouble II in 4th clutch pressure control valve
15SHMA TM E03 Electrical system
Trouble II in lockup clutch pressure control valve
15SJMA TM E03 Electrical system
(command holding pressure, detection of slip)
2C4MNX Clogging of retarder cooling oil filter BK E01 Electrical system
2D01CA Wear of brake (Front right) BK E01 Mechanical system
2D02CA Wear of brake (Front left) BK E01 Mechanical system
10 HD785-7

Failure contents
2D05CA Wear of brake (rear right) BK E01 Mechanical system
2D06CA Wear of brake (rear left) BK E01 Mechanical system
2F00KM Dragging of parking brake TM — Mechanical system
2G42ZG Lowering of accumulator oil pressure (front) TM E03 Mechanical system
2G43ZG Lowering of accumulator oil pressure (rear) TM E03 Mechanical system
6014NX Clogging of hydraulic oil filter BK E01 Mechanical system

Operation of engine overrun prevention device
989A00 (Note: Information is obtained from transmission controller MON E02 Mechanical system
and failure code is displayed on monitor panel)
Inclination alarm (Raising body while machine is inclined)
989D00 (Note: Information is obtained from transmission controller MON — Mechanical system
and failure code is displayed on monitor panel)
A570NX Clogging of engine oil filter BK E01 Mechanical system
AA10NX Clogging of air cleaner TM E01 Mechanical system

Alternator: Failure on battery charge circuit
AB00L4 PLC E01 Electrical system
(R terminal signal is present and engine is stopped)
AB00MA Trouble in battery charge circuit (No R-terminal signal) TM E03 Electrical system
Alternator: Failure on battery charge circuit
AB00MB PLC E01 Electricalsystem
(Absence of R terminal signal and detection error)
B@BAZG Lowering of engine oil pressure ENG E03 Mechanical system
B@BAZK Lowering of engine oil level BK E01 Mechanical system
B@BCNS Overheating of engine ENG E02 Mechanical system
B@BCZK Low coolant level alarm TM E01 Mechanical system
B@BFZK Lowering of fuel level MON — Mechanical system
B@C6NS Brake cooling oil overheat (Front) MON E02 Mechanical system
B@C7NS Overheating of brake cooling oil (rear) MON E02 Mechanical system
B@CENS Overheating of torque converter oil MON E02 Mechani cal system
B@GAZK Lowering of battery electrolyte level BK E01 Mechanical system
B@JANS Overheating of steering oil TM E02 Mechanical system
CA111 Abnormality in engine controller ENG E03 Electrical system
CA115 Abnormality in engine Ne/Bkup speed sensor ENG E03 Electrical system
CA122 Abnormally high level of charge pressure sensor ENG E03 Electrical system
CA123 Abnormally low level of charge pressure sensor ENG E03 Electrical system
CA131 Abnormally high level of throttle sensor ENG E03 Electrical system
CA132 Abnormally low level of throttle sensor ENG E03 Electrical system
CA135 Abnormally high level of oil pressure sensor ENG E01 Electrical system
CA141 Abnormally low level of oil pressure sensor ENG E01 Electrical system
CA144 Abnormally high level of coolant temperature sensor ENG E01 Electrical system
HD785-7 11

Failure contents
CA145 Abnormally low level of coolant temperature sensor ENG E01 Electrical system
CA153 Abnormally high level of charge temperature sensor ENG E01 Electrical system
CA154 Abnormally low level of charge temperature sensor ENG E01 Electrical system
CA187 Abnormally low level of sensor power supply 2 ENG E03 Electrical system
Abnormally high level of engine oil temperature sensor
CA212 ENG E01 Electrical system
(for VHMS)
Abnormally low level of engine oil temperature sensor
(for VHMS)
CA221 Abnormally high level of ambient pressure sensor ENG E01 Electrical system
CA222 Abnormally low level of ambient pressure sensor ENG E01 Electrical system
CA227 Abnormally high level of sensor power supply 2 ENG E03 Electrical system
CA234 Overspeed of engine ENG E02 Mechanical system
CA238 Abnormality in Ne speed sensor power supply ENG E03 Electrical system
CA263 Abnormally high level of fuel temperature sensor ENG E01 Electrical system
CA265 Abnormally low level of fuel temperature sensor ENG E01 Electrical system
CA271 Short circuit in PCV1 ENG E03 Electrical system
CA272 Disconnection in PCV1 ENG E03 Electrical system
CA273 Short circuit in PCV2 ENG E03 Electrical system
CA274 Disconnection in PCV2 ENG E03 Electrical system

Disconnection or short circuit in injector #1 (left bank #1)
system
system
system
system
system
system
CA342 Abnormality in matching of engine controller data ENG E03 Electrical system
CA351 Abnormality in injector drive circuit ENG E03 Electrical system
CA352 Abnormally low level of sensor power supply 1 ENG E03 Electrical system
CA386 Abnormally high level of sensor power supply 1 ENG E03 Electrical system
CA431 Abnormality in idle validation switch ENG E01 Electrical system
CA432 Abnormality in idle validation setting ENG E03 Electrical system
CA441 Abnormally low level of source voltage ENG E03 Electrical system
CA442 Abnormally high level of source voltage ENG E03 Electrical system
CA449 Abnormality 2 in common rail high pressure ENG E03 Electrical system
CA451 Abnormally high level of common rail pressure sensor ENG E03 Electrical system
12 HD785-7

Failure contents
CA452 Abnormally low level of common rail pressure sensor ENG E03 Electrical system
CA553 Abnormality 1 in common rail high pressure ENG E03 Electrical system
CA554 In-range trouble of common rail pressure sensor ENG E03 Electrical system
CA559 Lowering 1 of supply pump pressure ENG E03 Electrical system
CA689 Abnormality in engine Ne speed sensor ENG E03 Electrical system
CA691 Intake air temperature sensor abnormally high level ENG E01 Electrical system
CA692 Intake air temperature sensor abnormally low level ENG E01 Electrical system
CA731 Abnormality in engine Bkup speed sensor phase ENG E03 Electricalsystem
CA757 Loss of all engine controller data ENG E03 Electrical system
CA778 Abnormality in engine Bkup speed sensor ENG E03 Electrical system
CA781 Inter-multicontroller communication error ENG E03 Electrical system
CA1257 Multicontroller distinction wiring harness key error ENG E03 Electrical system
CA1633 Abnormality in KOMNET ENG E03 Electrical system
CA2185 Abnormally high level of throttle sensor power supply ENG E03 Electrical system
CA2186 Abnormally low level of throttle sensor power supply ENG E03 Electrical system
CA2249 Lowering 2 of supply pump pressure ENG E03 Electrical system
CA2555 Abnormally low level of intake air heater relay voltage ENG E01 Electrical system
CA2556 Abnormally high level of intake air heater relay voltage ENG E01 Electrical system
CB111 Engine controller internal abnormality (Right bank) ENG E03 Electrical system
CB115 Engine Ne/Bkup speed sensor abnormality (Right bank) ENG E03 Electrical system
CB187 Sensor power supply (2) abnormally low level (Right bank) ENG E03 Electrical system
CB227 Sensor power supply (2) abnormally high level (Right bank) ENG E03 Electrical system
CB238 Ne speed sensor power supply abnormality (Right bank) ENG E03 Electrical system
CB263 Fuel temperature sensor abnormally high level (Right bank) ENG E01 Electrical system
CB265 Fuel temperature sensor abnormally low level (Right bank) ENG E01 Electrical system
CB271 PCV1 short circuit (Right bank) ENG E03 Electrical system
CB272 PCV1 disconnection (Right bank) ENG E03 Electrical system
CB273 PCV2 short circuit (Right bank) ENG E03 Electrical system
CB274 PCV2 disconnection (Right bank) ENG E03 Electrical system
CB342 Engine controller data mismatch (Right bank) ENG E03 Electrical system
CB351 Injector drive circuit abnormality (Right bank) ENG E03 Electrical system
CB352 Sensor power supply 1 abnormally low level (Right bank) ENG E03 Electrical system
CB386 Sensor power supply 1 abnormally low high (Right bank) ENG E03 Electrical system
HD785-7 13

Failure contents
CB441 Power supply voltage abnormally low level (Right bank) ENG E03 Electrical system
CB442 Power supply voltage abnormally high level (Right bank) ENG E03 Electrical system
CB449 Common rail abnormally high pressure 2 (Right bank) ENG E03 Electrical system
Common rail pressure sensor abnormally high level
CB451 ENG E03 Electrical system
(Right bank)
Common rail pressure sensor abnormally low level
(Right bank)
CB553 Common rail abnormally high pressure 1 (Right bank) ENG E03 Electricalsystem
CB554 Common rail pressure sensor in-range error (Right bank) ENG E03 Electrical system
CB559 Supply pump low pressure 1 (Right bank) ENG E03 Electrical system
CB689 Engine Ne speed sensor abnormality (Right bank) ENG E03 Electrical system
CB731 Engine Bkup speed sensor abnormal phase (Right bank) ENG E03 Electrical system
CB757 Engine controller all data loss (Right bank) ENG E03 Electrical system
CB778 Engine Bkup speed sensor abnormality (Right bank) ENG E03 Electrical system
CB781 Inter-multicontroller communication error (Right bank) ENG E03 Electrical system
Multicontroller distinction wiring harness key error
(Right bank)
Injector #7 (Right bank #1) system disconnection/short cir-
cuit
cuit
cuit
cuit
cuit
cuit
CB2249 Supply pump low pressure 2 (Right bank) ENG E03 Electrical system
D180KA Preheating relay output system: Disconnection PLC E01 Electrical system
D180KB Preheating relay output system: Grounding fault PLC E01 Electrical system
D180KY Preheating relay output system: Hot short circuit PLC E01 Electrical system
D19HKB Trouble in stop lamp relay output system BK E01 Electrical system
D1EFKA Pre-lubrication start relay output system: Disconnection PLC E01 Electrical system
D1EFKB Pre-lubrication start relay output system: Grounding fault PLC E01 Electrical system
D1EFKY Pre-lubrication start relay output system: Hot short circuit PLC E01 Electrical system
DAF9KM Wrong connection of connector MON E03 Electrical system
(DAFRKR) Abnormality in CAN communication (monitor panel) TM E03 —
DAQ0KK Lowering of source voltage TM E03 Electrical system
DAQ0KT Abnormality in non-volatile memory TM E01 Electrical system
DAQ2KK Trouble in solenoid power supply system TM E03 Electrical system
14 HD785-7

Failure contents
Disagreement of model selection signals
(DAQ9KQ) MON E03 —
(transmission controller)
Abnormality in CAN communication
DAQRKR MON E03 Electrical system
(DAQRMA) Disagreement of option setting (transmission) MON E03 —
DB10KT Abnormality in non-volatile memory BK E01 Electrical system
DB12KK Trouble in solenoid power supply BK E03 Electrical system
DB13KK Lowering of battery direct power supply voltage BK E03 Electrical system
(DB19KQ) Disagreement of model selection signals (brake) MON E03 —
DB1RKR Abnormality in CAN communication (retarder controller) TM E03 Electrical system
(DB1RMA) Disagreement of option setting (brake) MON E03 —
DB2RKR Abnormality in CAN communication (engine controller) TM E03 Electrical system
dB2RKR CAN communication error (Right bank engine controller) TM E03 Electrical system
VHMS
DBB0KK VHMS controller: Low source voltage (input) — Electrical system
(Display: PLM)
VHMS
DBB0KQ VHMS controller: Disagreement of model selection signals — Electrical system
(Display: PLM)
VHMS controller battery power supply: VHMS
DBB3KK — Electrical system
Low source voltage (input) (Display: PLM)
VHMS controller 5 V power supply output: VHMS
DBB5KP — Electrical system
Low output voltage (Display: PLM)
VHMS controller CAN communication: Defective communi- VHMS
DBBQKR — Electrical system
cation (Abnormality in target component system) (Display: PLM)
DBBRKR Abnormality in CAN communication (VHMS) MON E01 Electrical system
DBC2KK Trouble in solenoid power supply system ABS E03 Electrical system
DBC3KK Lowering of battery direct power supply voltage ABS E03 Electrical system
(DBC9KQ) Disagreement of model selection signals (ABS) MON E03 —
DBCRKR Abnormality in CAN communication (ABS) TM E03 Electrical system
(DBCRMA) Disagreement of option setting (ABS) MON E03 —
DBG2KK Solenoid power supply: Low voltage PLC E03 Electrical system
DBG3KK Battery direct power supply: Low voltage PLC E03 Electrical system
DBG9KQ Model selection signal: Abnormal PLC E01 Electrical system
DDD7KX Trouble in travel speed setting switch system BK E03 Electrical system
DDD8KA Disconnection in ARSC system switch BK E03 Electrical system
DDD8KB Short circuit in ARSC system switch BK E03 Electrical system
DDD9KA Disconnection in ABS system switch ABS E03 Electrical system
DDD9KB Short circuit in ABS system switch ABS E03 Electrical system
DDDAKA Disconnection in ASR system switch BK E01 Electrical system
HD785-7 15

Failure contents
DDDAKB Short circuit in ASR system switch BK E01 Electrical system
DDE2KB Engine oil pressure switch error: Grounding fault PLC E01 Electrical system
Engine oil pressure switch error: Disconnection or hot short
DDE2L6 PLC E01 Electrical system
circuit
DDP6L4 Trouble in service brake pressure switch ABS E03 Electrical system
Trouble in high clutch flow sensor valve
DDTHKA TM E03 Electrical system
(command holding pressure, fill OFF, no slip)
Trouble in low clutch flow sensor valve
DDTJKA TM E03 Electrical system
Trouble in 1st clutch flow sensor valve
DDTKKA TM E03 Electrical system
Trouble in 2nd clutch flow sensor valve
DDTLKA TM E03 Electrical system
Trouble in 3rd clutch flow sensor valve
DDTMKA TM E03 Electrical system
Trouble in reverse clutch flow sensor valve
DDTNKA TM E03 Electrical system
Trouble in 4th clutch flow sensor valve
DDTPKA TM E03 Electrical system
DF10KA Input of no lever signal TM E03 Electrical system
DF10KB Input of multiple lever signal TM E03 Electrical system

VHMS
DGE5KX Atmospheric temperature sensor: Out of input signal range — Electrical system
(Display: PLM)
Transmission oil temperature sensor input signal out of
DGF1KX TM E03 Electrical system
range
Retarder oil temperature sensor (Rear wheel) system trou-
DGR2KB BK E01 Electrical system
ble (Disconnection/Short circuit)
Trouble in retarder oil temperature sensor (rear wheel) sys-
DGR2KZ BK E01 Electrical system
tem (ground fault)
Retarder oil temperature sensor (Front wheel) system trou-
DGR4KB BK E01 Electrical system
ble (Disconnection/Short circuit)
Retarder oil temperature sensor (Front wheel) system trou-
DGR4KZ BK E01 Electrical system
ble (Ground fault)
DGR6KX Steering oil temperature signal out of range TM E01 Electrical system
Torque converter oil temperature sensor input signal out of
DGT1KX TM E01 Electrical system
range
Left bank exhaust temperature sensor system (Front): VHMS
DGT5KA — Electrical system
Disconnection (Display: PLM)
Left bank exhaust temperature sensor system (Rear): VHMS
dGT5KA — Electrical system
Left bank exhaust temperature sensor system (Front): VHMS
DGT5KB — Electrical system
Short circuit (Display: PLM)
Left bank exhaust temperature sensor system (Rear): VHMS
dGT5KB — Electrical system
Right bank exhaust temperature sensor system (Front): VHMS
DGT6KA — Electrical system
Right bank exhaust temperature sensor system (Rear): VHMS
dGT6KA — Electrical system
Right bank exhaust temperature sensor system (Front): VHMS
DGT6KB — Electrical system
Right bank exhaust temperature sensor system (Rear): VHMS
dGT6KB — Electrical system
VHMS
DHE5KB Blow-by pressure sensor: Short circuit — Electrical system
(Display: PLM)
Blow-by pressure sensor: Short circuit with power supply VHMS
DHE5KY — Electrical system
line (Display: PLM)
Short circuit in suspension pressure sensor system (front VHMS
DHP4KY E01 Electrical system
right) (indication: PLM)
16 HD785-7

Failure contents
Disconnection or ground fault in suspension pressure sen- VHMS
DHP4KZ E01 Electrical system
sor system (front right) (indication: PLM)
Short circuit in suspension pressure sensor system VHMS
(front left) (indication: PLM)
sor system (front left) (indication: PLM)
DHP6KA Trouble in suspension pressure sensor system (rear right) BK E01 Electrical system
DHP6KX Trouble in suspension pressure sensor system (rear right) BK E03 Electrical system
(rear right) (indication: PLM)
sor system (rear right) (indication: PLM)
DHP7KA Trouble in suspension pressure sensor system (rear left) BK E01 Electrical system
DHP7KX Trouble in suspension pressure sensor system (rear left) BK E03 Electrical system
(rear left) (indication: PLM)
sor system (rear left) (indication: PLM)
Disconnection, ground fault or hot short in torque converter
DHT5KX TM E01 Electrical system
inlet oil pressure sensor
DHT5L6 Trouble in torque converter inlet oil pressure sensor TM E01 Electrical system
DHU2KX Trouble in accumulator oil pressure sensor (front) TM E01 Electrical system
DHU3KX Trouble in accumulator oil pressure sensor (rear) TM E01 Electrical system
DHU6KX Trouble in ABS control valve pressure sensor (front right) ABS E03 Electrical system
DHU7KX Trouble in ABS control valve pressure sensor (front left) ABS E03 Electrical system
DHU8KX Trouble in ABS control valve pressure sensor (rear right) ABS E03 Electrical system
DHU9KX Trouble in ABS control valve pressure sensor (rear left) ABS E03 Electrical system
DJF1KA Disconnection in fuel level sensor system TM E01 Electrical system
DK30KX Trouble in steering angle potentiometer BK E01 Electrical system
DK51L5 Trouble in manual retarder potentiometer and RVS BK E03 Electrical system
DK52KX Trouble 1 in hoist lever potentiometer sensor BK E03 Electrical system
DK53L8 Trouble 2 in hoist lever potentiometer sensor BK E03 Electrical system
DK54KX Trouble in boom positioner sensor BK E03 Electrical system
DKD0L6 Trouble in steering speed sensor BK E01 Electrical system
DKH0KX Inclinometer sensor signal out of range TM E01 Electrical system

VHMS
DKH1KX Abnormality in inclinometer E01 Electrical system
(indication: PLM)
Disconnection in transmission input shaft speed sensor sys-
DLF1KA TM E03 Electrical system
tem
DLF1LC Trouble in transmission input shaft speed sensor TM E03 Electrical system
Disconnection in transmission intermediate shaft speed
DLF2KA TM E03 Electrical system
sensor system
DLF2LC Trouble in transmission intermediate shaft speed sensor TM E03 Electrical system
DLF6KA Disconnection in wheel speed sensor (front right) ABS E03 Electrical system
HD785-7 17

Failure contents
DLF6L3 Trouble in wheel speed sensor (front right) ABS E03 Electrical system
DLF7KA Disconnection in wheel speed sensor (front left) ABS E03 Electrical system
DLF7L3 Trouble in wheel speed sensor (front left) ABS E03 Electrical system
DLF8KA Disconnection in wheel speed sensor (rear right) BK E01 Electrical system
DLF8L3 Trouble in wheel speed sensor (rear right) ABS E03 Electrical system
DLF8LC Trouble in wheel speed sensor system (rear right) BK E01 Electrical system
DLF8MA Disconnection in wheel speed sensor (rear right) ABS E03 Electrical system
DLF9KA Disconnection in wheel speed sensor (rear left) BK E01 Electrical system
DLF9L3 Trouble in wheel speed sensor (rear left) ABS E03 Electrical system
DLF9LC Trouble in wheel speed sensor system (rear left) BK E01 Electrical system
DLF9MA Disconnection in wheel speed sensor (rear left) ABS E03 Electrical system
Disconnection in transmission output shaft speed sensor
DLT3KA TM E03 Electrical system
system
DLT3LC Trouble in transmission output shaft sensor BK E01 Electrical system
DLT4KA Disconnection in transmission output shaft speed sensor BK E01 Electrical system
DLT4MA Disconnection in transmission output shaft speed sensor BK E03 Electrical system
Pre-lubrication operation lamp output abnormality: Hot short
DUM7KY PLC E01 Electricalsystem
circuit
Pre-lubrication operation lamp output abnormality: Discon-
DUM7KZ PLC E01 Electricalsystem
nection or grounding fault
DV00KB Short circuit in buzzer output MON E01 Electrical system
DW2AKA Disconnection in main pressure variable valve output TM E01 Electrical system
DW2AKB Ground fault in main pressure variable valve output circuit TM E01 Electrical system
DW2AKY Hot short in main pressure variable valve output circuit TM E01 Electrical system
DW2AL1 Defective reset of main pressure variable valve TM E01 Electrical system
DW2ALH Malfunction of main pressure variable valve TM E01 Electrical system
DW2BKA Main oil level selector valve output disconnection TM E01 Electrical system
DW2BKB Main oil level selector valve output circuit GND short circuit TM E01 Electrical system
DW2BKY Main oil level selector valve output circuit GND hot short TM E01 Electrical system
DW2BL1 Main oil level selector valve reset trouble TM E01 Electrical system
DW2BLH Main oil level selector valve malfunction TM E01 Electrical system
Transmission lubrication variable valve output disconnec-
DW2CKA TM E01 Electrical system
tion
Transmission lubrication variable valve output circuit GND
DW2CKB TM E01 Electrical system
short circuit
Transmission lubrication variable valve output circuit hot
DW2CKY TM E01 Electrical system
short
DW2CL1 Transmission lubrication variable valve reset trouble TM E01 Electrical system
DW2CLH Transmission lubrication variable valve malfunction TM E01 Electrical system
18 HD785-7

Failure contents
Trouble in auto-suspension solenoid 1 output system
DW35KZ BK E01 Electrical system
(disconnection or ground fault)
Trouble in auto-suspension solenoid 2 output system
Exhaust brake output system trouble (Disconnec-
tion/Ground fault)
Trouble in kick-out solenoid output system
Trouble (disconnection or ground fault) in hoist selector
valve output system (disconnection or ground fault)
DW78KZ Trouble in BCV output system BK E01 Electrical system
DWNBK4 Trouble in ASR shut-off valve (valve keeps operating) BK E01 Electrical system
DWNBKA Disconnection in ASR shut-off valve output circuit BK E01 Electrical system
DWNBKB Ground fault in ASR shut-off valve output circuit BK E01 Electrical system
DWNBKY Short circuit in ASR shut-off valve output circuit BK E01 Electrical system
DWNBMA Trouble in ASR shut-off valve (valve does not operate) BK E01 Electrical system
DWNDKZ Trouble in ABS cut valve (front) system ABS E03 Electrical system
DWNDMA Defective ABS cut valve (front) ABS E03 Electrical system
DWNEKZ Trouble in ABS cut valve (rear) system ABS E03 Electrical system
DWNEMA Defective ABS cut valve (rear) ABS E03 Electrical system
Trouble in rear wheel proportional pressure reducing sole-
DX11K4 BK E03 Electrical system
noid valve (valve keeps operating)
Disconnection in rear wheel proportional pressure reducing
DX11KA BK E03 Electrical system
solenoid valve output circuit
Ground fault in rear wheel proportional pressure reducing
DX11KB BK E03 Electrical system
Short circuit in rear wheel proportional pressure reducing
DX11KY BK E03 Electrical system
Trouble in rear wheel proportional pressure reducing sole-
DX11MA BK E03 Electrical system
noid valve (valve does not operate)
Front wheel proportional solenoid pressure reducing valve
trouble (Valve keeps operating)
output circuit disconnection
output circuit ground fault
output circuit short circuit
trouble (Valve does not operate)
DX13KA Disconnection in hoist EPC valve output circuit BK E03 Electrical system
DX13KB Ground fault in hoist EPC valve output circuit BK E03 Electrical system
DX13KY Short circuit in hoist EPC valve output circuit BK E03 Electrical system
Trouble in ASR proportional pressure reducing solenoid
valve (right) (valve keeps operating)
Disconnection in ASR proportional pressure reducing sole-
noid valve (right) output circuit
Ground fault in ASR proportional pressure reducing sole-
Short circuit in ASR proportional pressure reducing sole-
HD785-7 19

Failure contents
valve (right) (valve does not operate)
valve (left) (valve keeps operating)
Disconnection in ASR proportional pressure reducing sole-
noid valve (left) output circuit
Ground fault in ASR proportional pressure reducing sole-
Short circuit in ASR proportional pressure reducing sole-
valve (left) (valve does not operate)
Disconnection in ABS control valve (front right) output cir-
DX21KA ABS E03 Electrical system
cuit
DX21KB Ground fault in ABS control valve (front right) output circuit ABS E03 Electrical system
DX21KY Short circuit in ABS control valve (front right) output circuit ABS E03 Electrical system
DX21MA Defective ABS control valve (front right) ABS E03 Electrical system
DX22KA Disconnection in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22KB Ground fault in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22KY Short circuit in ABS control valve (front left) output circuit ABS E03 Electrical system
DX22MA Defective ABS control valve (front left) ABS E03 Electrical system
Disconnection in ABS control valve (rear right) output cir-
DX23KA ABS E03 Electrical system
cuit
DX23KB Ground fault in ABS control valve (rear right) output circuit ABS E03 Electrical system
DX23KY Short circuit in ABS control valve (rear right) output circuit ABS E03 Electrical system
DX23MA Defective ABS control valve (rear right) ABS E03 Electrical system
DX24KA Disconnection in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24KB Ground fault in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24KY Short circuit in ABS control valve (rear left) output circuit ABS E03 Electrical system
DX24MA Defective ABS control valve (rear left) ABS E03 Electrical system
DX25MA Defective ABS front wheel system control valve ABS E03 Electrical system
DX26MA Defective ABS rear wheel system control valve ABS E03 Electrical system
DXH1KA Disconnection in lockup clutch solenoid output circuit TM E03 Electrical system
DXH1KB Ground fault in lockup solenoid output circuit TM E03 Electrical system
DXH1KY Hot short in lockup clutch solenoid output circuit TM E03 Electrical system
DXH2KA Disconnection in high clutch solenoid output circuit TM E03 Electrical system
DXH2KB Ground fault in high clutch solenoid output circuit TM E03 Electrical system
DXH2KY Hot short in high clutch solenoid output circuit TM E03 Electrical system
DXH3KA Disconnection in low clutch solenoid output circuit TM E03 Electrical system
DXH3KB Ground fault in low clutch solenoid output circuit TM E03 Electrical system
DXH3KY Hot short in low clutch solenoid output circuit TM E03 Electrical system
20 HD785-7

Failure contents
DXH4KA Disconnection in 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KB Ground fault in 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KY Hot short in 1st clutch solenoid output circuit TM E03 Electrical system
DXH5KA Disconnection in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KB Ground fault in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KY Hot short in 2nd clutch solenoid output circuit TM E03 Electrical system
DXH6KA Disconnection in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KB Ground fault in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KY Hot short in 3rd clutch solenoid output circuit TM E03 Electrical system
DXH7KA Disconnection in reverse clutch solenoid output circuit TM E03 Electrical system
DXH7KB Ground fault in reverse clutch solenoid output circuit TM E03 Electrical system
DXH7KY Hot short in reverse clutch solenoid output circuit TM E03 Electrical system
DXHHKA Disconnection in 4th clutch solenoid output circuit TM E03 Electrical system
DXHHKB Ground fault in 4th clutch solenoid output circuit TM E03 Electrical system
DXHHKY Hot short in 4th clutch solenoid output circuit TM E03 Electrical system
VHMS
F@BBZL Blow-by pressure: High error — Electrical system
(Display: PLM)
Left front exhaust temperature sensor (1): Exhaust tempera- VHMS
F@BYNS — Electrical system
ture abnormal rise (Display: PLM)
Left rear exhaust temperature sensor (1): Exhaust tempera- VHMS
f@BYNS — Electrical system
Right front exhaust temperature sensor (1): Exhaust tem- VHMS
F@BZNS — Electrical system
perature abnormal rise (Display: PLM)
Right rear exhaust temperature sensor (1): Exhaust temper- VHMS
f@BZNS — Electrical system
ature abnormal rise (Display: PLM)
Left front exhaust temperature sensor (2): Exhaust tempera- VHMS
F@BYNR — Electrical system
Left rear exhaust temperature sensor (2): Exhaust tempera- VHMS
f@BYNR — Electrical system
Right front exhaust temperature sensor (2): Exhaust tem- VHMS
F@BZNR — Electrical system
perature abnormal rise (Display: PLM)
Right rear exhaust temperature sensor (2): Exhaust temper- VHMS
f@BZNR — Electrical system
ature abnormal rise (Display: PLM)
HD785-7 21
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and mechan-
ical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Machine monitor system
ENG: Engine controller system
TM: Transmission controller system
BK: Retarder controller system
ABS: ABS controller system
VHMS: PLM function system of VHMS controller (Note: Displayed as "PLM" on machine monitor)
PLC: Pre-lubrication controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure
history display function, a failure has been recorded.
a Note: Optional equipment is also included in this table.
22 HD785-7
tService mode
Procedure for switching to service mode and
screen display
a When using the service mode, change the
screen by the following special operation.
1. Confirming the screen display

Check that the machine monitor is in operator
mode and the screen is displaying either of the
"service meter and integrated odometer", "action
code", or "failure code".
2. Displaying ID input initial screen

Press the following 2 switches at the same time
for longer than 5 seconds to display the ID input 4. Displaying service menu selection screen
screen. After confirming all 4 digits of ID, display the
q [t] switch and [<] switch service menu selection screen in the service
a If the switch is pressed for longer than 5 sec- mode.
onds, the character display section becomes a By inputting and determining the ID once, it
blank. After confirming this condition, re- will be effective until the starting switch is
lease the switch. turned off.
3. Input and determination of ID 5. Selection of the service menu

After displaying ID input screen, operate [>], [<], If the [>] switch or [<] switch is pressed on the
U], and [t] switch and input 4 digits ID. service menu selection screen, the service
a ID: 6491 menu is displayed endlessly in the order of the
q [ > ]: Number at the cursor increases. following table, then select the menu that is
q [ < ]: Number at the cursor decreases used.
q [U]: Number at the cursor is determined q [>]: To proceed to next service menu.
q [t]: Cursor moves to left end or the display q [<]: To return to previous service menu.
returns to operator mode screen.
a If the ID input screen is left without switch op-
eration for longer than 60 seconds, it auto-
matically returns to the operator mode
screen.
HD785-7 23
a Displayed service menu: a If you return to the operator mode screen

No. Display Function by mistake, repeat the procedure from
1 ELECTRIC FAULT
Electrical system failure history step 1 above (however there is no need to
display function input the ID again)
Mechanical system failure his- q When completing all operations:
2 MACHINE FAULT
tory display function Turn the starting switch OFF.
REAL-TIME MONI-
3 Real-time monitoring function [11] Electrical system failure history display
TOR
CYLINDER Reduced cylinder mode func- function (ELECTRIC FAULT)
4 The machine monitor retains the data for problems
CUT-OUT tion
5 NO INJECTION No injection cranking function that occurred in the electrical system in the past as
6 TUNING Adjusting function failure history. They can be displayed as follows.
MAINTENANCE Filter and oil replacement time 1. Selection of the service menu
7
MONITOR setting function Select electrical system failure history display
Operation information display
8 OPERATION INFO function (ELECTRIC FAULT) in the service
function
FIX POWER menu selection screen.
9
MODE
Engine mode fixing function a The total number of failure history data items
10 SNAPSHOT Manual snap shot function recorded in memory is displayed in the [* *]
PLM (Payload meter) setting portion.
11 PLM
function
OPTIONAL
12 Option selection function
SELECT
13 MACHINE Model selection function
Initialize function (exclusive
14 INITIALIZE
function for factory)
a The service menu is displayed in the places
marked with [*].
2. Failure history data display

With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
6. Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current function and hierarchy.
q When continuing operations in another mode
or function:
Press the [t] switch and return to the mode
screen to be used or menu screen to be
used.
a Note that if the [t] switch is pressed on
the YES/NO screen, the function will be
executed.
24 HD785-7
3. Displayed failure history data 5. Deleting individual failure history data

With the electrical system failure history display 1) With the failure history data to be deleted
function, the following data can be displayed. displayed, press the [U] switch and display
1: Record number (recorded up to a maximum of the individual deletion screen.
20 items) q [U]: Display the deletion screen
A: Failure code (4-digits device code + 2-digits 2) When the individual deletion screen is
symptom code) displayed, operate each switch of [<], [>] and
2: Number of occurrences (number of occur- [t].
rences of same code in the past) q [<]: Select YES (move cursor)
3: Elapsed time 1 (time elapsed on service q [>]: Select NO (move cursor)
meter since first occurrence) q [t]: Execute YES or NO
4: Elapsed time 2 (time elapsed on service a An information which is active currently
meter since last occurrence) (display is flashing) cannot be deleted.
a Failure codes for problems that are still exist-
ing are shown on a flashing display.
a Refer to failure code table of operator mode
for details of displayed failure codes.
a Note that with the failure history display func-
tion and failure code display function (opera-
tor mode) for the electrical system, the
displayed data are partially different.
a If the fault history is not recorded, "-" is dis-
played on the display section of 1/A/2/3/4.
6. Deletion of all the failure history information

1) With the failure history data displayed, press
the [>] switch or [<] switch and display ALL
CLEAR menu screen.
a The ALL CLEAR menu is displayed at the
end of failure history data.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display switches
to another failure history data recorded.
q [>]: To proceed to data for next record num-
ber
q [<]: Go back to data for previous record num-
ber
2) When the ALL CLEAR menu is displayed,

press the [U] switch and display the ALL
CLEAR execution screen.
q [U]: Execute ALL CLEAR menu
HD785-7 25
3) When the ALL CLEAR execution screen is [12] Mechanical system failure history display
displayed, operate each switch of [<], [>] and function (MACHINE FAULT)
[t]. The machine monitor retains the data for problems
q [<]: Select YES (move cursor) that occurred in the mechanical system in the past
q [>]: Select NO (move cursor) as failure history. They can be displayed as follows.
q [t]: Execute YES or NO
a An information which is active currently 1. Selection of the service menu
(display is flashing) cannot be deleted. Select mechanical system failure history display
function (MACHINE FAULT) in the service menu
selection screen.
a The total number of failure history data items
recorded in memory is displayed in the [* *]
portion.
4) The screen changes to the fault history

screen. Check that the number of records in
** is "0".
2. Failure history data display

switch and display the failure history data
recorded in memory.
26 HD785-7
3. Displayed failure history data [13] Real time monitoring function (REAL-TIME
With the mechanical system failure history MONITOR)
display function, the following data can be The machine monitor can monitor the condition of
displayed. the machine in real time through the signals from the
1: Record number sensors installed to various parts of the machine.
A: Failure code (4-digits device code + 2-digits In the real time monitoring function, the following 2
symptom code) types of display can be shown.
2: Number of occurrences (number of occur- q 1 item independent display (for each controller)
rences of same code in the past) q 2 items simultaneous display (code input)
3: Elapsed time 1 (service meter at first occur- 1. Selection of the service menu
rence) Select real time monitoring function
4: Elapsed time 2 (service meter at last occur- (REAL-TIME MONITOR) in the service menu
rence) selection screen.
a Failure codes for problems that are still exist-
ing are shown on a flashing display.
a Refer to failure code table of operator mode
for details of displayed failure codes.
a Note that with the failure history display func-
tion and failure code display function (opera-
tor mode) for the mechanical system, the
displayed data are partially different.
a If the fault history is not recorded, "-" is dis-
played on the display section of 1/A/2/3/4.
2. Display and selection of monitoring system and

function
1) With the service menu selected, press the
[U] switch to display the monitoring system
and function selection screen.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display switches
to another failure history data recorded.
q [>]: To proceed to data for next record num-
ber
q [<]: Go back to data for previous record num-
ber
5. Deleting failure history data (not permitted)

a The failure history data for the mechanical
2) If the [>] switch or [<] switch is pressed on the
system cannot be deleted.
monitoring system and function selection
screen, the monitoring system and device is
displayed endlessly in the following order,
then select the system or function that is
used.
HD785-7 27
q [>]: To proceed to next monitoring system 2) With the monitoring system selected, press
and function the [U] switch and display the monitoring
q [<]: Go back to data for previous monitor- display and item selection screen.
ing system and function q [U]: Implement 1 item individual monitor-
a Monitoring system and function to be dis- ing
played: 3) With the monitoring display and item selec-
No. Display System and function tion screen displayed, press the [>] switch or
MONITOR [<] switch and select items to monitor.
1 Machine monitor system
PANEL q [>]: To proceed to the next monitoring
2 TRANSMISSION Transmission controller system item
3 ENGINE Engine controller system q [<]: Return to the previous monitoring
4 ENGINE SUB Engine sub controller system item

a The monitored items are scroll-displayed
5 BRAKE Retarder controller system
due to internal setting.
VHMS controller system
6 VHMS a If the switch is kept pressed, the monitor-
(if equipped is installed)
ABS controller ing items scroll at high speed.
7 ABS
(if equipped is installed) a In the monitoring display and item selec-
8 2 ITEMS 2 items simultaneous monitoring tion screen, the information of the moni-
tored items are displayed on real time.
a Display monitoring system and function in
the "*" section.
4) To hold or cancel monitoring data:

If the [U] switch is pressed during moni-
3. Setting 1 item individual monitoring toring, the monitor data is held and the [U]
1) In the monitoring system and function selec- mark flashes. If the [U] switch is pressed
tion screen, select the monitoring system again, hold is canceled and it becomes active
(example: ENGINE) to be used. again.
q [U]: Hold and release of data
4. Display data for 1 item individual monitoring

On the 1 item individual monitoring display
screen, the following data are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
a For details, see "Monitoring code table".
28 HD785-7
3) In the monitoring code input screen, operate

each of the switches [>], [<], [U] and [t], and
directly input 2-digit monitoring codes.
q [ > ]: Number at the cursor increases.
q [ < ]: Number at the cursor decreases
q [U]: Number at the cursor is determined
q [t]: Cursor moves to the left end / To re-
turn to the monitoring system and func-
tion selection screen.
5. Setting 2 items simultaneous monitoring

1) Select 2 items simultaneous monitoring (2
ITEMS) in the monitoring system and func-
2) With 2 items simultaneous monitoring
selected, press the [U] switch and display
the monitoring code input screen.
q [U]: Implement 2 items simultaneous
monitoring
4) When both of the monitoring codes have
been confirmed, the screen switches to the 2
items simultaneous monitoring display
screen.
5) To hold or cancel monitoring data:

If the [U] switch is pressed during moni-
toring, the monitor data is held and the [U]
mark flashes.
If the [U] switch is pressed again, hold is
canceled and it becomes active again.
q [U]: Hold and release of data
HD785-7 29
6. Display data for 2 items simultaneous monitoring

On the 2 item simultaneous monitoring display
screen, the following data are displayed.
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
a For details, see "Monitoring code table".
30 HD785-7
Monitoring code table
Monitor panel [machine monitor system]
Monitoring
No. Monitoring item Display of item Display range of data Unit
code
********
1 Part No. of software VERSION 20200 —
(8 digits/symbols)
********
2 Version No. of application VERSION (APP) 20221 —
(8 digits/symbols)
********
3 Version No. of data VERSION (DATA) 20222 —
(8 digits/symbols)
4 Rheostat (Night decrease light) RHEOSTAT 30300 0.0 – 51.0 V
0 – F, 0 – F, 0 – F, Display of
5 Rotary switch (SW1 - 3) SW1, SW2, SW3 30800
(SW1, SW2, SW3 from left) condition
ON/OFF, ON/OFF Display of
6 DIP switch (SW5-1, 2) SW5-1, SW5-2 30900
(SW5-1, SW5-2 from left) condition
01010101
10 Input signal (0 - 7) D-IN--0------7 40900 0: OFF/1: ON
(8 digits of 0/1. See detail.)
01010101
11 Input signal (8 - 15) D-IN--8-----15 40901 0: OFF/1: ON
01010101
12 Input signal (16 - 23) D-IN-16-----23 40902 0: OFF/1: ON
01010101
01010101
0101
15 Output signal (0 - 3) D-OUT-0--3 40925 0: OFF/1: ON
HD785-7 31
Detailed information of 40900 (D-IN--0------7) Detailed information of 40925 (D-OUT-0--3)

[0]: Dimmer switch (High beam: 1) [0]: Headlamp selection (ON: 1)
[1]: Machine monitor check switch (ON: 1) [1]: Buzzer (Operated: 1)
[2]: AISS switch (ON: 1) [2]: (Unused)
[3]: Exhause brake switch (Upper) [3]: (Unused)
[4]: Exhause brake switch (Lower)
[5]: ABS system switch [If equipped] (Installed: 1)
[6]: Dimmer switch (Passing: 1)
[7]: Power mode switch (Economy: 1)
Detailed information of 40901 (D-IN--8-----15)

[8]: Connector check (Always: 1)
[9]: Machine monitor mode switch
([t] is pressed: 1)
([>] is pressed: 1)
([<] is pressed: 1)
[12]: Turn signal lever (Operated to right: 1)
[13]: Turn signal lever (Operated to left: 1)
([U] is pressed: 1)
[15]: (Unused)
Detailed information of 40902 (D-IN--16----23)

[16]: ARSC switch (Upper position: 1)
[17]: ARSC switch (Lower position: 1)
[18]: ABS switch (Upper position: 1)
[19]: ABS switch (Lower position: 1)
[20]: ASR switch (Upper position: 1)
[21]: ASR switch (Lower position: 1)
[22]: (Unused)
[23]: (Unused)

[24]: Headlamp switch (ON: 1)
[25]: Seat belt switch (Belt is fastened: 1)
[26]: (Unused)
[27]: (Unused)
[28]: (Unused)
[29]: (Unused)
[30]: (Unused)
[31]: (Unused)

[32]: (Unused)
[33]: (Unused)
[34]: Connector check (Always: 1)
[35]: (Unused)
[36]: (Unused)
[37]: (Unused)
[38]: (Unused)
[39]: (Spare for service)
32 HD785-7
Transmission [Transmission controller system]
Monitoring
code
********
1 Part No. of software VERSION 20201 —
(8 digits/symbols)
********
(8 digits/symbols)
********
(8 digits/symbols)
0 – 32767
4 Transmission input shaft speed T/M SPEED: IN 31200 rpm
Transmission intermediate shaft 0 – 32767
5 T/M SPEED: MID 31300 rpm
speed ---- [Other than above]
0 – 32767
6 Transmission output shaft speed T/M SPEED: OUT 31400 rpm
0 – 250
7 Fuel level FUEL SENSOR 04201 Ω
0.00 – 5.00
8 Fuel level FUEL SENSOR 04200 V
9 Alternator R ALTERNATOR R 04301 OFF/ON 0: OFF/1: ON
0 – 160
10 Torque converter oil temperature T/C OIL TEMP 30100 °C
0.00 – 5.00
11 Torque converter oil temperature T/C OIL TEMP 30101 V
0 – 160
12 Transmission oil temperature T/C OIL TEMP 32500 °C
0.00 – 5.00
13 Transmission oil temperature T/C OIL TEMP 32501 V
0 – 160
14 Steering oil temperature STRG OIL TEMP 32701 °C
0.00 – 5.00
15 Steering oil temperature STRG OIL TEMP 32702 V
0.00 – 5.00
16 Torque converter oil pressure T/C OIL PRESS 32600 Mpa
0.00 – 5.00
17 Torque converter oil pressure T/C OIL PRESS 32605 V
0.00 – 99.99
18 Accumulator oil pressure (front) ACC OIL PRE F 35500 Mpa
0.00 – 99.99
19 Accumulator oil pressure (rear) ACC OIL PRE R 35501 Mpa
0.00 – 5.00
20 Accumulator oil pressure (front) ACC OIL PRE F 35504 V
0.00 – 5.00
21 Accumulator oil pressure (rear) ACC OIL PRE R 35505 V
0 – 1000
22 Solenoid output (high) ECMV H DIR 31600 mA
0 – 1000
23 Solenoid output (low) ECMV L DIR 31601 mA
0 – 1000
24 Solenoid output (1st) ECMV 1 DIR 31602 mA
0 – 1000
25 Solenoid output (2nd) ECMV 2 DIR 31603 mA
HD785-7 33
Monitoring
code
0 – 1000
26 Solenoid output (3rd) ECMV 3 DIR 31604 mA
0 – 1000
27 Solenoid output (4th) ECMV 4 DIR 31605 mA
0 – 1000
28 Solenoid output (R) ECMV R DIR 31606 mA
0 – 1000
29 Solenoid output (lockup) ECMV LU DIR 31609 mA
Transmission main oil pressure 0 – 1000
30 ECMV MAIN P 31643 mA
variable solenoid output ---- [Other than above]
0 – 1000
31 Main flow selector valve output ECMV MAIN V 31644 mA
-180.0 – +180.0
32 Pitch angle sensor ANGLE SENSOR 32900 ° [degree]
0.00 – 5.00
33 Pitch angle sensor ANGLE SENSOR 32903 V
0 – 100
34 Brake output (front wheel) BK OUTP DIR F 33807 %
0 – 100
35 Brake output (rear wheel) BK OUTP DIR R 33806 %
-100 – 100
36 Throttle correction value THROTTLE MOD 36000 %
Transmission lubricating oil level 0 – 1000
37 ECMV LUB V 38001 mA
variable solenoid output ---- [Other than above]
Low clutch trigger correction quan- 00000000 – FFFFFFFF Display of
38 TRIGGER MOD L 38900
tity (8 digits of 0 – F) condition
High clutch trigger correction quan- 00000000 – FFFFFFFF Display of
39 TRIGGER MOD H 38901
1st clutch trigger correction quan- 00000000 – FFFFFFFF Display of
40 TRIGGER MOD 1 38902
2nd clutch trigger correction quan- 00000000 – FFFFFFFF Display of
41 TRIGGER MOD 2 38903
00000000 – FFFFFFFF Display of
42 3rd clutch trigger correction quantity TRIGGER MOD 3 38904
(8 digits of 0 – F) condition
43 4th clutch trigger correction quantity TRIGGER MOD 4 38905
44 R clutch trigger correction quantity TRIGGER MOD R 38906
0101010 Recognition
45 Clutch fill switch FILL HL1234R 38919 (Data is displayed under of fill switch
HL1234R) 0: OFF/1: ON
0101010 Learning flag
46 Trigger initial learning flag TRIG HL1234R 38920 (Data is displayed under of clutch
HL1234R) 0: OFF/1: ON
0 – 2550
47 Fill time (low) FILL TIME L 41800 ms
0 – 2550
48 Fill time (high) FILL TIME H 41801 ms
0 – 2550
49 Fill time (1st) FILL TIME 1 41802 ms
34 HD785-7
Monitoring
code
0 – 2550
50 Fill time (2nd) FILL TIME 2 41803 ms
0 – 2550
51 Fill time (3rd) FILL TIME 3 41804 ms
0 – 2550
52 Fill time (4th) FILL TIME 4 41805 ms
0 – 2550
53 Fill time (R) FILL TIME R 41806 ms
Throttle quantity lower limit value 0.0 – 100.0
54 THROT LIMIT LO 44201 %
output ---- [Other than above]
Throttle quantity upper limit value 0.0 – 100.0
55 THROT LIMIT HI 44200 %
output ---- [Other than above]
01010101
56 Input signal (0 – 7) D-IN--0------7 40905 0: OFF/1: ON
01010101
57 Input signal (8 – 15) D-IN--8-----15 40906 0: OFF/1: ON
01010101
58 Input signal (16 – 23) D-IN-16-----23 40907 0: OFF/1: ON
01010101
0.
01010101
61 Output signal (0 – 7) D-OUT-0------7 40949 0: OFF/1: ON
01010101
62 Output signal (8 – 15) D-OUT-8-----15 40950 0: OFF/1: ON
01010101
63 Output signal (16 – 23) D-OUT-16----23 40951 0: OFF/1: ON
HD785-7 35
Detailed information of 40905 (D-IN--0------7) Detailed information of 40949 (D-OUT--0------7)

[0]: (Unused) [0]: (Unused)
[1]: Transmission filter switch 1 [1]: (Unused)
[2]: Transmission filter switch 2 [2]: (Unused)
[3]: Emergency escape switch (ON: 1) [3]: (Unused)
[4]: Starting switch C terminal signal (Start of en- [4]: (Unused)
gine: 1) [5]: (Unused)
[6]: Emergency steering relay 1 (Driving: 1) [7]: (Unused)
[7]: Gearshift lever (N position: 1)
Detailed information of 40950 (D-OUT--8-----15)
Detailed information of 40906 (D-IN--8-----15) [8]: (Unused)
[8]: Low clutch fill switch (ON: 1) [9]: (Unused)
[9]: 4th clutch fill switch (ON: 1) [10]: (Unused)
[10]: High clutch fill switch (ON: 1) [11]: (Unused)
[11]: 1st clutch fill switch (ON: 1) [12]: (Unused)
[12]: 2nd clutch fill switch (ON: 1) [13]: (Unused)
[13]: 3rd clutch fill switch (ON: 1) [14]: (Unused)
[14]: Reverse clutch fill switch (ON: 1) [15]: (Unused)
[15]: (Unused)
Detailed information of 40951 (D-OUT--16-----23)
Detailed information of 40907 (D-IN--16----23) [16]: (Unused)
[16]: Gearshift lever (R position: 1) [17]: (Unused)
[17]: Gearshift lever (D position: 1) [18]: (Unused)
[18]: Gearshift lever (6 position: 1) [19]: (Unused)
[23]: Gearshift lever (L position: 1)

[24]: (Unused)
[25]: Coolant level
[26]: Air cleaner switch
[27]: Main pressure variable valve pressure switch
[28]: Main flow rate selector valve pressure switch
[29]: Lubricating oil quantity variable valve pressure
switch
[30]: (Unused)
[31]: (Unused)

[32]: (Unused)
36 HD785-7
Engine [Engine controller system] (Main side (Left bank side))
Monitoring
code
1 Serial No. of hardware (left bank) ECM S/N 20400 0 – 49999999 —
0.0 – 480.0
2 Battery voltage (left bank) POWER SUPPLY 03200 V
0 – 4000
3 Engine speed ENG SPEED 01002 rpm
-40 – 210
4 Engine coolant temperature COOLANT TEMP 04104 °C
Engine coolant temperature sensor 0.00 – 5.00
5 COOLANT TEMP 04105 V
voltage ---- [Other than above]
-99.9 – 999.9
6 Oil pressure sensor ENG OIL PRESS 37200 kPa
0.00 – 5.00
7 Oil pressure sensor voltage ENG OIL PRESS 37201 V
-40 – 210
8 Engine oil temperature ENG OIL TEMP 42700 °C
Engine oil temperature sensor volt- 0.00 – 5.00
9 ENG OIL TEMP 42702 V
age ---- [Other than above]
0 – 400
10 Common rail pressure (left bank) RAIL PRESS 36400 Mpa
Common rail pressure sensor volt- 0.00 – 5.00
11 RAIL PRESS 36402 V
age (left bank) ---- [Other than above]
-99.9 – 999.9
12 Atmospheric pressure AMBIENT PRESS 37400 kPa
Atmospheric pressure sensor volt- 0.00 – 5.00
13 AMBIENT PRESS 37402 V
-50 – 200
14 Intake air temperature INTAKE TEMP 18400 °C
Intake air temperature sensor volt- 0.00 – 5.00
15 INTAKE TEMP 18401 V
-40 – 210
16 Fuel temperature (left bank) FUEL TEMP 04204 °C
Fuel temperature sensor voltage 0.00 – 5.00
17 FUEL TEMP 04201 V
(left bank) ---- [Other than above]
-50 – 200
18 Boost temperature CHG TEMP 18500 °C
0.00 – 5.00
19 Boost temperature sensor voltage CHG TEMP 18501 V
-99.9 – 999.9
20 Boost pressure CHG PRESS-A 36500 kPa
0.00 – 5.00
21 Boost pressure sensor voltage CHG PRESS-A 36502 V
-24000 – 24000
22 Engine output torque OUTPUT TORQUE 18700 Nm
0 – 100
23 Converted torque TORQUE RATIO 36700 %
0 – 100
24 Final accelerator position FINAL THROTTLE 31706 %
0.0 – 999.9
25 Momentary fuel consumption FUEL RATE 37300 L/h
HD785-7 37
Engine [Engine controller system] (Main side (Left bank side))
Monitoring
code
Final injection rate command 0 – 1000
26 INJECT COMMAND 18600 mg
(by weight) ---- [Other than above]
-180.0 – 180.0
27 Final injection timing command INJECT TIMING 36300 CA
0 – 100
28 Accelerator pedal position THROTTLE POS 31701 %
0.00 – 5.00
29 Accelerator pedal sensor voltage THROTTLE POS 31707 V
30 Idlie validation signal IVS 1 18300 ON or OFF —
31 Idlie validation signal IVS 2 18301 ON or OFF —
Controller inside temperture -40 – 210

32 ECM IN TEMP 18900 °C
(left bank) ---- [Other than above]
Final common rail pressure com- 0 – 400
33 PRESS COMMAND 36200 Mpa
mand ---- [Other than above]
PCV valve closing timing (based on -180 – 180
34 PCV TIMING 17201 CA
BTDC) (left bank) ---- [Other than above]
35 Engine mode selection POWER MODE 17500 0–4 —
Transmitted value is dis-

36 Selected model (left 8 digits) MACHINE ID (H) 00400 —
played (Left 8 of 16 letters)
37 Selected model (right 8 digits) MACHINE ID (L) 00401 —
played (Left 8 of 16 letters)
38 Build version No. BUILD VER 20216 —
played (8 letters)
Calibration data version No. Transmitted value is dis-
39 CAL VER 20217 —
(left bank) played (8 letters)
a "CA" in the unit column is an abbreviation for the Crankshaft Angle.
38 HD785-7
Engine sub [Engine sub controller system] (Sub side (Right bank side))
Monitoring
code
Serial No. of hardware
1 R-ECM S/N 20401 0 – 49999999 —
(right bank)
0.0 – 480.0
2 Battery voltage (right bank) R-POWER SUPPLY 03205 V
Common rail pressure 0 – 400
3 R-RAIL PRESS 36403 Mpa
(right bank) ---- [Other than above]
Common rail pressure sensor voltage 0.00 – 5.00
4 R-RAIL PRESS 36404 V
-40 – 210
5 Fuel temperature (right bank) R-FUEL TEMP 04205 °C
Fuel temperature sensor voltage 0.00 – 5.00
6 R-FUEL TEMP 14202 V
Controller inside temperture -40 – 210
7 R-ECM IN TEMP 18901 °C
PCV valve closing timing (based on -180 – 180
8 R-PCV TIMING 17202 CA
BTDC) (right bank) ---- [Other than above]
Calibration data version No. Transmitted value is
9 R-CAL VER 20218 —
(right bank) displayed (8 letters)
a "CA" in the unit column is an abbreviation for the Crankshaft Angle.
HD785-7 39
Brake [Retarder controller system]
Monitoring
code
********
1 Version of software VERSION 20214 —
(8 digits/symbols)
********
(8 digits/symbols)
********
(8 digits/symbols)
0.00 – 5.00
4 ARSC set switch ARSC SET SP SW 37701 V
Transmission output shaft 0 – 32767
5 T/M SPEED: OUT 31403 rpm
speed ---- [Other than above]
0 – 32767
6 Wheel speed (left) WHEEL SPEED L 39705 rpm
0 – 32767
7 Wheel speed (right) WHEEL SPEED R 39704 rpm
Retarder cooling oil tempera- 0 – 160
8 BRAKE OIL T F 30201 °C
ture (front) ---- [Other than above]
Retarder cooling oil tempera- 0.00 – 5.00
9 BRAKE OIL T F 30204 V
ture (front) ---- [Other than above]
Retarder cooling oil tempera- 0 – 160
10 BRAKE OIL T R 30211 °C
ture (rear) ---- [Other than above]
Retarder cooling oil tempera- 0.00 – 5.00
11 BRAKE OIL T R 30212 V
ture (rear) ---- [Other than above]
0 – 1000
12 Brake output (front wheel) BK OUTP DIR F 33700 mA
0 – 1000
13 Brake output (rear wheel) BK OUTP DIR R 33806 mA
0.00 – 5.00
14 Retarder lever RETARD LEVER 33900 V
0.00 – 5.00
15 Body positioner BODY POSITION 34602 V
Dump lever (Hoist lever) poten- 0.00 – 5.00
16 DUMP LEVER 1 34304 V
tiometer 1 ---- [Other than above]
Dump lever (Hoist lever) poten- 0.00 – 5.00
17 DUMP LEVER 2 34305 V
tiometer 2 ---- [Other than above]
0 – 1000
18 Hoist EPC output HOIST EPC DIR 45600 mA
Seating control command γ 0 – 1000
19 S CNT DIR H 45102 mA
(high) ---- [Other than above]
Seating control command γ 0 – 1000
20 S CNT DIR L 45103 mA
(low) ---- [Other than above]
Seating condition calibration 0.00 – 5.00
21 S CAL A 45201 V
value (α) ---- [Other than above]
Cylinder stopper calibration 0.00 – 5.00
22 S CAL B 45301 V
value (β) ---- [Other than above]
0.0 – 10.00
23 Seating control time (high) S CNT TIME H 45402 second
0.0 – 10.00
24 Seating control time (low) S CNT TIME L 45403 second
25 Shut-off valve output SHUT OFF VALVE 45700 0/1 (1 digit of 0/1) 0: OFF/1: ON
-180.0 – +180.0
26 Steering angle sensor STRG ANGLE 35402 ° (degree)
---- [Other than above
0.00 – 5.00
27 Steering angle sensor STRG ANGLE 35400 V
STRG ANG 0.0 – 99.99
28 Steering speed 35403 rad/second
SPEED ---- [Other than above]
0.00 – 20.10
29 Suspension pressure (left) SUS PRESS (L) 32814 MPa
0.00 – 5.00
30 Suspension pressure (left) SUS PRESS (L) 32815 V
40 HD785-7
Brake [Retarder controller system]
Monitoring
code
0.00 – 20.10
31 Suspension pressure (right) SUS PRESS (R) 32816 MPa
0.00 – 5.00
32 Suspension pressure (right) SUS PRESS (R) 32817 V
0/1 (1 digit of 0/1) --- [Other 0: EMPTY/1:
33 Judgment of empty/loaded EMPTY OR LOAD 39400
than above] LOAD
0 – 1020
34 ASR output (left) command ASR OUTP DIR L 39601 mA
0 – 1020
35 ASR output (right) command ASR OUTP DIR R 39603 mA
01010101
01010101
01010101
01010101
0
01010101
41 Output signal (0 – 7) D-OUT-0------7 40955 0: OFF/1: ON
01010101
42 Output signal (8 – 15) D-OUT-8-----15 40956 0: OFF/1: ON
01010101
43 Output signal (16 – 23) D-OUT-16----23 40957 0: OFF/1: ON
HD785-7 41
Detailed information of 40932 (D-IN--0------7) Detailed information of 40955 (D-OUT--0------7)

[0]: Exhaust brake switch [0]: Auto-suspension solenoid 1
[1]: Service brake switch [1]: Hoist selector valve
[2]: Retarder switch (Front) [2]: Lever kick-out solenoid
[3]: Retarder switch (Rear) [3]: Auto-suspension solenoid 2
[4]: Validation switch 1 [4]: (Unused)
[5]: Validation switch 2 [5]: Exhaust brake solenoid
[6]: Memory clear switch [6]: (Unused)
[7]: Brake oil filter [7]: (Unused)
Detailed information of 40933 (D-IN--8-----15) Detailed information of 40956 (D-OUT--8-----15)

[8]: ASR pressure switch (Rear left) [8]: (Unused)
[9]: ASR pressure switch (Rear right) [9]: (Unused)
[10]: Shut-off valve switch [10]: (Unused)
[11]: ASR check switch [11]: ASR shut-off valve
[12]: Parking brake pressure switch [12]: (Unused)
[15]: (Unused) [15]: Body "Float" signal
Detailed information of 40934 (D-IN--16----23) Detailed information of 40957 (D-OUT--16-----23)

[16]: Starting switch C terminal signal [16]: Stop lamp relay
[18]: (Unused) [18]: Sensor power supply (24 V)
[19]: Brake wear switch (Rear left) [19]: BCV relay
[20]: Brake wear switch (Rear right) [20]: (Unused)
[21]: Parking brake solenoid [21]: (Unused)

[24]: Steering wheel speed
[25]: (Unused)
[26]: Retarder cooling filter
[27]: Engine oil level switch
[28]: Engine oil filter
[29]: Steering hoist level switch
[30]: Steering hoist filter switch
[31]: Battery electrolyte level switch
[32]: Transmission/Brake oil level switch
42 HD785-7
VHMS [VHMS controller system]
Monitoring
code
Suspension pressure 0.00 – 20.10
1 SUS PRESS (FR) 32804 (*) MPa
(front right) ---- [Other than above]
0.00 – 20.10
2 Suspension pressure (front left) SUS PRESS (FL) 32805 (*) MPa
3 SUS PRESS (RR) 32806 (*) MPa
(rear right) ---- [Other than above]
0.00 – 20.10
4 Suspension pressure (rear left) SUS PRESS (RL) 32807 (*) MPa
5 SUS PRESS (FR) 32810 (*) V
0.00 – 5.00
6 Suspension pressure (front left) SUS PRESS (FL) 32811 (*) V
7 SUS PRESS (RR) 32812 (*) V
0.00 – 5.00
8 Suspension pressure (rear left) SUS PRESS (RL) 32813 V
-15.0 – +15.0
9 Inclinometer (pitch angle) INCLINOMETER 32901 (*) ° (degree)
0.00 – 5.10
10 Inclinometer (pitch angle) INCLINOMETER 32902 (*) V
-30 – +100
11 Ambient temperature AIR TEMP 37501 °C
0.00 – 5.00
12 Ambient temperature AIR TEMP 37504 V
01010101
01010101
0101
15 Output signal (0 – 7) D-OUT-0--3 40946 0: OFF/1: ON
0101
16 SEL signal (0 – 3) D-SEL--0--3 40947 0: OFF/1: ON
0.0 – 655.4
17 Payload PAYLOAD 42200 (*) t
0.0 – 655.4
18 Rated load weight RATE WEIGHT 42201 (*) t
19 Status of truck TRUCK STATUS 42400 (*) 0 – 8 —
20 Gearshift lever N signal SHIFT LEVER N 42500 (*) 0/1 (1 digit of 0/1) 0: OFF/1: ON
Exhaust temperature EXHAUST TMP 200 – 950

21 42600 °C
(left bank front) FL ---- [Other than above]
22 42601 °C
(right bank rear) RR ---- [Other than above]
23 42602 °C
(right bank front) FR ---- [Other than above]
Exhaust temperature EXHAUST TMP 0.00 – 5.00
24 42603 V
(right bank front) FR ---- [Other than above]
25 42604 V
(left bank front) FL ---- [Other than above]
HD785-7 43
VHMS [VHMS controller system]
Monitoring
code
26 42605 V
(right bank rear) RR ---- [Other than above]
Exhaust temperature EXHAUST TMP 2.00 – 950
27 42606 °C
(left bank rear) RL ---- [Other than above]
28 42607 V
(left bank rear) RL ---- [Other than above]
0.0 – 20.0
29 Blow-by pressure BLOWBY PRESS 42801 kPa
0.00 – 5.00
30 Blow-by pressure BLOWBY PRESS 42802 V
31 Stop and run flags STOP RUN FLAG 45000 0/1 (1 digit of 0/1) 0: OFF/1: ON
*: When PLM in VHMS is set.
44 HD785-7
Detailed information of 40944 (D-IN--0------7)

[0]: (Unused)
[1]: Connection of ORBCOM (Connected: 1)
[2]: (Unused)
[3]: (Unused)
[4]: (Unused)
[5]: (Unused)
[6]: Download switch under cab (ON: 1)
[7]: Body float state (ON: 1)
Detailed information of 40945 (D-IN--8-----15)

[8]: Protocol selector connector (Automatic trans-
mission: 1)
[9]: Protocol selector connector (MMS communica-
tion: 1)
[10]: (Unused)
[11]: (Unused)
[12]: (Unused)
[13]: (Unused)
[14]: (Unused)
[15]: (Unused)
Detailed information of 40946 (D-OUT-0--3)

[0]: External indicator lamp (Lighting of green lamp:
0)
[1]: External indicator lamp (Lighting of orange
lamp: 0)
[2]: External indicator lamp (Lighting of red lamp: 0)
[3]: Operation of VHMS (Operating: 1)
Detailed information of 40947 (D-SEL-0--3)

[0]: SEL-0 (Always: 0)
Detailed information of 42400

[1]: Empty truck is stopped
[2]: Empty truck is traveling
[3]: Truck is being loaded
[4]: Loaded truck is traveling
[5]: Loaded truck is stopped
[6]: Truck is dumping
HD785-7 45
ABS [ABS controller system] (If equipped)
Monitor-
ing code
1 Part No. of software VERSION 20210 ******** (8 digits/symbols) —
2 Version No. of application VERSION (APP) 20233 ******** (8 digits/symbols) —
3 Version No. of data VERSION (DATA) 20234 ******** (8 digits/symbols) —
0 – 3000
4 Wheel speed (front left) WHEEL SPEED FL 39706 rpm
0 – 3000
5 Wheel speed (front right) WHEEL SPEED FR 39707 rpm
0 – 3000
6 Wheel speed (rear left) WHEEL SPEED RL 39708 rpm
0 – 3000
7 Wheel speed (rear right) WHEEL SPEED RR 39709 rpm
01010101
8 Input signal (0 - 7) D-IN--0------7 40937 0: OFF/1: ON
01010101
9 Input signal (8 - 15) D-IN--8-----15 40938 0: OFF/1: ON
01010101
01010101
01010101
12 Output signal (0 - 7) D-OUT-0------7 40958 0: OFF/1: ON
01010101
13 Output signal (8 - 15) D-OUT-8-----15 40959 0: OFF/1: ON
01010101
14 Output signal (16 - 23) D-OUT-16----23 40960 0: OFF/1: ON
ABS control valve output 0 – 1000
15 ABS CNT VAL FL 43308 mA
(front left) ---- [Other than above]
16 ABS CNT VAL FR 43309 mA
17 ABS CNT VAL RL 43310 mA
(rear left) ---- [Other than above]
18 ABS CNT VAL RR 43311 mA
ABS control oil pressure 0.00 – 99.99
19 CONT PRESS FL 43312 MPa
20 CONT PRESS FL 43313 V
21 CONT PRESS FR 43314 Mpa
22 CONT PRESS FR 43315 V
23 CONT PRESS RL 43316 Mpa
24 CONT PRESS RL 43317 V
25 CONT PRESS RR 43318 Mpa
26 CONT PRESS RR 43319 V
46 HD785-7
Detailed information of 40937 (D-IN--0------7) Detailed information of 40959 (D-OUT--8-----15)

[0]: ABS cut pressure switch (Front) [8]: (Unused)
[1]: ABS cut pressure switch (Rear) [9]: (Unused)
Detailed information of 40938 (D-IN--8-----15) Detailed information of 40960 (D-OUT--16-----23)

[10]: (Unused) [18]: ABS cut valve (Front) (* Through relay)
[11]: (Unused) [19]: ABS cut valve (Rear) (* Through relay)

[16]: Starting switch C terminal signal
[17]: (Unused)
[18]: (Unused)
[19]: (Unused)
[20]: (Unused)
[21]: (Unused)
[22]: (Unused)
[23]: (Unused)

[24]: (Unused)
[25]: (Unused)
[26]: (Unused)
[27]: (Unused)
[28]: (Unused)
[29]: (Unused)
[30]: (Unused)
[31]: (Unused)
Detailed information of 40958 (D-OUT--0------7)

[0]: (Unused)
[1]: (Unused)
[2]: (Unused)
[3]: (Unused)
[4]: (Unused)
[5]: (Unused)
[6]: (Unused)
[7]: (Unused)
HD785-7 47
[14] Reduced cylinder mode (CYLINDER 3) Selection of operation/non-operation by bank

CUT-OUT) On the operation/non-operation screen,
As one method of troubleshooting for the engine, operate the [>], [<] and [t] switches to select
the machine monitor has a reduced cylinder mode operation/non-operation of the left bank or
that can set the desired cylinder to the no injection right bank.
condition. q [ > ]: Change selection screen
q [ < ]: Change selection screen
1. 1.Starting engine q [t]: Return to reduced cylinder mode
Use this function while the engine is running, screen
because a defective cylinder is determined q [U]: Go to reduced cylinder mode opera-
depending on the engine speed in the reduced tion screen
cylinder mode. a Since it takes some time to stop all the
cylinders of each bank, wait for at least 8
2. 2.Selection of the service menu seconds before changing the screen.
1) 1)Select the reduced cylinder mode q When checking left bank and operating all
(CYLINDER CUT-OUT) in the service menu cylinders of right bank

selection screen.
q When checking left bank and stopping all

cylinders of right bank
2) While the service menu is selected, press the
[U] switch to display reduced cylinder mode
bank unit selection screen.
a The screen in the figure is displayed.
48 HD785-7
q When checking right bank and operating

all cylinders of left bank
4. Canceling cylinder cut-out

Cancellation of cylinder cut-out is done by the
same procedure as setting cut-out cylinder.
q When checking right bank and stopping a When the [U] switch is used to confirm the
all cylinders of left bank cancellation of the cut-out cylinder, commu-
nication is carried out between the machine
monitor and engine controller. During this
time, the cylinder No. flashes.
After completion of the communication, the
segment under the cylinder No. becomes
white to show that the cylinder cut-out has
been canceled.
3. Setting cut-out cylinder

In the reduced cylinder mode execution screen,
operate each of the switches [>], [<], [U] and [t]
to select the cut-out cylinder.
q [ > ]: Selector cursor moves to the right.
q [ < ]: Selector cursor moves to the left.
q [U]: Determine the cylinder.
q [t]: To return to the service menu selection
screen.
a When the [U] switch is used to confirm the
cut-out cylinder, communication is carried
out between the machine monitor and engine
controller. During this time, the cylinder No.
flashes.
After completion of the communication, the
segment under the cylinder No. becomes
black to show that the cylinder has been cut
out.
a A single cylinder or multiple cylinders can be
cut out.
HD785-7 49
[15] No injection cranking function (NO INJEC- 3. Setting is denied during engine running
TION) During engine running, if the setting of none
The machine monitor has the function of none injec- injection cranking is attempted, "STOP
tion cranking, which carries out cranking after ENGINE" is displayed in the lower line, and
long-term storage, stopping fuel injection of all the setting is rejected.
cylinders without starting the engine. a None injection cranking function cannot be
a The function of none injection cranking must be used during engine running.
operated under the condition that the engine is
stopped.
1. Selection of the service menu

In the service menu selection screen, select
none injection cranking function (NO INJEC-
TION).
4. Canceling no injection cranking

If the [t] switch is pressed on the no injection
cranking execution screen, the screen returns to
the service menu selection screen and the no
injection cranking is cancelled.
q [t]: To return to the service menu selection
screen.
2. Establishment of no injection cranking
switch to display none injection cranking execu-
tion screen.
a If "CRANKING READY" is displayed on the
lower line, the none injection cranking is set.
a If the starting switch is operated to the
START position under this condition, the en-
gine cranks but will not start.
50 HD785-7
[16] Adjustment function (TUNING) The adjustment is implemented by operating the

Machine monitor can run "Adjusting transmission machine monitor and machine body following the
ECMV electric current" and "Reset the transmission below procedure.
initial learning and implement learning " through the 1. Preparing operations for "Adjusting transmission
transmission controller. ECMV electric current"
(Real time monitoring function)
2. Adjusting transmission ECMV electric current
(02: AUTO of ECMV TUNING)
3. Reset the transmission initial learning and imple-
ment learning (TUNED/Real-time monitoring
function for 01: TM TRIGGER)
a ( ) indicates service menu or adjustment
function used for the adjustment.
a [MANUAL] menu of [02: ECMV TUNING] is
the function only used by plants and not used
by services.
a For details concerning the operation method
of real time monitoring function, refer to "[11]
real time monitoring function".
If power train related operation such as the following
is carried out, execute the adjustment operation.
q If transmission is overhauled or changed
q If transmission valve is replaced
q Transmission controller has been replaced.
q When an abnormality occurred in the power train
speed sensor and has been repaired
(refer to the below table for failure code)
q If the transmission oil temperature sensor is trou-
bled and repaired (refer to the below table for
failure code)
q If the transmission oil filter is clogged and re-
paired (refer to the below table for failure code)
Failure code Device name
DLF1KA Transmission input shaft speed 1. Preparing operations for "Adjusting trans-
DLF1LC sensor mission ECMV electric current"
DLF2KA a The adjusting operation should be carried out
Transmission intermediate shaft
speed sensor with the specified oil temperature. Confirm
DLF2LC
the machine is not displaying abnormality
Transmission output shaft R
DLF3KA and adjust the transmission oil temperature
speed sensor
Transmission valve oil tempera- following the next procedure.
DGF1KX 1) Select real time monitoring function
ture sensor
15BONX Transmission oil filter (REAL-TIME MONITOR) in the service menu
selection screen.
HD785-7 51
2) With the service menu selected, press the 7) Depress the brake pedal, and set the gear
[U] switch to display the monitoring system shift lever to D position.
and function selection screen. a Confirm that the shift indicator displays
q [U]: Runs service menu "F2".
3) In the monitoring system and function selec- 8) Stall the torque converter and raise the trans-
tion screen, press [>] switch or [<] switch to mission oil temperature up to 70 – 80°C.
select transmission system (TRANSMIS- a Be careful not to overheat the oil while
SION). stalling the torque converter.
q [>]: To proceed to next monitoring system 9) Return the gear shift lever to "N" position,
and function keep it for 3 minutes, and confirm that the
q [<]: To go back to data for previous moni- transmission oil temperature is stable
toring system and function between 70 – 80 °C.
a In addition to the above, check that the
machine has not detected a trouble.
2. Adjusting transmission ECMV electric

current
a Adjustment is carried out four times automat-
ically against the Hi, Lo, R, 1st, 2nd and 3rd,
4th valves respectively.
1) Refer to "1. Preparation of operations for
adjusting transmission ECMV electric
current", and select the monitoring code of
transmission oil temperature.
q Monitoring code:
32500 (T/M OIL TEMP)
4) With the transmission system selected, press a At this time, do not start the engine.
the [U] switch and display the monitoring
display and item selection screen.
q [U]: Implement 1 system individual mon-
itoring
q The program version No. is displayed on
********.
5) In the monitoring display and item selection
screen, press [>] switch or [<] switch and
select monitoring code of transmission oil
temperature.
q [>]: Goes on to the next monitoring item
q [<]: Goes back to the previous monitoring
item
q Monitoring code:
32500 (T/M OIL TEMP) 2) Run the engine, set the machine to the next
condition, and confirm that the transmission
oil temperature is between 70 – 80 °C.
q Parking break switch: PARKING
q AISS LOW switch: LOW (low speed)
q Gear shift lever: N position
q Engine: Low idling
q Accelerator pedal: OFF (Release)
6) Confirm that the parking brake switch is

PARKING, and start the engine.
52 HD785-7
3) Return to the service menu selection screen, a The figure shows the state in which the
and select the adjustment function automatic compensation is selected,
(TUNING). therefore, [AUTO] is indicated in the lower
a Press [t] switch several times to return to line. \ In the state in which the manual
the service menu selection screen. compensation is selected, [MANUAL] is
indicated in the lower line.
4) While the service menu is selected, hold

down the [U] switch for a minimum of 5
seconds to display the adjustment menu 7) Confirm the machine condition again and
selection screen. press the [U] switch to start adjustment.
q [U]: Runs service menu q [U] switch: To start the adjustment
5) On the adjustment menu selection screen, a The lower line display changes from "IP"
press [>] switch or [<] switch, and select to "IP ***".
ECMV current adjustment item (02: ECMV
TUNING).
q [>]: To proceed to the next adjustment
menu
q [<]: To go back to the previous adjustment
menu
a Adjustments are carried out 4 times con-

tinuously for each objective clutch, and
the below table is displayed.
No. Valve 1st time 2nd time 3rd time 4th time
1 LOW IP L-1 IP L-2 IP L-3 IP L-4
2 HIGH IP H-1 IP H-2 IP H-3 IP H-4
6) With the adjustment menu selected, press
3 1ST IP 1-1 IP 1-2 IP 1-3 IP 1-4
[U] switch and display the automatic
4 2ND IP 2-1 IP 2-2 IP 2-3 IP 2-4
compensation (AUTO) or manual compensa-
tion (MANUAL) selection screen. Press [<] 5 3RD IP 3-1 IP 3-2 IP 3-3 IP 3-4
switch or [>] switch to select the automatic 6 REV IP R-1 IP R-2 IP R-3 IP R-4
compensation (AUTO). 7 4TH IP 4-1 IP 4-2 IP 4-3 IP 4-4
q [U]: To execute the adjustment menu
q [ > ]: To switch to the next compensation
screen.
q [ < ]: To switch to the next compensation
screen.
q Compensation menu: AUTO
HD785-7 53
8) Normal and abnormal results are displayed 3. Reset the transmission initial learning and
for each adjustment, therefore take action implementation of learning
depending on the display. a Before carrying out this adjustment item, be
sure to implement "2. Transmission ECMV
current adjustment".
a Before proceeding to the learning, confirm
that the transmission oil temperature is at the
specified temperature referring to "1. Prepar-
ing operations for "Adjusting transmission
ECMV electric current". (If adjustments are
made at temperatures other than specified
temperature, time lag or gear shift shock may
occur.)
k The learning should be carried out in an area
with a sufficient traveling distance, paying at-
tention to the surroundings for safety.
q Indicated code for the normal or abnormal 1) Select (TUNING) in the service menu selec-
result tion screen.
Code Condition
OK Normal result
NG1 Out of compensation conditions
Abnormal
NG2 No fill
result
NG3 Over the compensation values
q If "OK" (normal result) is displayed:

Adjustment is done without error.
q If "NG1" is displayed (out of compensa-
tion condition):
Adjust the transmission oil temperature
exactly, and confirm the machine setting
conditions again, then carry out the
adjustment from procedure 1).
q If "NG2" (no fill) is displayed: 2) While the service menu is selected, hold
Carry out troubleshooting of failure code down the [U] switch for a minimum of 5
[15S*MA][DDT*KA], and if the condition seconds to display the adjustment menu
is confirmed to be normal,then start again selection screen.
q [U]: To conduct the service menu.
from procedure 1)
(The symbol with * mark varies by objec- 3) With the adjustment menu selection screen,
tive clutches). confirm that the transmission trigger adjust-
q If "NG3" is displayed (compensation val- ment item (01: TM TRIGGER) is displayed.
ue over):
Carry out troubleshooting of failure code
[15S*L1], and if the condition is confirmed
to be normal, then start it again from
procedure 1) (The symbol with * mark
varies by objective clutches).
9) If the adjustments has been completed
normally, the adjustment values are recorded
in the transmission controller about 3
seconds after the starting switch has been
turned off.
a If the starting switch needs to be turned
ON soon after the adjustment, keep the
starting switch in the OFF position for
more than 10 seconds as a precautionary
measure then turn it ON.
54 HD785-7
4) With the adjustment menu selected, press

the [U] switch to display the initial learning
resetting screen.
q [U]: To execute the adjustment menu
a The current initialization state is displayed
in the lower line.
q Initialization is done: INITIAL STATUS
q Initialization is not yet done: TUNED
a If [TUNED] is indicated, proceed to the
next procedure to initialize the learning
data.
a If the resetting operation is to be aborted,
press [t] switch to return to the former
screen.
7) Return to service menu selection screen and
q [t]: To return to the previous screen
select real time monitoring function
(REAL-TIME MONITOR).
a Press [t] switch several times to return to
the service menu selection screen.
5) With the initial learning resetting screen

displayed, press the [U] switch to display the
initializing operation screen.
q [U] switch:
8) With the service menu selected, press the
To execute the initial learning reset
[U] switch to display the monitoring system
q [U]: To conduct the service menu.
9) In the monitoring system and function selec-
tion screen, press [>] switch or [<] switch to
select 2 items simultaneous monitoring (2
ITEMS).
q [>]: To proceed to next monitoring system
and function
q [<]: Go back to data for previous monitor-
ing system and function
6) With the initialization operation screen

displayed, operate each of the switches [<],
[>] and [t] to execute initialization.
q [<]: Select YES (move cursor)
q [>]: Select NO (move cursor).
a After initializing, confirm that the display
on the lower line indicates that initializa-
tion is completed.
q Initialization is done: INITIAL STATUS
HD785-7 55
10)With 2 items simultaneous monitoring

selected, press the [U] switch and display
the monitoring code input screen.
q [U]: Execute monitoring system and
function.
11)In the monitoring code input screen, operate
each of the switches [>], [<], [U] and [t], and
directly input 2-digit monitoring codes.
q [>]: Number at the cursor increases.
q [<]: Number at the cursor decreases
q [U]: Number at the cursor is determined
q [t]: Cursor moves to the left end / To re-
turn to the monitoring system and func-
q Monitoring code: 32500 and 38920 15)Set the gearshift lever in the 6 position and
a Indicate the transmission oil temperature press the accelerator pedal fully to run the
in the upper row (32500) and study condi- truck and shift up the gear to F6.
tion of clutch trigger in the lower row a Shifting up: F1 o F2 o F3 o F4 oF5 o
(38920) (0: not learned yet, 1: already F6
learned). 16)After the gear is shifted up to F6, release the
accelerator pedal and shift down the gear to
F1 by coasting run.
a Shift down: F6 o F5 o F4 o F3 o F2 o
F1
a Do not apply the brake during coasting
run.
17)Check that the trigger learning of the 4th
clutch is displayed on the monitor.
a If "1" is displayed, go to the next step.
a If the display is "0", repeat procedure 15)
– 16) until it becomes "1".
a If "1" is not displayed after repeating the
steps 4 times, the ECMV may be defec-
tive. In this case, replace the ECMV.
12)Set AISS LOW switch to LOW. a The * marked clutch display can be either
13)Start the engine, keep the gear shift lever at "0" or "1".
N position for 10 seconds at the low idle, then
operate the gear shift lever as follows.
a Gear shift lever operation:
NoRoN
14)Confirm the trigger learning display of R
clutch in the monitoring display.
a Proceed to the next step if the display is
"1".
a If the display is "0", repeat procedure 13)
until it becomes "1".
a The * marked clutch display can be either
"0" or "1".
56 HD785-7
18)Set the gearshift lever in the 4 position and 23)Check that the trigger learning of the Hi
press the accelerator pedal fully to run the clutch is displayed on the monitor.
truck and shift up the gear to F4. a If "1" is displayed, go to the next step.
a Shifting up: F1 o F2 o F3 o F4 a If "0" is displayed, repeat steps 21) – 23)
19)After running the machine at F4 for 10 until "1" is displayed.
seconds, release the accelerator pedal and a If "1" is not displayed after repeating the
shift down the gear to F1 by coasting run. steps 4 times, the ECMV may be defec-
a Shifting down: F4 o F3 o F2 o F1 tive. In this case, replace the ECMV.
a Do not apply the brake during coasting a The * marked clutch display can be either
run. "0" or "1".
20)Check that the trigger learning of the 2nd
a If "1" is displayed, go to the next step.
a If "0" is displayed, repeat steps 18) – 20)
until "1" is displayed.
a The * marked clutch display can be either
"0" or "1".
24)Set the gearshift lever in position 4 and press

the accelerator pedal fully to shift up the gear
to F3 and then continue travel at F3,
adjusting the accelerator pedal.
a Shifting up: F1 o F2 o F3
25)After running the machine at F3 for 10
seconds, press the accelerator pedal fully to
shift up the gear to F4.
a Shifting up: F3 o F4
26)Stop the machine and check that the trigger
learning of the low clutch and 3rd clutch is
21)Set the gearshift lever in the 3 position and displayed on the monitor.
press the accelerator pedal fully to run the a If "1" is displayed, go to the next step.
truck and shift up the gear to F3. a If "0" is displayed, repeat steps 24) – 26)
a Shifting up: F1 o F2 o F3 until "1" is displayed.
22)After running the machine at F3 for 10 a If "1" is not displayed after repeating the
seconds, release the accelerator pedal and steps 4 times, the ECMV may be defec-
shift down the gear to F1 by coasting run. tive. In this case, replace the ECMV.
a Shifting down: F3 o F2 o F1 a The * marked clutch display can be either
a Do not apply the brake during coasting "0" or "1".
run.
HD785-7 57
27)Set the gearshift lever in the 2 position and

press the accelerator pedal fully to run the
truck and shift up the gear to F2.
a Shifting up: F1 o F2
28)After running the machine at F2 for 10
seconds, release the accelerator pedal and
shift down the gear to F1 by coasting run.
a Shifting down: F2 o F1
29)Check that the trigger learning of the 1st
a If "1" is displayed the initial learning has
completed finally.
a If "0" is displayed, repeat steps 27) – 29)
until "1" is displayed.
30)In the monitiring display, confirm finally the

trigger learning display of lower line.
a If displayed as drawing, the initial learning
has completed normally.
31)Press [t] switch sereral times and complete

service menu.
q [t]: To return to the previous screen.
58 HD785-7
[17] Filter and oil replacement time setting func- a Displayed maintenance item and func-
tion (MAINTENANCE MONITOR) tion:
Machine monitor can set the maintenance intervals Maintenance items and func-
No. Display
for various filters and oil which become the base of tions
replacement time display for filter and oil. Also the 1 41: FUEL P FILT Fuel pre filter
machine monitor can activate or deactivate the dis- 2 01: ENG OIL Engine oil
play function. 3 02: ENG FILT Engine oil filter
4 13: TM FILT Transmission oil filter
Select the filter and oil replacement time setting
5 03: FUEL FILT Fuel main filter
function (MAINTENANCE MONITOR) in the
service menu selection screen. 6 06: CORR RES Corrosion resistor
17: TC/TM/ BK Torque convertery/ Transmis-
7
OIL sion/Brake oil
8 14: BK OIL FILT Brake oil filter
9 16: BK C FILT Brake cooling oil filter
10 04: HYD FILT Hydraulic oil filter
11 11: DIFF OIL Differential oil
12 08: FNL OIL Final drive oil
13 10: HYD OIL Hydraulic oil
Setting default value for all
14 INITIALIZE
items
Setting validity or invalidity for
15 ALL ITEMS
all items
a No.1 – 13 are the maintenance items
where the setting is changed by item, and
2. Displaying and selecting the maintenance item No.14 – 15 are the functions which allows
and function to change the setting of all items simulta-
1) With the service menu selected, press the neously.
[U] switch to display the maintenance item a Display the item and function in the [*]
and function selection screen. section.
2) If [>] switch or [<] switch is pushed while the

maintenance item and function selection
screen is displayed, the maintenance item
and function will be displayed endlessly in
the order shown by the below table. Select
the item or the function which will be used.
q [>]: To proceed to next maintenance item
and function.
q [<]: To return to the previous maintenance
item and function.
HD785-7 59
3. Display contents of the maintenance item

(Items No.1 – 14)
If the maintenance item for filter or oil is selected,
the following contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
3: Number of times of replacement up to present
3) When the interval time is completely deter-

mined, the screen to confirm the changes is
displayed. Then, operate each of the
switches [<], [>] and [t].
q [<]: Select YES (move cursor)
q [>]: Select NO (move cursor)
4. Changing the interval time by maintenance item

(Items No.1 – 14)
1) With the item selected on the maintenance
item and the function selection screen to
change the interval time (ex: P FUEL FILT),
press the [U] switch to display the interval
change screen.
q [U]: Implement the function to change
maintenance item.
a The currently set interval is displayed on
the screen.
a With this screen displayed, if the [>]
switch or the [<] switch is operated, the 5. Set the function activation or deactivation by
screen switches to the setting screen for maintenance item (items No.1 – 14).
activating or deactivating the mainte-
1) With the item selected on the maintenance
nance item.
item and function selection screen (ex: FUEL
2) On the interval change screen, operate each P FILT) to change the activation or deactiva-
of the switches [>], [<], [U] and [t] to input tion of the function, press the [U]switch to
the interval time. display the interval input screen.
q [ > ]: Number at the cursor increases.
q [U]: Implement the function to change
q [ < ]: Number at the cursor decreases.
maintenance item.
q [U]: Number at the cursor is determined.
q [t]: To return to the service menu selec-
tion screen.
a The time must always be input with 4 dig-
its. For the time with less than 4 digits, in-
put 0s in place of the vacant number.
60 HD785-7
2) After displaying the screen to input intervals, a If the timer which has been OFF is turned
press the [>] switch or the [<] switch to ON, the interval is set to the value before
display the activation or deactivation setting it was turned OFF and the rest of set time
screen. of the timer is reset. The number of reset-
q [>]: Switch the setting screen. ting times is set to the value before it was
q [<]: Switch the setting screen turned OFF.
a If the function is activated, it is displayed
like the upper line. And if it is deactivated,
it is displayed like the lower line. 6. Setting default values of interval time for all items
3) After the activate or deactivate setting screen (function of No.15)
is displayed, check the present setting status 1) With all item default value setting
and the contents of change. Then operate (INITIALIZE) selected on the maintenance
each of the switches [U] and [t]. item and function selection screen, press the
q [U]: Switch to the change confirmation [U] switch to display the all item default
screen value setting screen.
q [t]: To return to the maintenance item q [U]: Implement the function to set the de-
and function selection screen. fault values of all the items.
q [<]: Switch to the interval change screen.
2) Display the all item default value setting

4) When the change confirmation screen is screen and operate each [<], [>] and
displayed, operate each [<], [>] and [t]switches.
[t]switches. q [<]: Select YES (move cursor)
q [<]: Select YES (move cursor) q [>]: Select NO (move cursor)
q [>]: Select NO (move cursor) q [t]: Execute YES or NO
a To make return to default setting regard-

less individual setting of activation or de-
activation or interval.
a The rest of the set time of the timer is set
to the [default value/elapsed time after
the previous replacement].
HD785-7 61
a The number of resetting times is kept at a If activation of all the items (ON) is set, the
the value before the default was set. maintenance function of all the items
a Each item is set turned ON. starts to work regardless of setting by the
maintenance item and the interval is set
7. Setting the function activation or deactivation for to the previous time before the interval
all the items (function No.15) has been deactivated.
1) With the activation or deactivation setting for a The timer is reset simultaneously and it
all items selected (ALL ITEMS) on the main- restarts to count from 0 h.
tenance item and function selection screen, The number of resetting times is set to the
press the [U] switch to display the all items value before it was turned OFF.
activation or deactivation setting screen.
q [U]: Implement the function to set activa-
tion or deactivation of all the items.
4) When the change confirmation screen is

displayed, operate each [<], [>] and [t]
2) After the all items activation or deactivation switches.
setting screen is displayed, press the [>] q [<]: Select YES (move cursor)
switch or the [<] switch to display the activa- q [>]: Select NO (move cursor)
tion setting or deactivation setting screen. q [t]: Execute YES or NO
q [>]: Switch the setting screen.

q [<]: Switch the setting screen
a To deactivate all the items, display the
upper line setting screen (OFF), and to
activate all the items, display the lower
line setting screen (OFF).
3) Confirm the setting screen, press the [U]
switch or the [t] switch to display the change
confirmation screen.
q [U]: To switch to the change confirmation
screen.
q [t]: To return to the maintenance item
a If deactivation of all the items (OFF) is set,
it will stop the maintenance function of all
the items, regardless of the setting by the
maintenance item.
62 HD785-7
Table of filter and oil replacement time set items

Replacement frequency
No. System and function Code Display Remarks
(Default value)
1 Fuel pre filter 41 FUEL P FILT 0500
2 Engine oil 01 ENG OIL 0500
3 Engine oil filter 02 ENG FILT 0500
4 Transmission oil filter 13 TM FILT 0500
5 Fuel main filter 03 FUEL FILT 1000
6 Corrosion resistor 06 CORR RES 1000
Torque converter/Transmission/
7 24 TC/TM/ BK OIL 1000
Brake oil
8 Brake oil filter 14 BK OIL FILT 1000
9 Brake cooling oil filter 16 BK C FILT 1000
10 Hydraulic oil filter 04 HYD FILT 2000
11 Differential oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
All item simultaneous
14 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
15 Setting enable or disable for all items (None) ALL ITEMS —
setting function
HD785-7 63
[18] Operation information display function (OP- a There are four types of information screen.
ERATION INFO)
Machine monitor can display the fuel consumption 4. Information to be displayed (screen 1 – 4)
per mile and per time, the fuel consumption per any Above: Fuel consumption per km or mile from
accumulated time and the travel distance, and the the last reset point (distance unit is km or mile
fuel consumption during any accumulated time and and it depends on the setting of the inte-
its accumulated time. grated odometer in the operator mode).
a Fuel consumption value is the integration of the Maximum display value:
targeted injection rate signal which is sent from 99999.9 L/km (L/mile)
the engine controller. It is not the measurement Below: Fuel consumption per time started from
of the actual fuel consumption. Therefore the the last reset point
displayed fuel consumption is used as a guide Maximum display value: 99999.9 L/h
value.
Select the operation information display function
(OPERATION INFO) on the service menu selec-
tion screen.
Above: Integrated fuel consumption started from

the last reset point
Maximum display value: 9999999.9 l
Below: Accumulated travel distance from the
last reset point (travel distance unit is km or
mile and it depends on the setting of the inte-
2. Displaying the operation information grated odometer in the operator mode).
With the service menu selected, press the Maximum display value:
[U]switch and display the operation information 9999999.9 km(mile)
and item selection screen.
3. Selecting displayed information

With the operation information and item selec-
tion screen displayed, operate the [>] switch or
the [<] switch to select the information screen to
display.
q [>]: To display the next information screen.
q [<]: To display the previous information
screen.
64 HD785-7
Above: Integrated fuel consumption started from

the last reset point
Maximum display value: 9999999.9 l
Below: Elapsed time from the last reset point
Maximum display value: 9999999.9 h
6. Correction of integrated fuel consumption

a When there is the difference between the in-
tegrated fuel consumption (L) in display and
the actually measured fuel consumption, cor-
rect it in the following way.
a In case of "PLM function in VHMS" equpped. 1) With the reset screen displayed, press the [>]
Above: Loading weight started from the last switch or the [<] switch to display the fuel
reset point. [ton] consumption correction screen.
Below: Loading the number of time from the q [>]: Switch the displayed screen
last reset point. [times] q [<]: Change the displayed screen
2) After the fuel consumption correction screen

5. Resetting displayed information
is displayed, press the [U] switch or the [t]
1) With any information screen displayed, press switch to switch to the correction value input
the [U] switch to display the reset screen. screen.
q [U]: Switch to the reset screen.
q [U]: Switch to the correction value input
2) After the reset screen is displayed, press the screen
[U] switch or the [t] switch and execute or q [t]: To return to the service menu screen
cancel the reset.
q [U]: Implement resetting.
q [t]: Cancel resetting
a When the resetting is carried out, all the
information goes to "0", and the monitor-
ing starts newly from that point of time
(Monitoring is only conducted while en-
gine is running.)
a If the [>] switch or the [<] switch is operat-
ed with this screen displayed, the screen
is switched to the fuel consumption cor-
rection screen.
HD785-7 65
a Refer to "Standard valve table" about mode

and spec.
2. Selection of service menu

While the service menu selection screen is
displayed, select the engine mode fixing function
(FIX POWER MODE).
3) After displaying the compensation value

input screen, operate each of the switches
[>], [<], [U] and [t] to input the compensa-
tion value directly.
q [ > ]: To switch the cursor symbol (+/-) /
Number increases.
q [ < ]: To switch the cursor symbol (+/-) /
Number decreases.
q [U]: Sign/number at the cursor is deter- 3. Selection of mode
mined. While the service menu is selected, press the
q [t]: Return to the fuel correction screen [U] switch to display the engine mode fixing
a The correction value at the plant before screen.
shipment is [+/-00.0%] (In case of input- q [U]: Execute service menu
ting 00.0, +/- does not matter.)
a The compensation value can be input
within the range of [-50.0% – +50.0%].
4. Selection of displayed information

While the engine mode fixing screen is
displayed, select the information screen to be
[19] Engine mode fixing function (FIX POWER displayed with the [>] or [<] switch.
MODE) q [>] switch: Select setting screen
While the screen is displayed, the operator can q [<] switch: Select setting screen
measure the high idle speed and torque converter q [t] switch: Engine mode fixing function
stall speed to check the engine performance. a The mode is four kind of A – D.
q Engine high idle speed
q Torque converter stall speed 5. Finishing of display
If a mode is selected by the following operation, it is Press the [t] switch to return to the engine mode
sent to the transmission controller, which sends it to fixing function screen.
the engine controller. q Fixing of the engine mode is reset.
1. Advance check
Before the operation, check the following items.
q Parking brake: ON (Parking)
q Failure code: Not displayed
66 HD785-7
[20] Manual snapshot function (Snapshot) 3. Press [U] switch to start the snapshot.
q This function is applicable to only machines a The upper column displays the elapsed time.
equipped with VHMS. a [–] sign in the leftmost position of the lower
q The manual snapshot function stores 7 minutes column is replaced with [*] and it starts flash-
and 30 seconds worth data to be used for Pm ing.
clinic or testing/adjustment to VHMS controller. a For every 30 seconds, [–] is replaced with [*]
q When collecting data at a regular interval for Pm starting with the leftmost one. When two or
clinic, it is required to observe the machine oper- more [*] signs are displayed, the rightmost
ating procedure specified for the quick Pm. As one flashes.
for the data collection for the testing or adjust- a Pressing [t] switch while the snapshot is tak-
ment purpose, however, no specified machine ing place stops the snapshot.
operating procedure is stipulated.
q When using the data being stored with the man-
ual snapshot function, a PC must be connected.
For the connecting as well as operating proce-
dure, refer to VHMS controller initial setting pro-
cedure. (Connection of a PC may be done
before or after the snapshot.)
a For detail of operation of the snapshot function,
see the Quick Pm implementation procedure.
1. Display the SNAPSHOT screen from the menu
screen of Service mode.
4. Refer to the Pm clinic implementation procedure

for the machine operation.
a After 10th [*] is displayed (5 minutes elapsed
from the start), [#] will be displayed for 11th
through 15th positions.
q *: Indicates the data sampling interval is once
every 10 seconds.
q #: Data sampling interval is once every 1 sec-
ond.
5. As 7 minutes and 30 seconds elapsed from start

2. Pressing [U] switch to turn on the ready of the snapshot, following screen appears and
(READY) screen. then the initial screen is restored in 5 seconds
a The lower column displays 15 pieces of [–] later.
sign. (End of snapshot)
HD785-7 67
[21] PLM setting function (PLM)

q This function is applicable when the PLM in
VHMS is installed.
Set various items of the payload meter (PLM) with
the machine monitor.
The details refer to "Setting of payload meter built in
VHMS" ("Testing and adjusting, Part 5").
[24] Initializing function (INITIALIZE)

a This function is exclusive for the plant, and is not
used for service.
[22] Option selection function (OPTIONAL SE-

LECTION)
Machine monitor can set and adjust various optional
devices which have been installed or removed.
a The operating method of this function refers to
the item of "Setting and adjusting various equip-
ment".
[23] Model selection function (MACHINE)

Machine monitor is common among many models,
and if the machine monitor is replaced, select the
same model as the one currently installed.
a The operating method of this function refers to
the item of "Setting and adjusting various equip-
ment".
68 HD785-7
HD785-7 69
HD785-7 Dump truck
©2010KOMATSU
All Rights Reserved
70
SEN01774-04
HD785-7
SEN01774-03
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Opening ORBCOMM terminal .................................................................................................................... 2

VHMS controller initial setting procedure.................................................................................................... 4
Precautions for replacing VHMS controller ................................................................................................. 29
Pm Clinic check sheet................................................................................................................................. 35
Initial setting of payload meter .................................................................................................................... 39
Setting of payload meter built in VHMS ...................................................................................................... 40
HD785-7 1
Opening ORBCOMM terminal
Request for opening ORBCOMM terminal
If the machine is “equipped with ORBCOMM”, fill in the “Request for opening ORBCOMM terminal” and
send it by fax or mail to “KOMATSU KOMTRAX SUPPORT CENTER” before initializing the VHMS controller.
a Initialize the VHMS controller after the opening notification is received from “KOMATSU KOMTRAX SUP-
PORT CENTER”.
a If the ORBCOMM antenna is installed and the starting switch is turned to the ON position before the open-
ing notification is received, the ORBCOMM terminal transmits radio waves and ORBCOMM CO. LTD.
sends out the stop signal automatically. In this case, troublesome procedure and long time are required to
start the ORBCOMM terminal service.
2 HD785-7
HD785-7 3
VHMS controller initial setting 1. Confirmation of machine information, engine

procedure information, transmission controller information
and controller information
a This confirmation procedure is targeted at
a Testing instrument the entire machine.
Symbol Part No. Part name Confirm and record the machine information,
1 799-608-3211 Diskette engine information, VHMS controller infor-
mation and ORBCOM terminal information.
2 799-608-3220 Wiring harness
Note type PC No. Information to be confirmed
N
Commercially (Windows 1 Model name
3
available 98/2000/Me/XP/Vista and 2 Machine serial No.
terminal "RS232C" is with it)
3 Current service meter hour
4 Engine serial No.
a Initial setting of VHMS controller shall be done
5 Transmission serial No.
according to the following procedure. This oper-
ation is needed prior to a full-scale operation of 6 VHMS controller serial No.
a machine being delivered and assembled in the ORBCOM terminal serial No.
7
[Only for machines equipped with ORBCOM]
field, or prior to resumption of its operation after
a long time of storage.
a Machine data collected with VHMS controller are 2. Connecting a PC
stored and managed on WebCARE database. In a This work is done inside the cab.
order to endure smooth data processing on We- 1) Make sure the starting switch is at OFF posi-
bCARE, consistency must be provided among tion.
the settings done on VHMS controller. Inconsis- k Before connecting or disconnecting a
tencies in the settings obstruct loading of data to PC, be sure to turn off the starting
WebCARE, hampering appropriate use of switch.
VHMS data. The initial setting, therefore, is a 2) Using harness N2, connect the PC N3 and
must. download connector DPC7.
a For the method of installing the VHMS Initializa- a Then connect the PC to RS232C termi-
tion Program to the personal computer, refer to nal.
the Operation and Maintenance Manual con-
tained in the package of diskette N1.
a In the procedure, service menus of the monitor
panel are used. Thus, it is advisable to reference
the information contained in the "Special func-
tions of monitor panel" to understand their proce-
dure beforehand.
a The initial setting procedure is described in the
ORBCOM installation specification and the OR-
BCOM-less specification. When using the ORB-
COM installation specification, implement the
procedures needed for VHMS alone, bypassing
those prepared only for ORBCOM installation
specification.
a Check each step of the setting work referencing
the VHMS initial setting work check sheet.
a Information such as models shown in the figures
may not be identical with actual ones.
4 HD785-7
a Download connector DPC7 is installed to

box (1) in the cover at the rear of the op-
erator's seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the one
that represents the decimal point to check
whether or not ORBCOM terminal has
captured the communication satellite.
[ORBCOM installation specification]
a Check whether or not ORBCOM terminal
is capturing the communication satellite
from VHMS controller.
a Perform this check within 3 minutes after
the VHMS starts.
a If the decimal point LED of the right-hand
7-segment LED blinks, the ORBCOMM
terminal has captured the satelite and is
operating normally.
a The ORBCOMM terminal may take time
3. Confirming VHMS controller operation and to capture the satelite, depending on the
confirming satellite capturing state strengh of the signals from the satelite.
a This work is done inside the cab.
a Confirmation of capturing of the satellite is
done for [ORBCOM installation specifica-
tion].
1) Turn the starting switch ON.
2) Check the controller for normal operation
referencing 7-segment LED of VHMS
controller.
a The VHMS controller is powered with the
accessory power supply. Accordingly,
when the starting switch is turned ON, the
7-segment LED must blink to display rota-
tion and then count up in hexadecimal no-
tation. If the LED operates in this way, the
VHMS controller is operating normally.
HD785-7 5
– States of decimal point LED –

q OFF: The terminals cannot communicate
with the ORBCOMM terminal.
q ON: Communication between the VHMS
and ORBCOMM terminal is normal. The
terminals has not captured the satellite.
q Quick blink: Communication between the
VHMS and ORBCOMM terminal is nor-
mal. The ORBCOMM terminal does not
have data to transmit although it has cap-
tured the satelite.
q Slow blink: Communication between the
VHMS and terminal is normal.The ORB-
COMM terminal has data to transmit al-
though it has captured the satelite.
6 HD785-7
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or
a This work is done inside the cab (from PC). older version)
1) Turn on the PC power and start the OS. a This work is done inside the cab (from PC).
2) Operating [VHMS initial setting tool] icon on a It is prohibited in the initial setting to modify
the PC, start up the VHMS initial setting tool. the data of service meter [SMR].
[Machine Information]
Important 1) Open [Machine Information] tab.
a Appearance of the setup screen of the a [Data clear and Set up] menu displays
VHMS setting tool depends its tool. [Machine Information] tab first.
a When using Ver.3.5.2.1 or older version 2) Check every data for correctness.
(CD-ROM), the setting procedure shall a The figure shows the display of another
conform to that described in Section 5. model as an example.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the latest
VHMS version from WebCARE to update
the currently used version.
(Related material: SERVICE MATE
SMP-623)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826138000
4) Select [Data clear and Set up] from [Select
Function] item.
5) Click [OK] button to proceed to the setup
screen.
a Select a [Variation Code] from the follow-

ing table.
3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right side
of [Date/Time] box to display the correc-
tion screen.
2] After correcting it to the correct informa-
tion, press [OK] button.
HD785-7 7
Setting with VHMS initial setting manual (tool) (*1)

Date
PLM function in Payload meter (PLM) Time
VHMS controller
VHMS controller function Model Type Variation code Time difference
(GMT)
Summer time
Installed Not installed Not installed ST
HD785 –7 Set properly
Installed Installed Installed PV
(*1)For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool)
a A variation code is an item among the model, date, etc. that are set with the personal computer
software when the VHMS is initialized. It is used to notify the VHMS "whether the PLM in the VHMS
is effective (Code: PV), and whether the machine has the payload meter (PLM) function (Code:
ST)".
a Since A and B of the short connector to be connected to connector No. HM-50 are not used, con-
nect them normally.
8 HD785-7
4) When [Machine Information] information is [Communication Setting] [ORBCOM

not appropriate, correct it in the following installation specification only]
manner. a This setting shall be implemented after
1] Press [Edit] button in the lower right side the request for station opening has been
of [Machine Information] dialog box to made and station of ORBCOM has been
display the correction screen. opened.
2] After correcting it to the correct informa- 6) Open [Communication Setting] tab.
tion, press [OK] button. 7) Check every data for correctness.
5) As every data in [Machine Information] has

been checked and corrected, press [Apply]
button to settle the setting.
a As [Apply] button is pressed, a message
confirming above setting will appear on
the screen. Check the setting again and, 8) When modifying the setting of [SHORT
if the setting is correct, press [OK] button. FAULT HISTRY], employ the following
a ORBCOM installation specification re- procedure.
quires the settlement operation after 1] Select [SHORT FAULT HISTRY] from the
[Communication Setting] is completed. screen and then press [Edit] button in the
lower left side of [File Transfer Setting]
block to display the setup screen.
2] Correct the setting and, as it is
completed, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then set
the function to ON.
HD785-7 9
9) When modifying the setting of [SHORT 11)As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] from a As [Apply] button is pressed, a message
the screen and then press [Edit] button in confirming above setting will appear on
the lower left side of [File Transfer the screen. Check the setting again and,
Setting] block to display the setup screen. if the setting is correct, press [OK] button.
2] Correct the setting and, as it is
completed, press [OK] button.
a In the initial setting, enter [20] to
[SMR] and then set the function to
ON.
10)When modifying the setting of [Satellite 12)As every data in [Machine Information] and
Setting], employ the following procedure. [Communication Setting] has been checked
1] Press [Edit] button in the [Satellite and corrected, press [Exit] button to end
Setting] block to display the correction [VHMS initial setting tool].
screen.
2] Set the GCC code to the region applied
and, as setting is completed, press [OK]
button.
GCC codes and applicable regions
Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 1 Brazil
120 Malaysia 130 Japan
a If the combination of the country name
and code in the list box displayed by the
setting tool is different from this table, se-
lect the GCC code in the table or input the
value through the keyboard.
10 HD785-7
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 or 3) Confirm the machine information and, if they
later version) are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to modify
the data of service meter [SMR].
1) Select [VHMS Setting] and then press [Next]
button.
a When VHMS has been installed later, it is

required to enter the information such as
[Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
HD785-7 11
4) Select the time zone. 8) If there is no problem in the setting displayed

5) Enter the local time. last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press [Next]
button.
a Selecting DST advances the clock by an
hour. Thus, correction of the time is need-
ed again.
9) A screen message will confirm whether or not

the data before the setting is to be saved. If
the data is not necessary, select [NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions
Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 1 Brazil
120 Malaysia 130 Japan
a If the combination of the country name

and code in the list box displayed by the
setting tool is different form this table, se-
lect the GCC code in the table or input the
value through the keyboard.
10)As correction of the first setting is completed,
press [OK] button to end the program.
12 HD785-7
11)Turn the starting switch OFF.

Check that the 7-segment LED of the VHMS
controller keeps displaying for several
seconds and then goes off securely.
HD785-7 13
7. Executing quick Pm 6) Press the buzzer cancel switch [U] to start

a Quick Pm denotes the Pm click done by use the snapshot.
of the manual snapshot function of the ma- a As the snapshot is started, the upper col-
chine monitor. umn starts displaying the elapsed time.
a It stores 7 minutes and 30 seconds worth of a [–] in the leftmost position of the lower col-
data to VHMS controller. umn is replaced with [*] for every 30 sec-
k Park the machine in a flat place. onds. When two or more [*] signs are
displayed, the rightmost one flashes.
1) Start the engine. a When stopping the snapshot currently
2) Switch the machine monitor to Service menu. taking place, press the buzzer cancel
a For the procedure of opening Service switch [t].
menu, see "Special functions of machine
monitor".
3) Display the manual snapshot function screen
from the menu screen of Service mode.
7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tempera-
ture and torque converter oil temperature
4) Press the buzzer cancel switch [U]. are within the operating range.
5) [READY] will be displayed on the screen, a After 10th [*] is displayed (5 minutes
turning on the standby mode. elapsed from the start), [#] will be dis-
a The lower column displays 15 pieces of played for 11th through 15th positions.
q *: Indicates the data sampling interval is
[–] sign.
once every 10 seconds.
q #: Indicates the data sampling interval is
once every 1 second.
14 HD785-7
a Machine operation for snapshot

Measurement conditions
Start Finish Time Operation of machine AISS Power mode Shift Parking Dump Remarks
Retarder
switch setting lever brake lever
1 0 : 00 2: 00 120 sec Low idle (Low) Auto Economy N ON ON Hold
2 2 : 00 3: 00 60 sec Low idle (high) Auto Economy N OFF OFF Hold (*1)
3 3 : 00 4: 00 60 sec High idle (Stationary mode) Auto Economy N ON ON Float
4 4 : 00 5: 00 60 sec Low idle (high) Auto Economy N ON ON Hold
5 5 : 00 5: 30 30 sec High idle (Econormy mode) Auto Economy N ON ON Hold
6 5 : 30 6: 00 30 sec Torque converter stall (Econormy mode) Auto Economy D OFF ON Hold (*2, *3)
7 6: 00 6: 30 30 sec High idle (Power mode) Power Economy N ON ON Hold
8 6: 30 7: 00 30 sec Torque converter stall (Power mode) Power Economy D OFF ON Hold (*2, *3)
High idle (Power mode)
9 7: 00 7: 30 30 sec + Power Economy N ON ON Hold
20 pumping operations of foot brake
(*1) Press the foot brake.

(*2) When stalling the torque converter [Portion marked with (*)], do not overheat it.[Stall of torque converter
for 30 seconds is only a reference. When the oil temperature gauge reaches the top of the white range
while the torque converter is stalled, return the transmission (gearshift) lever to the N position.]
(*3) When setting the gearshift lever in the D position, return the engine speed to low idle temporarily (to
prevent the machine from running out).
HD785-7 15
8) As 7 minutes and 30 seconds elapsed from 10)Open the quick Pm data to draw a graph.
start of the snapshot, following screen a Set the Time to the X-axis and set the fol-
appears and then the initial screen is lowing to the Y-axis.
restored in 5 seconds. (End of snapshot) q Engine Speed (Engine speed)
q Fuel Inject (Fuel injection rate)
q Blowby Press (Blow-by pressure)
q FL Exhaust Temp (Exhaust temperature
of left bank of No. 1, 2, 3 cylinders)
q RL Exhaust Temp (Exhaust temperature
of left bank of No. 4, 5, 6 cylinders)
q FR Exhaust Temp (Exhaust temperature
of right bank of No. 1, 2, 3 cylinders)
q RR Exhaust Temp (Exhaust temperature
of right bank of No. 4, 5, 6 cylinders)
q Engine Oil Press (Engine oil pressure)
q Engine Oil Temp (Engine oil temperature)
q Coolant Temp (Engine coolant tempera-
ture)
Important q Ambient Temp (Ambient temperature)
Data of quick Pm are recorded only once. q Boost Press (Boost pressure)
Thus, if another quick PM is repeated, the q Accelerator Pos (Accelerator position)
current data will be overwritten with the last q Hoist Lev Pos (Dump lever position)
one. In order to avoid above trouble, be sure q T/C Oil Temp (Torque converter oil tem-
to download data of every completed quick perature)
Pm shall to PC. For the procedure, see 8. q T/M Out speed (Transmission output
Download of setting data. speed)
q Shift Indicator (Gearshift position)
9) Read the quick PM data by use of the anal- q Lock Up Signal (Lockup signal)
ysis tool. q Retarder Temp (Retarder oil tempera-
a For detailed usage of the analysis tool, ture)

see the operation and maintenance man- q F Brake Press (Front brake oil pressure)
ual. q R Brake Press (Rear brake oil pressure)

q Retarder Position (Retarder position)
q Foot Brake Position (Foot brake position)
16 HD785-7
11)Apply a check mark to the Display graph

value at clicked position.
HD785-7 17
12)Clicking the graph shows, below the graph,

the X-axis value of respective measurement
items. (An example of a graph displayed –
Not an actual one)
18 HD785-7
8. Download of setting data

1) Using harness N2, connect PC N3 to down-
load connector DPC7 in the cab or download
connector VDL on the ground.
a Download connector DPC7 in the cab is

installed to box (1) in the cover at the rear
of the operator's seat.
2) When using download connector DPC7 in the

cab, set the starting switch to ON position.
3) When using download connector VDL on the
ground, set switch (3) to ON position.
a The green LED will come on.
4) Operating [VHMS analysis tool] on PC, start

up the VHMS analysis tool.
a Ground download connector VDL is in-

stalled to box (2) in the cover at the rear
of the ladder on the front right side of the
machine.
HD785-7 19
a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and main- a For the operating procedure, see the
tenance manual. VHMS analysis tool operation and main-
tenance manual.
a Make sure that [MFA0] code, which was
used in the quick snapshot, is indicated in
[Fault History].
a Make sure the snap shot data are record-
ed.
5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and main-
tenance manual.
2) As check of the setting data is finished, end
a After making sure the download is com-
[VHMS analysis tool].
plete, proceed to the next step.
20 HD785-7
10. Disconnecting the PC

1) Make sure the starting switch is at OFF posi-
tion.
k Before connecting or disconnecting a
PC, be sure to turn off the starting
switch.
2) End the OS of PC N3 and then turn off the PC
power.
11. Report to Komatsu

As steps 1 – 10 are completed, send
VHMS/WebCARE setting report to
VHMS/WebCARE Support Center in Komatsu
Headquarters.
a This report is a must since setting on the re-
ceiving end in the satellite communication
must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness N2 from download a When using the KOMTRAX functions on the
connector DPC7. machine "equipped with the ORBCOMM",
complete the sign up test on the machine
side and enter the use of the KOMTRAX
functions in the "VHMS/WebCARE setting
notification form”.
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
4) When the data was download to the ground,

disconnectN2 from download connector
VDL.
HD785-7 21
Using method of KOMTRAX functions of ORBCOMM terminal
The ORBCOMM terminal equipped with the KOMTRAX function can display the machine on the control
screen of the KOMTRAX system.
a Whether the ORBCOMM terminal has the KOMTRAX functions can be checked by the part No.of the OR-
BCOMM terminal.
When using the KOMTRAX functions,perform the following procedure.
1) Make the request for opening the ORBCOMM terminal and receive the opening notification.
2) “Initialize the VHMS controller” and set the GCC code of the machine location.
3) Perform the sign-up test on the machine side.
4) Register the machine using the KOMTRAX client personal computer.
1. Sign-up test on machine side
1) Check that the VHMS controller, ORBCOMM terminal, ORBCOMM antenna and GPS antenna are con-
nected to the wiring harness of the machine.
2) Turn the starting switch to the ON position.
3) Wait until LED1 lights up.
a LED1 keeps blinking until the sign-up test is completed.
a The ORBCOMM terminal executes the sign-up test and judges the result by itself. The criteria are as fol-
lows.
1. The starting switch is in the ON position.
2. The VHMS controller can communicate with the ORBCOMM terminal(They are connected normally).
3. A valid GCC code is set to the VHMS controller.
4. The ORBCOMM terminal is receiving the signals from the ORBCOMM communication satellite(The ORB-
COMM antenna is connected).
5. Positioning of the machine with the GPS satellite was completed(The GPS antenna is connected).
a It may take time to complete the sign-up test, depending on the condition of receiving signals from the OR-
BCOMM satellite and GPS satellite.
a It is ideal to perform the sign-up test in an open-air place. In an indoor place where the radio waves from
the satellite are obstructed, the inspection may not be completed.
22 HD785-7
HD785-7 23
[LED] [Conditions]
(1) LED – Green state of KOMTRAX Waiting for communication to be ready: ON
Nurmall operating state: OFF
(2) LED – Red Capturing of ORBCOMM satellite Satellite is not captured: ON
Satellite is captured (There is no data to be transmitted): Quick
blink
Satellite is captured (There is data to betransmitted): Slow blink
Power OFF: OFF
(3) LED – Yellow Recognition of operation of VHMS VHMS is recognized to be in operation: ON
VHMS is recognized to be stopped: OFF
(4) LED – Green State of power supply of ORB- ON: ON
COMM MODEM
OFF: OFF
(5) LED – Red Unused Kept OFF
(6) LED – Red Unused Kept OFF
(7) 7 – segment Number of mails waiting to be sent (Max. of 9)
(8) Dot Capturing of GPS satellite Satellite is not captured: OFF

Satellite is captured: ON
* Blink interval
Quick blink: Period of 1 sec (ON for 0.5 sec and OFF for 0.5 sec repeatedly)
Slow blink: Period of 4 sec (ON for 2 sec and OFF for 2 sec repeatedly)
24 HD785-7
2. Application for starting to use
1) Notify the KOMTRAX operations administrator of the following information of the machine which has com-
pleted the sign-up test.
1. Information of machine which has completed sign-up test (Model,Model No., Serial No.)
2. Part No. and serial No. of ORBCOMM terminal
3. Reading of service meter when sign-up test was completed (0.1h unit)
2) Fill in the"VHMS/WebCARE setting notification form” and enter “Use” in the column of ”Use of KOMTRAX
Service”.
3) Send the “VHMS/WebCARE setting notification form” to VHMS/WebCARE SUPPORT CENTER in KO-
MATSU HEAD OFFICE.
4) The KOMTRAX operations administrator registers the machine using the KOMTRAX client personal com-
puter.
a For the procedure, see the following.
[Global KOMTRAX Web Reference Manual (For Key Person)]
HD785-7 25
Date of setting:
[For storage] DB/branch office
VHMS Initial Setting Work Check Sheet name
Data entered by:
Setup step Check item Result

Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.
Connection between PC and VHMS
2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to rota- yes no
operation
tion)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body information) Is engine serial No. correctly entered? yes no
5
Is today's date entered? yes no
In this step, basic machine body infor- Is current time entered? yes no
mation are set on VHMS controller Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the switch
8 Execution of quick Pm yes no
hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no
The time downloaded (Reference wrist watch) Hour, minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with settings? yes no
Is any data missing in Snap Shot? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
26 HD785-7
[For storage] Date of setting:

DB/branch office
ORBCOM Station Opening Work name
Check Sheet Data entered by:
Setup step Check item Result

Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
VHMS controller serial No.
ORBCOM terminal serial No.
Connection between PC and VHMS
2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to rota- yes no
operation
tion)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
Entry of setting to S.Fault History
Presence/absence of communication On Off
Number of cases (Default is 8 cases)
Initial setting of VHMS controller Number of cases (Default is 8 cases)
1.Setting of communication
(Setting of machine body information
5 Interval (Default is 20H)
and PLM are completed)
Entry of setting of S.Payload data
Tabulation start time
Interval of tabulation (in days) day
2.Setting for start of communication Is GCC code set? (130 for Japan) yes no
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor (7-seg-
ORBCOM controller performance
7 ment)? yes no
check
(OFF, ON, long/short flashing)
HD785-7 27
28 HD785-7
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller controller setting information (Ver. 3. 5. 2. 1 or
older version)
a Testing instrument a Setting information is saved from the VHMS
Symbol Part No. Part name controller to be replaced to the PC and the
1 799-608-3211 Diskette saved information is loaded to the new
2 799-608-3220 Wiring harness VHMS controller after the replacement.
N Note type PC 2-1. Confirmation of VHMS controller setting infor-
3
Commercially (Windows 98/2000/Me/XP/Vista mation prior to replacement
available and terminal "RS232C" is with 1) Connect the PC and start the VHMS initial
it) setting tool.
a See the "VHMS controller initial setting
a When it is required to replace a VHMS controller, procedure" for this operation.
setup of the replacing VHMS controller shall be 2) Select [Save/Load] and press [OK] button.
conducted before and after the replacement ac-
cording to the following procedure.
a Machine data collected with VHMS controller are
stored and managed on WebCARE database. In
order to endure smooth data processing on We-
bCARE, consistency must be provided among
the settings done on VHMS controller. Inconsis-
tencies in the settings obstruct loading of data to
WebCARE, hampering appropriate use of
VHMS data. Setting work after replacement,
therefore, is a must.
a Check each step of the setting work referencing
the "VHMS initial setting work check sheet".
a Information such as models shown in the figures
may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a Using [Download] function, download the
currently recorded and remained data on
VHMS to PC. 3) Confirm every information before the
a For the operating procedure, refer to "8. replacement.
Download of setting data" in "VHMS control- 4) Select [Save] from [File] of the menu.
ler initial setting procedure".
HD785-7 29
2-2. Loading the setting information to the

replacing VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
procedure" for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Select [Load] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end the

VHMS initial setting tool.
7) Disconnect the PC.
a Refer to "10. Disconnecting the PC" in
"VHMS controller initial setting proce-
dure".
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
30 HD785-7
4) Currently saved information will be 7) After adjusting time, press [OK] button.
displayed. Press [OK] button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if it
is acceptable, press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
HD785-7 31
9) The confirmation screen will ask whether or 3. Confirmation, saving and loading of VHMS
not the data before the above setup is to be controller setting information (Ver. 3. 5. 2. 1 or
saved. Press [NO] button. later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-

mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
10)The setup result is displayed. Confirm the

contents and press [Close] button.
3) Select [Save current setting before replace-

ment of VHMS controller] and press [Next]
button.
11)Select [Exit] from [File] of the menu to end the

VHMS initial setting tool.
32 HD785-7
4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] button. ment of VHMS controller] and press [Next]
button.
5) Select [Exit] from [File] of the menu to end the

VHMS initial setting tool. 4) Currently saved information will be
6) Disconnect the PC. displayed. Press [Next] button.
a Refer to "10. Disconnecting the PC" in
"VHMS controller initial setting proce-
dure".
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the

replacing VHMS controller
1) Connect the PC again and start the VHMS
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
5) Adjust the time and press [Apply] button.
HD785-7 33
6) The confirmation screen will ask whether or [Operations needed after replacement of VHMS
not the data before the above setup is to be controller]
saved. Press [NO] button. a Execute the quick Pm referring "7. Executing
a It is not necessary to save the data before quick Pm" in "VHMS controller initial setting pro-
the setting. cedure".
a Download the data referring "8. Download of set-
ting data" in "VHMS controller initial setting pro-
cedure".
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded be-
fore and after the VHMS replacement, via Notes
(LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
7) The above completes modification of the

setting. Press [OK] button to end the VHMS
34 HD785-7
Pm Clinic check sheet

Machine Serial No.
HD785-7 Engine Serial No.

Hour inspec-
tion
Work No. Date Service meter Name of inspector

Year Month Day hrs
Questions to operator and inspection around the machine
Was there any abnormality before start of inspection ? Ambient Temperature
Max. °C(°F)
Min. °C(°F)
Altitude m
Is maximum coolant temperature level normal ? Is maximum torque converter oil tempera- Is maximum retarder oil tempera-
(During operation) ture level normal ? ture level normal ?
(During operation) (During operation)
a After starting engine!

Standard value
Measurement Service limit Measure-
Measurement conditions Unit for new Accepted Rejected
items value ment result
machine
A mode 1,700 – 1,900 1,700 – 1,900
Torque con- B mode 1,635 – 1,835 1,635 – 1,835
Engine
Engine speed verter stall

speed C mode 1,585 – 1,785 1,585 – 1,785
D mode 1,535 – 1,735 1,535 – 1,735
*: Detail of each mode (Setting is changed as follows, depending on selection of modes A – D)

Mode setting Condition (*) Rated output High idle speed
Mode A Power mode High load (Loaded) 895 kW {1,200 HP} /1,900 rpm 2,250 rpm
Mode B Power mode Low load (Unloaded) 809 kW {1,080 HP} /1,900 rpm 2,250 rpm
Mode C Economy mode High load (Loaded) 750 kW {1,010 HP} /1,900 rpm 2,250 rpm
Mode D Economy mode Low load (Unloaded) 699 kW {937 HP} /1,900 rpm 2,100 rpm
*: Remarks
q High load (When loaded): The load (dump truck) is judged high (loaded) when the rear suspension gas pres-
sure is confirmed to be 10.8 MPa {110 kg/cm2} or higher.
q Low load (When unloaded): The load (dump truck) is judged low (unloaded) when the rear suspension gas
pressure is confirmed to be below 10.8 MPa {110 kg/cm2}.
Standard value
machine
Blow-by pres- Engine speed: 1,900 rpm (Rated kPa Max. 2.94 5.88
sure speed) {mmH2O} {Max. 300} {600}
SAE0W30E0S Engine speed:
0.29 – 0.44 0.2
SAE5W40E0S 1,900 rpm
Lubricating oil Mpa {3.0 – 4.5} {2.0}
SAE10W30DH (Rated speed)
pressure {kg/cm2}
Engine
SAE15W40DH Min. 0.08 0.07

Low idle
SAE30DH {Min. 0.8} {0.7}
Boost pres- Engine speed: 1,900 rpm (Rated kPa Min. 165.4 Min. 165.4
sure speed) {mmHg} {Min. 1,250} {Min. 1,250}
Exhaust tem- Ambient temperature 22 —

°C
perature All speed range Max. 700 750
HD785-7 35
Standard value
machine
Torque converter oil temperature:
— — —
75 – 85°C
Max. 0.85 Max. 0.85
Inlet oil pressure
{Max. 8.67} {Max. 8.67}
When brake is 0.45 – 0.53 0.45 – 0.53
Outlet oil ON {4.59 – 5.41} {4.59 – 5.41}
Torque converter
pressure When brake is 0.45 – 0.59 0.45 – 0.59

OFF {4.59 – 6.01} {4.59 – 6.01}
Engine speed: Mpa 1.32 – 1.72 1.32 – 1.72
Lockup operating pressure 1,900 rpm
(Rated speed) {kg/cm2} {13.5 – 17.5} {13.5 – 17.5}
3.33 – 3.73 3.33 – 3.73
N, F1 – F3
Main relief {34.0 – 38.0} {34.0 – 28.0}
pressure 1.96 – 2.36 1.96 – 2.36
F4 – F7
{20.0 – 24.0} {20.0 – 24.0}
Transmission lubricating oil 0.12 – 0.22 0.12 – 0.22
pressure {1.2 – 2.2} {1.2 – 2.2}
36 HD785-7
a Replace oil and clean inside of transmission case and strainer every 1,000 hours!
Standard
Measurement Service limit Measurement
Measurement conditions Unit value for new Accepted Rejected
items value result
machine
T/M
Visual inspection of transmission strainer — There is not excessive metal powder or black powder.
Steering time Lock o Lock sec. Max. 4 Max. 5

Steering
20.2 – 21.1 20.2 – 21.1

Rated speed (1,900 rpm)
Mpa {206 – 215} {206 – 215}
Relief pressure
Low idle (650 rpm) {kg/cm2} 18.1 – 19.1 18.1 – 19.1
[Reference value] {185 – 195} {185 – 195}
9.11 – 10.49 9.11 – 10.49

Service brake 1st operation
Brake oil pres- {93 – 107} {93 – 107}
after charging
sure 5.81 – 7.09 5.81 – 7.09
Retarder accumulator
Mpa {59 – 72} {59 – 72}
{kg/cm2} 11.8 – 12.78 11.8 – 12.78
Cut-in
Charge valve Engine: Full {120 – 130} {120 – 130}
set pressure throttle 20.6 – 21.58 20.6 – 21.58
Cut-out
{210 – 220} {210– 220}
Brake
Service brake 1,760 1,570

When brake is applied and
Retarder brake engine speed is increased gradu- 1,340 1,200
ally in gear speed F2, machine rpm
Parking brake must not start at speed shown in 1,790 1,610
table.
Emergency
1.790 1,610
brake
Hydraulic oil temperature:

— — —
50 – 80°C
20.2 – 21.1 20.2 – 21.1
Rated speed (1,900 rpm)
Hoist valve relief {206 – 215} {206 – 215}
pressure Low idle (650 rpm) 18.1 – 19.1 18.1 – 19.1
Hydraulic system
[Reference value] Mpa {185 – 195} {185 – 195}

{kg/cm2} 2.91 – 3.89 2.91 – 3.89
Dump EPC High idle (2,250 rpm)
{30 – 40} {30 – 40}
valve basic
pressure Low idle (650 rpm) 2.11 – 3.09 2.11 – 3.09
[Reference value] {22 – 32} {22 – 32}
Dump body rais-
Rated speed (1,900 rpm) 11.5 – 14.5 11.5 – 14.5
ing time
sec.
Dump body low- Low idle (650 rpm)
12.5 – 15.5 12.5 – 15.5
ering time Dump lever: "Float" position
a Set dump body and stop engine!

Hydraulic oil temperature:
Hydraulic drift
— — —
50 – 80°C
Hydraulic drift Set dump body to 20 mm
mm/15
of hoist cylin- extraction position of No. 2 Max. 85 Max. 170
min.
der cylinder.
a Replace drain plug with spare plug!

Visual check
There is not excessive
of differential Engine: Stopped —
metal powder.
drain plug
Axle
Visual check Left side

There is not excessive
of final drive —
metal powder.
drain plug Right side
HD785-7 37
a Every 1000 hours service

Left side Within wear gauge range.
Front brake
(Disc wear gauge)
Right side Within wear gauge range.
Brake
—
Left side Within wear gauge range.
Rear brake
(Disc wear gauge)
Right side Within wear gauge range.
Suspension cylinder
mm 237 – 257 227 – 267
length
Left front suspension
Oil/Gas leakage — No leakage
Suspension cylinder
mm 237 – 257 227 – 267
length
Right front suspension
Suspension cylinder
Suspension
mm 189 – 209 179 – 219

length
Left rear suspension
Suspension cylinder
mm 189 – 209 179 – 219
length
Right rear suspension
Left side — No contact

Contact of rear suspension
stopper
Right side — No contact
Failure code record
ho h Time ho h Time
Contents: Contents:
ho h Time ho h Time
Contents: Contents:
ho h Time ho h Time
Contents: Contents:
MEMO : Write any data or phenomena that you noticed during today's check.
38 HD785-7
Initial setting of payload meter
In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS initial-
ization manual (tool)" according to Table 1
1. When the payload meter in the VHMS is installed for the first time
2. When the payload meter in the VHMS is removed
3. When the VHMS controller or transmission controller is replaced
4. When setting of VHMS controller is changed
Table 1
Setting with VHMS initial setting manual (tool) (*1)
Date
PLM function in Payload meter (PLM) Time
VHMS controller
VHMS controller function Model Type Variation code Time differ-
ence (GMT)
Summer time
Installed Not installed Not installed ST
HD785 –7 Set properly
Installed Installed Installed PV
(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool)
When there is not a problem in installation and wiring of the payload meter but there are the following prob-
lems, check the above setting again.
1. Items related to the payload meter are not displayed on the machine monitor.
"The payload is not displayed when the machine is loaded and stopped", "There are not the menue related
to the payload meter to match", etc.
a In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS
initialization manual (tool)" according to Table 1.
2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on the
machine monitor.
a In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS
initialization manual (tool)" according to Table 1.
3. While the payload meter in the VHMS is set, the payload does not match to the lighting condition of the
red lamp of the outside indicator lamps.
a Wrong setting of the model and serial No. with the VHMS initial setting tool.
4. The storage place of the data file made by the download software is not found.
a Wrong setting of the model and serial No. with the VHMS initial setting tool.
5. Data cannot be downloaded.
a Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool.
6. Date and time of the downloaded data are wrong.
a Wrong setting of the date and time with the VHMS initial setting tool.
HD785-7 39
Setting of payload meter built in VHMS

Outline of procedure
40 HD785-7
Set various items of the payload meter (PLM) with 3. Correction of calculation of load weight
the machine monitor. a Since this function affects the accuracy di-
1. Selection of service menu rectly, execute the following procedure se-
While the service menu selection screen is curely.
displayed, select the PLM setting function a Be sure to measure the weight of the empty
(PLM). machine and that of the fully loaded machine
as a set in order according to the following
procedure.
a The machine must travel for about 3 minutes
each after its empty weight and its fully load-
ed weight are measured. Accordingly, se-
cure a road for this purpose.
a The relationship between the suspension
pressure and load weight corrected with this
function cannot be returned to the condition
at the time of shipment. Accordingly, perform
the following procedure very carefully.
1) Measure the weight of the empty machine
with the load meter and record it (Write it on
a sheet of paper, etc.)
2. Setting of travel distance to recognize comple- 2) Input the measured weight of the empty
tion of loading machine and drive the machine for about 3
minutes.
1] Select "EMPTY WEIGHT".
Input a travel distance to recognize completion

of loading by pressing the following buttons.
The setting range is 0 – 255 m (0.0 – 0.158 q [>], [<] buttons: Select "EMPTY
miles). WEIGHT" or "LOADED WEIGHT"
q [>] button: Number at cursor moves forward q [U] button: Enter the selection
q [<] button: Number at cursor moves back- q [t] button: Return to the previous
ward screen
q [U] button: Enter number at cursor If the weight of the empty machine has
q [t] button: Stop inputting number been input and the machine has been
a If the set value is too small, the system may driven for about 3 minutes, "LOADED
recognize that loading is completed while the WEIGHT" is displayed when the menu
machine is still being loaded. is selected.Check the unit of the input
value. The unit is indicated in the ( )
on the right side of WEIGHT.
(SHORT): short ton
HD785-7 41
2] Check that measurement of the weight of 4] Check the input value.

the empty machine has been completed.
q [>] button: Select "YES"

q [U] button: Check that measurement q [<] button: Select "NO"
has been completed and go to the q [t] button: Enter
next step 5] Move the machine to a place where you
q [t] button: Return to the previous can drive it for about 3 minutes.
screen
3] Input the measured weight of the empty
machine.
q [U] button: After getting ready for

drive, press this button and start driv-
ing the machine
q [>] button: Number at cursor moves q [t] button: Return to the value input-
forward ting screen
q [<] button: Number at cursor moves Drive the machine for about 3 minutes (at
backward a speed higher than 8 km/h) to settle the
q [U] button: Enter number at cursor relationship between the weight of the
q [t] button: Return to the largest posi- machine and the suspension pressure
tion of the number to input the value under that weight.
again. If this button is pressed again,
inputting of the value is stopped and
the previous screen appears.
q Inputtable range
HD785-7:
68.5 [t] (Operating weight ± 15%)
(metricton)
42 HD785-7
6] Display the progress of measurement. 5) Input the measured weight of the fully loaded
machine and drive the machine for about 3
minutes.
1] Select "LOADED WEIGHT".
For the method of displaying the following
screen, see the steps up to the above
step.
q[t]button: Stop measurement and re-

turn to the previous screen As mea-
surement is executed, the number of
"*" increases. When measurement is
finished, the next screen appears au-
tomatically.
3) Load the machine to measure its fully loaded q [>], [<] buttons: Select "EMPTY
weight. WEIGHT" or "LOADED WEIGHT"
q [U] button: Enter the selection
q [t] button: Return to the previous
screen
If the weight of the empty machine has
been input and the machine has been
driven for about 3 minutes, "LOADED
WEIGHT" is displayed when the menu is
selected.Check the unit of the input value.
The unit is indicated in the ( ) on the right
side of WEIGHT.
(SHORT): short ton
2] Check that measurement of the weight of
the fully loaded machine has been
q [t button: Return to the menu screen completed.
When loading is started, the menu screen
appears automatically. When indicating
the current load for reference while the
machine is being loaded, go out of
"Service mode 1" temporarily and return
to "Display of load weight/integrated
odometer". On this screen, you can
check the current load.
4) Measure the weight of the fully loaded
machine with the load meter and record it
(Write it on a sheet of paper, etc.)
q [U] button: Check that measurement

has been completed and go to the
next step
q [t] button: Return to the previous
screen
HD785-7 43
3] Input the measured weight of the fully 5] Move the machine to a place where you
loaded machine. can drive it for about 3 minutes.
q [>] button: Number at cursor moves q [U] button: After getting ready for
forward drive, press this button and start driv-
q [<] button: Number at cursor moves ing the machine
backward q [t] button: Return to the screen for in-
q [U] button: Enter number at cursor putting values
q [t] button: Return to the highest-order Drive the machine for about 3 minutes at
degit of the number to input the value a speed higher than 8 km/h to settle the
again. If this button is pressed again, relationship between the weight of the
inputting of the value is stopped and machine and the suspension pressure
the previous screen appears. under that weight.
a Inputtable range 6] The progress of measurement, is
HD785-7: A1± (A1×0.25) (metric displayed.
ton)
However,
A1 = {68.5 [t] (Operating weight) + 91
[t] (Max. payload)}
4] Check the input value.
q [t] button: Stop measurement and re-

turn to the previous screen
As measurement is executed, the number
of "*" increases. When measurement is
finished, the next screen appears auto-
q [<] button: Select "YES" matically.
q [>] button: Select "NO"
q [t] button: Enter
44 HD785-7
7] Dump the load in the dump area. The current standard level value is
displayed on the upper line. The incli-
nometer value (F) at the current position
blinks. Enter it when it is stabilized.
2] Turn the machine 180 degrees (Stop it in
the opposite direction).
3] Enter value of (R).
q [t] button: Return to the menu screen

If the load is dumped with the dump lever,
the menu screen appears automatically.
If the load is dumped normally, correction
is finished.
4. Correction of level of inclinometer Input a travel distance to recognize

1) Move the machine to a level place. completion of loading by pressing the
2) Input the inclinometer reading (F) at the following buttons.
current position and that (R) after turning the the setting range is 0 – 255 m (0.0 – 0.158
machine 180 degrees (stopping it in the mile).
opposite direction) on the same position and q [>] button: Number at cursor moves
use the average value as the standard level. forward

q [<] button: Number at cursor moves
1] Enter value of (F).
backward
q [U] button: Enter the blinking value
displayed on the upper line. The incli-
nometer value at the current position
blinks. Enter it when it is stabilized.

HD785-7 45
4] Enter the standard level value. 6. Setting of load weight to recognize start of
loading
q [<] button: Select "YES"

q [>] button: Select "NO" Input a load weight to recognize start of loading
q [t] button: Enter by pressing the following buttons.
q [>] button: Number at cursor moves forward
5. Setting of criterion of maximum travel speed q [<] button: Number at cursor moves back-
ward
q [U] button: Enter number at cursor
q [t] button: Stop inputting number
The setting range is 6 – 25.5% of the rated load
weight.
(Default: 15%)
a This function does not assure the operation
because of the contrary phenomena shown
below.
q If the value is reduced, start of loading may
be recognized wrongly.
q If the value is increased and a loader having
a small-capacity bucket is used, the forecast
function of the outside indicator lamps and
Input a criterion of the maximum travel speed by the MMS communication may not operate
pressing the following buttons. normally.
q [<] button: Number at cursor moves back- 7. Setting of indication range of outside indicator
ward lamps
The setting range is 0 – 99 km/h (0 – 62 MPH).
(Default: 99 km/h)
Input an indication range of the outside indicator

lamps by pressing the following buttons.
46 HD785-7
q [<] button: Number at cursor moves back-

ward
a % The setting range is 0 - 130% of the rated
load weight.
Set A (Yellow lamp) higher than G (Green
lamp) and set R (Red lamp) higher than A
(Yellow lamp), however.
8. Setting of OFFSET range
Input an offset range by pressing the following

buttons.
q [<] button: Number at cursor moves back-
ward
a The setting range is -5.0 – +5.0 [t].
Check the unit of the input value by the
previous menu screen.
a The unit is indicated in the ( ) on the right side
of the input value [t].
(SHORT): short ton
HD785-7 47
HD785-7 Dump truck
©2010 KOMATSU
All Rights Reserved
48
SEN01936-02
DUMP TRUCK
HD785-7

HD785-7 7001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations............................................................................................................................................... 18
HD785-7 1
SEN01936-02 40 Troubleshooting
Failure codes table 1

Failure Applicable Action History Reference
codes Failure contents equipment code classification manual
Mechanical
1500L0 Detection of double engagement TM E03
system
Mechanical
15B0NX Clogging of transmission oil filter TM E01
system
Mechanical
15F0KM Abuse 1 of gear shifting from reverse to forward TM —
system
Mechanical
15F0MB Abuse 2 of gear shifting from reverse to forward TM —
system
Mechanical
15F7KM Abuse of transmission forward clutch disk TM —
system
Trouble in reverse clutch system Electrical
15G0MW TM E03
(command holding pressure, fill ON, detection of slip) system
Mechanical
15G7KM Abuse of transmission reverse clutch disk TM —
system
Trouble in high clutch system Electrical
15H0MW TM E03
Trouble in low clutch system Electrical
15J0MW TM E03
Trouble in 1st clutch system Electrical
15K0MW TM E03
Troubleshooting
Trouble in 2nd clutch system Electrical by failure code,
15L0MW TM E03
(command holding pressure, fill ON, detection of slip) system Part 1
SEN01938-01
Trouble in 3rd clutch system Electrical
15M0MW TM E03
Trouble in 4th clutch system Electrical
15N0MW TM E03
Trouble I in reverse clutch pressure control valve Electrical
15SBL1 TM E03
(command OFF, fill ON) system
Trouble II in reverse clutch pressure control valve Electrical
15SBMA TM E03
(command holding pressure, fill OFF, detection of slip) system
Trouble I in high clutch pressure control valve Electrical
15SCL1 TM E03
Trouble II in high clutch pressure control valve Electrical
15SCMA TM E03
Trouble I in low clutch pressure control valve Electrical
15SDL1 TM E03
Trouble II in low clutch pressure control valve Electrical
15SDMA TM E03
Trouble I in 1st clutch pressure control valve Electrical
15SEL1 TM E03
Trouble II in 1st clutch pressure control valve Electrical
15SEMA TM E03
Trouble I in 2nd clutch pressure control valve Electrical
15SFL1 TM E03
Trouble II in 2nd clutch pressure control valve Electrical Troubleshooting
15SFMA TM E03
(command holding pressure, fill OFF, detection of slip) system by failure code,
Trouble I in 3rd clutch pressure control valve Electrical Part 2
15SGL1 TM E03 SEN01939-02
Trouble II in 3rd clutch pressure control valve Electrical
15SGMA TM E03
2 HD785-7
Failure Failure contents Applicable Action History Reference

codes equipment code classification manual
Trouble I in 4th clutch pressure control valve Electrical
15SHL1 TM E03
Troubleshooting
Trouble II in 4th clutch pressure control valve Electrical by failure code,
15SHMA TM E03
(command holding pressure, fill OFF, detection of slip) system Part 2
SEN01939-02
Trouble II in lockup clutch pressure control valve Electrical
15SJMA TM E03
(command holding pressure, detection of slip) system
Electrical
2C4MNX Clogging of retarder cooling oil filter BK E01
system
Mechanical
2D01CA Wear of brake (Front right) BK E01
system
Mechanical
2D02CA Wear of brake (Front left) BK E01
system
*
Mechanical
2D05CA Wear of brake (rear right) BK E01
system
Mechanical
2D06CA Wear of brake (rear left) BK E01
system
Mechanical
2F00KM Dragging of parking brake TM —
system
Troubleshooting
Mechanical by failure code,
2G42ZG Lowering of accumulator oil pressure (front) TM E03
system Part 2
SEN01939-02
Mechanical
2G43ZG Lowering of accumulator oil pressure (rear) TM E03
system
Mechanical
6014NX Clogging of hydraulic oil filter BK E01
system
*
Operation of engine overrun prevention device
Mechanical
989A00 (Note: Information is obtained from transmission con- MON E02
system
troller and failure code is displayed on monitor panel)
Inclination alarm (Raising body while machine is
inclined) Mechanical
989D00 MON —
(Note: Information is obtained from transmission con- system
troller and failure code is displayed on monitor panel)
Mechanical
A570NX Clogging of engine oil filter BK E01
system
Mechanical
AA10NX Clogging of air cleaner TM E01
system
Alternator: Failure on battery charge circuit Electrical
AB00L4 PLC E01
(R terminal signal is present and engine is stopped) system Troubleshooting
Trouble in battery charge circuit Electrical by failure code,
AB00MA TM E03 Part 2
(No R-terminal signal) system
SEN01939-02
Alternator: Failure on battery charge circuit Electrical
AB00MB PLC E01
(Absence of R terminal signal and detection error) system
Mechanical
B@BAZG Lowering of engine oil pressure ENG E03
system
Mechanical
B@BAZK Lowering of engine oil level BK E01
system
Mechanical
B@BCNS Overheating of engine ENG E02
system
Mechanical
B@BCZK Low coolant level alarm TM E01
system
Mechanical
B@BFZK Lowering of fuel level MON —
system
*: Failure codes are set but the system does not use them at present.
HD785-7 3

Mechanical
B@C6NS Brake cooling oil overheat (Front) MON E02
system
Mechanical
B@C7NS Overheating of brake cooling oil (rear) MON E02
system
Troubleshooting
Mechanical by failure code,
B@CENS Overheating of torque converter oil MON E02
system Part 2
SEN01939-02
Mechanical
B@GAZK Lowering of battery electrolyte level BK E01
system
Mechanical
B@JANS Overheating of steering oil TM E02
system
Electrical
CA111 Abnormality in engine controller ENG E03
system
Electrical
CB111 Engine controller internal abnormality (Right bank) ENG E03
system
Electrical
CA115 Abnormality in engine Ne/Bkup speed sensor ENG E03
system
Engine Ne/Bkup speed sensor abnormality (Right Electrical
CB115 ENG E03
bank) system
Electrical
CA122 Abnormally high level of charge pressure sensor ENG E03
system
Electrical
CA123 Abnormally low level of charge pressure sensor ENG E03
system
Electrical
CA131 Abnormally high level of throttle sensor ENG E03
system
Electrical
CA132 Abnormally low level of throttle sensor ENG E03
system
Electrical
CA135 Abnormally high level of oil pressure sensor ENG E01
system
Electrical Troubleshooting
CA141 Abnormally low level of oil pressure sensor ENG E01
system by failure code,
Electrical Part 3
CA144 Abnormally high level of coolant temperature sensor ENG E01 SEN01940-02
system
Electrical
CA145 Abnormally low level of coolant temperature sensor ENG E01
system
Electrical
CA153 Abnormally high level of charge temperature sensor ENG E01
system
Electrical
CA154 Abnormally low level of charge temperature sensor ENG E01
system
Electrical
CA187 Abnormally low level of sensor power supply 2 ENG E03
system
Sensor power supply (2) abnormally low level Electrical
CB187 ENG E03
(Right bank) system
Abnormally high level of engine oil temperature Electrical
CA212 ENG E01
sensor (for VHMS) system
Abnormally low level of engine oil temperature sensor Electrical
CA213 ENG E01
(for VHMS) system
Electrical
CA221 Abnormally high level of ambient temperature sensor ENG E01
system
Electrical
CA222 Abnormally low level of ambient temperature sensor ENG E01
system
4 HD785-7

Electrical
CA227 Abnormally high level of sensor power supply 2 ENG E03
system
Sensor power supply (2) abnormally high level Electrical
CB227 ENG E03
(Right bank) system
Mechanical
CA234 Overspeed of engine ENG E02
system
Electrical
CA238 Abnormality in Ne speed sensor power supply ENG E03
system
Ne speed sensor power supply abnormality Electrical
CB238 ENG E03
(Right bank) system
Electrical
CA263 Abnormally high level of fuel temperature sensor ENG E01
system
Fuel temperature sensor abnormally high level Electrical
CB263 ENG E01
(Right bank) system
Electrical
CA265 Abnormally low level of fuel temperature sensor ENG E01
system
Troubleshooting
Fuel temperature sensor abnormally low level Electrical by failure code,
CB265 ENG E01
(Right bank) system Part 3
SEN01940-02
Electrical
CA271 Short circuit in PCV1 ENG E03
system
Electrical
CB271 PCV1 short circuit (Right bank) ENG E03
system
Electrical
CA272 Disconnection in PCV1 ENG E03
system
Electrical
CB272 PCV1 disconnection (Right bank) ENG E03
system
Electrical
CA273 Short circuit in PCV2 ENG E03
system
Electrical
CB273 PCV2 short circuit (Right bank) ENG E03
system
Electrical
CA274 Disconnection in PCV2 ENG E03
system
Electrical
CB274 PCV2 disconnection (Right bank) ENG E03
system
Disconnection or short circuit in injector #1 (left bank Electrical
CA322 ENG E03
#1) system system
CA323 ENG E03
#5) system system
CA324 ENG E03
#3) system system
CA325 ENG E03
#6) system system
Troubleshooting
Disconnection or short circuit in injector #2 (left bank Electrical by failure code,
CA331 ENG E03
#2) system system Part 4
SEN01941-02
CA332 ENG E03
#4) system system
Electrical
CA342 Abnormality in matching of engine controller data ENG E03
system
Electrical
CB342 Engine controller data mismatch (Right bank) ENG E03
system
Electrical
CA351 Abnormality in injector drive circuit ENG E03
system
HD785-7 5

Electrical
CB351 Injector drive circuit abnormality (Right bank) ENG E03
system
Electrical
CA352 Abnormally low level of sensor power supply 1 ENG E03
system
Sensor power supply 1 abnormally low level Electrical
CB352 ENG E03
(Right bank) system
Electrical
CA386 Abnormally high level of sensor power supply 1 ENG E03
system
Sensor power supply 1 abnormally low high Electrical
CB386 ENG E03
(Right bank) system
Electrical
CA431 Abnormality in idle validation switch ENG E01
system
Electrical
CA432 Abnormality in idle validation setting ENG E03
system
Electrical
CA441 Abnormally low level of source voltage ENG E03
system
Power supply voltage abnormally low level Electrical
CB441 ENG E03
(Right bank) system
Electrical
CA442 Abnormally high level of source voltage ENG E03
system
Power supply voltage abnormally high level Electrical
CB442 ENG E03
(Right bank) system
Electrical
CA449 Abnormality 2 in common rail high pressure ENG E03
system
CB449 Common rail abnormally high pressure 2 (Right bank) ENG E03
Electrical Part 4
CA451 Abnormally high level of common rail pressure sensor ENG E03 SEN01941-02
system
Common rail pressure sensor abnormally high level Electrical
CB451 ENG E03
(Right bank) system
Electrical
CA452 Abnormally low level of common rail pressure sensor ENG E03
system
Common rail pressure sensor abnormally low level Electrical
CB452 ENG E03
(Right bank) system
Electrical
CA553 Abnormality 1 in common rail high pressure ENG E03
system
Electrical
CB553 Common rail abnormally high pressure 1 (Right bank) ENG E03
system
Electrical
CA554 In-range trouble of common rail pressure sensor ENG E03
system
Common rail pressure sensor in-range error Electrical
CB554 ENG E03
(Right bank) system
Electrical
CA559 Lowering 1 of supply pump pressure ENG E03
system
Electrical
CB559 Supply pump low pressure 1 (Right bank) ENG E03
system
Electrical
CA689 Abnormality in engine Ne speed sensor ENG E03
system
Electrical
CB689 Engine Ne speed sensor abnormality (Right bank) ENG E03
system
Electrical
CA691 Intake air temperature sensor abnormally high level ENG E01
system
6 HD785-7

Electrical
CA692 Intake air temperature sensor abnormally low level ENG E01
system
Troubleshooting
Electrical by failure code,
CA731 Abnormality in engine Bkup speed sensor phase ENG E03
system Part 4
SEN01941-02
Engine Bkup speed sensor abnormal phase Electrical
CB731 ENG E03
(Right bank) system
Electrical
CA757 Loss of all engine controller data ENG E03
system
Electrical
CB757 Engine controller all data loss (Right bank) ENG E03
system
Electrical
CA778 Abnormality in engine Bkup speed sensor ENG E03
system
Electrical
CB778 Engine Bkup speed sensor abnormality (Right bank) ENG E03
system
Electrical
CA781 Inter-multicontroller communication error ENG E03
system
Electrical
CB781 Inter-multicontroller communication error (Right bank) ENG E03
system
Electrical
CA1257 Multicontroller distinction wiring harness key error ENG E03
system
Multicontroller distinction wiring harness key error Electrical
CB1257 ENG E03
(Right bank) system
Injector #7 (Right bank #1) system disconnection/ Electrical
CB1548 ENG E03
short circuit system
CB1549 ENG E03
Troubleshooting
Injector #10 (Right bank #4) system disconnection/ Electrical by failure code,
CB1551 ENG E03
short circuit system Part 5
SEN01942-02
CB1552 ENG E03
CB1553 ENG E03
CB1622 ENG E03
Electrical
CA1633 Abnormality in KOMNET ENG E03
system
Electrical
CA2185 Abnormally high level of throttle sensor power supply ENG E03
system
Electrical
CA2186 Abnormally low level of throttle sensor power supply ENG E03
system
Electrical
CA2249 Lowering 2 of supply pump pressure ENG E03
system
Electrical
CB2249 Supply pump low pressure 2 (Right bank) ENG E03
system
Electrical
CA2555 Abnormally low level of intake air heater relay voltage ENG E01
system
Abnormally high level of intake air heater relay volt- Electrical
CA2556 ENG E01
age system
D180KA Preheating relay output system: Disconnection PLC E01
Electrical Part 6
D180KB Preheating relay output system: Grounding fault PLC E01 SEN01943-02
system
HD785-7 7

Electrical
D180KY Preheating relay output system: Hot short circuit PLC E01
system
Electrical
D19HKB Trouble in stop lamp relay output system BK E01
system
Pre-lubrication start relay output system: Disconnec- Electrical
D1EFKA PLC E01
tion system
Pre-lubrication start relay output system: Grounding Electrical
D1EFKB PLC E01
fault system
Pre-lubrication start relay output system: Hot short Electrical
D1EFKY PLC E01
circuit system
Electrical
DAF9KM Wrong connection of connector MON E03
system
(DAFRKR) Abnormality in CAN communication (monitor panel) TM E03 —
Electrical
DAQ0KK Lowering of source voltage TM E03
system
Electrical
DAQ0KT Abnormality in non-volatile memory TM E01
system
Electrical
DAQ2KK Trouble in solenoid power supply system TM E03
system
Disagreement of model selection signals
(DAQ9KQ) MON E03 —
Abnormality in CAN communication Electrical
DAQRKR MON E03
(transmission controller) system
(DAQRMA) Disagreement of option setting (transmission) MON E03 —
DB10KT Abnormality in non-volatile memory BK E01
Electrical Part 6
DB12KK Trouble in solenoid power supply BK E03 SEN01943-02
system
Electrical
DB13KK Lowering of battery direct power supply voltage BK E03
system
(DB19KQ) Disagreement of model selection signals (brake) MON E03 —
DB1RKR TM E03
(retarder controller) system
(DB1RMA) Disagreement of option setting (brake) MON E03 —
DB2RKR TM E03
(engine controller) system
CAN communication error Electrical
dB2RKR TM E03
(Right bank engine controller) system
VHMS Electrical
DBB0KK VHMS controller: Low source voltage (input) —
(Display: PLM) system
VHMS controller: VHMS Electrical
DBB0KQ —
Disagreement of model selection signals (Display: PLM) system
VHMS controller battery power supply: VHMS Electrical
DBB3KK —
Low source voltage (input) (Display: PLM) system
VHMS controller 5 V power supply output: VHMS Electrical
DBB5KP —
Low output voltage (Display: PLM) system
DBB6KP —
DBB7KP —
VHMS controller CAN communication: Defective com- VHMS Electrical
DBBQKR —
munication (Abnormality in target component system) (Display: PLM) system
8 HD785-7

Electrical
DBBRKR Abnormality in CAN communication (VHMS) MON E01
system
Electrical
DBC2KK Trouble in solenoid power supply system ABS E03
system
Electrical
DBC3KK Lowering of battery direct power supply voltage ABS E03
system
(DBC9KQ) Disagreement of model selection signals (ABS) MON E03 —
Electrical
DBCRKR Abnormality in CAN communication (ABS) TM E03
system
(DBCRMA) Disagreement of option setting (ABS) MON E03 —
Electrical
DBG2KK Solenoid power supply: Low voltage PLC E03
system
Electrical
DBG3KK Battery direct power supply: Low voltage PLC E03
system
Electrical
DBG9KQ Model selection signal: Abnormal PLC E01
system
Electrical
DDD7KX Trouble in travel speed setting switch system BK E03
system
Electrical
DDD8KA Disconnection in ARSC system switch BK E03
system
Electrical
DDD8KB Short circuit in ARSC system switch BK E03
system
Electrical
DDD9KA Disconnection in ABS system switch ABS E03
system
DDD9KB Short circuit in ABS system switch ABS E03
Part 6
Electrical
DDDAKA Disconnection in ASR system switch BK E01 SEN01943-02
system
Electrical
DDDAKB Short circuit in ASR system switch BK E01
system
Electrical
DDE2KB Engine oil pressure switch error: Grounding fault PLC E01
system
Engine oil pressure switch error: Disconnection or hot Electrical
DDE2L6 PLC E01
Electrical
DDP6L4 Trouble in service brake pressure switch ABS E03
system
Trouble in high clutch flow sensor valve Electrical
DDTHKA TM E03
(command holding pressure, fill OFF, no slip) system
Trouble in low clutch flow sensor valve Electrical
DDTJKA TM E03
Trouble in 1st clutch flow sensor valve Electrical
DDTKKA TM E03
Trouble in 2nd clutch flow sensor valve Electrical
DDTLKA TM E03
Trouble in 3rd clutch flow sensor valve Electrical
DDTMKA TM E03
Trouble in reverse clutch flow sensor valve Electrical
DDTNKA TM E03
Trouble in 4th clutch flow sensor valve Electrical
DDTPKA TM E03
Electrical
DF10KA Input of no lever signal TM E03
system
HD785-7 9

Electrical
DF10KB Input of multiple lever signal TM E03
system
Atmospheric temperature sensor: VHMS Electrical
DGE5KX —
Out of input signal range (Display: PLM) system
Transmission oil temperature sensor input signal out Electrical
DGF1KX TM E03
of range system
Retarder oil temperature sensor (Rear wheel) system Electrical
DGR2KB BK E01
trouble (Disconnection/Short circuit) system
Troubleshooting
Trouble in retarder oil temperature sensor (rear Electrical by failure code,
DGR2KZ BK E01
wheel) system (ground fault) system Part 6
SEN01943-02
Retarder oil temperature sensor (Front wheel) system Electrical
DGR4KB BK E01
trouble (Disconnection/Short circuit) system
Retarder oil temperature sensor (Front wheel) system Electrical
DGR4KZ BK E01
trouble (Ground fault) system
Electrical
DGR6KX Steering oil temperature signal out of range TM E01
system
Torque converter oil temperature sensor input signal Electrical
DGT1KX TM E01
out of range system
Left bank exhaust temperature sensor system (Front): VHMS Electrical
DGT5KA (Display: PLM) —
Disconnection system
Left bank exhaust temperature sensor system (Rear): VHMS Electrical
dGT5KA —
Disconnection (Display: PLM) system
Left bank exhaust temperature sensor system (Front): VHMS Electrical
DGT5KB —
Short circuit (Display: PLM) system
Left bank exhaust temperature sensor system (Rear): VHMS Electrical
dGT5KB (Display: PLM) —
Short circuit system
Right bank exhaust temperature sensor system VHMS Electrical
DGT6KA —
(Front): Disconnection (Display: PLM) system
dGT6KA —
(Rear): Disconnection (Display: PLM) system
DGT6KB (Display: PLM) —
(Front): Short circuit system
dGT6KB —
(Rear): Short circuit (Display: PLM) system
VHMS Electrical Troubleshooting
DHE5KB Blow-by pressure sensor: Short circuit — by failure code,
Part 7
Blow-by pressure sensor: Short circuit with power VHMS Electrical SEN01944-01
DHE5KY (Display: PLM) —
supply line system
VHMS
Short circuit in suspension pressure sensor system Electrical
DHP4KY (indication: E01
(front right) system
PLM)
VHMS
Disconnection or ground fault in suspension pressure Electrical
DHP4KZ (indication: E01
sensor system (front right) system
PLM)
VHMS
(front left) system
PLM)
VHMS
sensor system (front left) system
PLM)
Trouble in suspension pressure sensor system Electrical
DHP6KA BK E01
(rear right) system
DHP6KX BK E03
(rear right) system
10 HD785-7

VHMS
(rear right) system
PLM)
VHMS
sensor system (rear right) system
PLM)
DHP7KA BK E01
(rear left) system
DHP7KX BK E03
(rear left) system
VHMS
(rear left) system
PLM)
VHMS
sensor system (rear left) system
PLM)
Disconnection, ground fault or hot short in torque Electrical
DHT5KX TM E01
converter inlet oil pressure sensor system
Electrical
DHT5L6 Trouble in torque converter inlet oil pressure sensor TM E01
system
Electrical
DHU2KX Trouble in accumulator oil pressure sensor (front) TM E01
system
Electrical
DHU3KX Trouble in accumulator oil pressure sensor (rear) TM E01
system
Trouble in ABS control valve pressure sensor Electrical
DHU6KX ABS E03
(front right) system Troubleshooting
Trouble in ABS control valve pressure sensor Electrical by failure code,
DHU7KX ABS E03 Part 7
(front left) system
SEN01944-01
DHU8KX ABS E03
(rear right) system
DHU9KX ABS E03
(rear left) system
Electrical
DJF1KA Disconnection in fuel level sensor system TM E01
system
Electrical
DK30KX Trouble in steering angle potentiometer BK E01
system
Electrical
DK51L5 Trouble in manual retarder potentiometer and RVS BK E03
system
Electrical
DK52KX Trouble 1 in hoist lever potentiometer sensor BK E03
system
Electrical
DK53L8 Trouble 2 in hoist lever potentiometer sensor BK E03
system
Electrical
DK54KX Trouble in boom positioner sensor BK E03
system
Electrical
DKD0L6 Trouble in steering speed sensor BK E01
system
Electrical
DKH0KX Inclinometer sensor signal out of range TM E01
system
VHMS
Electrical
DKH1KX Abnormality in inclinometer (indication: E01
system
PLM)
Disconnection in transmission input shaft speed Electrical
DLF1KA TM E03
sensor system system
HD785-7 11

Electrical
DLF1LC Trouble in transmission input shaft speed sensor TM E03
system
Troubleshooting
Disconnection in transmission intermediate shaft Electrical by failure code,
DLF2KA TM E03
speed sensor system system Part 7
SEN01944-01
Trouble in transmission intermediate shaft speed Electrical
DLF2LC TM E03
sensor system
Electrical
DLF6KA Disconnection in wheel speed sensor (front right) ABS E03
system
Electrical
DLF6L3 Trouble in wheel speed sensor (front right) ABS E03
system
Electrical
DLF7KA Disconnection in wheel speed sensor (front left) ABS E03
system
Electrical
DLF7L3 Trouble in wheel speed sensor (front left) ABS E03
system
Electrical
DLF8KA Disconnection in wheel speed sensor (rear right) BK E01
system
Electrical
DLF8L3 Trouble in wheel speed sensor (rear right) ABS E03
system
Electrical
DLF8LC Trouble in wheel speed sensor system (rear right) BK E01
system
Electrical
DLF8MA Disconnection in wheel speed sensor (rear right) ABS E03
system
Electrical
DLF9KA Disconnection in wheel speed sensor (rear left) BK E01
system
Electrical
DLF9L3 Trouble in wheel speed sensor (rear left) ABS E03
system
Electrical
DLF9LC Trouble in wheel speed sensor system (rear left) BK E01
system
Troubleshooting
DLF9MA Disconnection in wheel speed sensor (rear left) ABS E03
system Part 8
SEN01945-02
Disconnection in transmission output shaft speed Electrical
DLT3KA TM E03
sensor system system
Electrical
DLT3LC Trouble in transmission output shaft sensor BK E01
system
DLT4KA BK E01
sensor system
DLT4MA BK E03
sensor system
Pre-lubrication operation lamp output abnormality: Electrical
DUM7KY PLC E01
Hot short circuit system
Pre-lubrication operation lamp output abnormality: Electrical
DUM7KZ PLC E01
Disconnection or grounding fault system
Electrical
DV00KB Short circuit in buzzer output MON E01
system
Electrical
DW2AKA Disconnection in main pressure variable valve output TM E01
system
Ground fault in main pressure variable valve output Electrical
DW2AKB TM E01
circuit system
Hot short in main pressure variable valve output Electrical
DW2AKY TM E01
circuit system
Electrical
DW2AL1 Defective reset of main pressure variable valve TM E01
system
12 HD785-7

Electrical
DW2ALH Malfunction of main pressure variable valve TM E01
system
Electrical
DW2BKA Main oil level selector valve output disconnection TM E01
system
Main oil level selector valve output circuit GND short Electrical
DW2BKB TM E01
circuit system
Main oil level selector valve output circuit GND hot Electrical
DW2BKY TM E01
short system
Electrical
DW2BL1 Main oil level selector valve reset trouble TM E01
system
Electrical
DW2BLH Main oil level selector valve malfunction TM E01
system
Transmission lubrication variable valve output Electrical
DW2CKA TM E01
disconnection system
Transmission lubrication variable valve output circuit Electrical
DW2CKB TM E01
GND short circuit system
Transmission lubrication variable valve output circuit Electrical
DW2CKY TM E01
hot short system
Electrical
DW2CL1 Transmission lubrication variable valve reset trouble TM E01
system
Electrical
DW2CLH Transmission lubrication variable valve malfunction TM E01
system
Trouble in auto-suspension solenoid 1 output system Electrical
DW35KZ BK E01
(disconnection or ground fault) system
Trouble in auto-suspension solenoid 2 output system Electrical
DW36KZ BK E01 Troubleshooting
by failure code,
Exhaust brake output system trouble (Disconnection/ Electrical Part 8
DW71KZ BK E01
Ground fault) system SEN01945-02
Trouble in kick-out solenoid output system Electrical
DW72KZ BK E01
Trouble (disconnection or ground fault) in hoist selec-
Electrical
DW73KZ tor valve output system (disconnection or ground BK E03
system
fault)
Electrical
DW78KZ Trouble in BCV output system BK E01
system
Electrical
DWNBK4 Trouble in ASR shut-off valve (valve keeps operating) BK E01
system
Electrical
DWNBKA Disconnection in ASR shut-off valve output circuit BK E01
system
Electrical
DWNBKB Ground fault in ASR shut-off valve output circuit BK E01
system
Electrical
DWNBKY Short circuit in ASR shut-off valve output circuit BK E01
system
Trouble in ASR shut-off valve (valve does not Electrical
DWNBMA BK E01
operate) system
Electrical
DWNDKZ Trouble in ABS cut valve (front) system ABS E03
system
Electrical
DWNDMA Defective ABS cut valve (front) ABS E03
system
Electrical
DWNEKZ Trouble in ABS cut valve (rear) system ABS E03
system
Electrical
DWNEMA Defective ABS cut valve (rear) ABS E03
system
HD785-7 13

Trouble in rear wheel proportional pressure reducing Electrical
DX11K4 BK E03
solenoid valve (valve keeps operating) system
Disconnection in rear wheel proportional pressure Electrical
DX11KA BK E03
reducing solenoid valve output circuit system
Ground fault in rear wheel proportional pressure Electrical
DX11KB BK E03
Short circuit in rear wheel proportional pressure Electrical
DX11KY BK E03
Trouble in rear wheel proportional pressure reducing Electrical
DX11MA BK E03
solenoid valve (valve does not operate) system
Front wheel proportional solenoid pressure reducing Electrical
DX12K4 BK E03
valve trouble (Valve keeps operating) system
DX12KA BK E03
valve output circuit disconnection system
DX12KB BK E03
valve output circuit ground fault system
DX12KY BK E03
valve output circuit short circuit system
DX12MA BK E03
valve trouble (Valve does not operate) system
Electrical
DX13KA Disconnection in hoist EPC valve output circuit BK E03
system
Electrical
DX13KB Ground fault in hoist EPC valve output circuit BK E03
system
DX13KY Short circuit in hoist EPC valve output circuit BK E03
Trouble in ASR proportional pressure reducing Electrical Part 9
DX17K4 BK E01 SEN01946-01
solenoid valve (right) (valve keeps operating) system
Disconnection in ASR proportional pressure reducing Electrical
DX17KA BK E01
solenoid valve (right) output circuit system
Ground fault in ASR proportional pressure reducing Electrical
DX17KB BK E01
Short circuit in ASR proportional pressure reducing Electrical
DX17KY BK E01
Trouble in ASR proportional pressure reducing sole- Electrical
DX17MA BK E01
noid valve (right) (valve does not operate) system
Trouble in ASR proportional pressure reducing sole- Electrical
DX18K4 BK E01
noid valve (left) (valve keeps operating) system
Disconnection in ASR proportional pressure reducing Electrical
DX18KA BK E01
solenoid valve (left) output circuit system
Ground fault in ASR proportional pressure reducing Electrical
DX18KB BK E01
Short circuit in ASR proportional pressure reducing Electrical
DX18KY BK E01
Trouble in ASR proportional pressure reducing Electrical
DX18MA BK E01
solenoid valve (left) (valve does not operate) system
Disconnection in ABS control valve (front right) output Electrical
DX21KA ABS E03
circuit system
Ground fault in ABS control valve (front right) output Electrical
DX21KB ABS E03
circuit system
Short circuit in ABS control valve (front right) output Electrical
DX21KY ABS E03
circuit system
14 HD785-7

Electrical
DX21MA Defective ABS control valve (front right) ABS E03
system
Disconnection in ABS control valve (front left) output Electrical
DX22KA ABS E03
circuit system
Ground fault in ABS control valve (front left) output Electrical
DX22KB ABS E03
circuit system
Short circuit in ABS control valve (front left) output Electrical
DX22KY ABS E03
circuit system
Electrical
DX22MA Defective ABS control valve (front left) ABS E03
system
Disconnection in ABS control valve (rear right) output Electrical
DX23KA ABS E03
circuit system
Ground fault in ABS control valve (rear right) output Electrical
DX23KB ABS E03
circuit system
Troubleshooting
Short circuit in ABS control valve (rear right) output Electrical by failure code,
DX23KY ABS E03
circuit system Part 9
SEN01946-01
Electrical
DX23MA Defective ABS control valve (rear right) ABS E03
system
Disconnection in ABS control valve (rear left) output Electrical
DX24KA ABS E03
circuit system
Ground fault in ABS control valve (rear left) output Electrical
DX24KB ABS E03
circuit system
Short circuit in ABS control valve (rear left) output Electrical
DX24KY ABS E03
circuit system
Electrical
DX24MA Defective ABS control valve (rear left) ABS E03
system
Electrical
DX25MA Defective ABS front wheel system control valve ABS E03
system
Electrical
DX26MA Defective ABS rear wheel system control valve ABS E03
system
Electrical
DXH1KA Disconnection in lockup clutch solenoid output circuit TM E03
system
Electrical
DXH1KB Ground fault in lockup solenoid output circuit TM E03
system
Electrical
DXH1KY Hot short in lockup clutch solenoid output circuit TM E03
system
Electrical
DXH2KA Disconnection in high clutch solenoid output circuit TM E03
system
Electrical
DXH2KB Ground fault in high clutch solenoid output circuit TM E03
system
Troubleshooting
DXH2KY Hot short in high clutch solenoid output circuit TM E03
system Part 10
SEN01947-01
Electrical
DXH3KA Disconnection in low clutch solenoid output circuit TM E03
system
Electrical
DXH3KB Ground fault in low clutch solenoid output circuit TM E03
system
Electrical
DXH3KY Hot short in low clutch solenoid output circuit TM E03
system
Electrical
DXH4KA Disconnection in 1st clutch solenoid output circuit TM E03
system
Electrical
DXH4KB Ground fault in 1st clutch solenoid output circuit TM E03
system
HD785-7 15

Electrical
DXH4KY Hot short in 1st clutch solenoid output circuit TM E03
system
Electrical
DXH5KA Disconnection in 2nd clutch solenoid output circuit TM E03
system
Electrical
DXH5KB Ground fault in 2nd clutch solenoid output circuit TM E03
system
Electrical
DXH5KY Hot short in 2nd clutch solenoid output circuit TM E03
system
Electrical
DXH6KA Disconnection in 3rd clutch solenoid output circuit TM E03
system
Electrical
DXH6KB Ground fault in 3rd clutch solenoid output circuit TM E03
system
Electrical
DXH6KY Hot short in 3rd clutch solenoid output circuit TM E03
system
Electrical
DXH7KA Disconnection in reverse clutch solenoid output circuit TM E03
system
Electrical
DXH7KB Ground fault in reverse clutch solenoid output circuit TM E03
system
Electrical
DXH7KY Hot short in reverse clutch solenoid output circuit TM E03
system
DXHHKA Disconnection in 4th clutch solenoid output circuit TM E03
Electrical Part 10
DXHHKB Ground fault in 4th clutch solenoid output circuit TM E03 SEN01947-01
system
Electrical
DXHHKY Hot short in 4th clutch solenoid output circuit TM E03
system
VHMS Electrical
F@BBZL Blow-by pressure: High error —
Left front exhaust temperature sensor (1): Exhaust VHMS Electrical
F@BYNS —
temperature abnormal rise (Display: PLM) system
Left rear exhaust temperature sensor (1): Exhaust VHMS Electrical
f@BYNS (Display: PLM) —
temperature abnormal rise system
Right front exhaust temperature sensor (1): Exhaust VHMS Electrical
F@BZNS —
Right rear exhaust temperature sensor (1): Exhaust VHMS Electrical
f@BZNS —
Left front exhaust temperature sensor (2): Exhaust VHMS Electrical
F@BYNR (Display: PLM) —
temperature abnormal rise system
Left rear exhaust temperature sensor (2): Exhaust VHMS Electrical
f@BYNR —
Right front exhaust temperature sensor (2): Exhaust VHMS Electrical
F@BZNR —
Right rear exhaust temperature sensor (2): Exhaust VHMS Electrical
f@BZNR —
16 HD785-7
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
ABS : ABS controller system
VHMS : PLM function system of VHMS controller (Note: Displayed as "PLM" on machine monitor)
PLC : Pre-lubrication controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note : Optional equipment is also included in this table.
HD785-7 17
Fuse locations 1
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Circuit breaker and fuse locations in battery box and connection table
a This connection table shows the devices to which each power supply of the circuit breakers and fuse
box supplies power (An accessory power supply is a device which supplies power while the starting
switch is in the ON position and an unswitched power supply is a device which supplies power while the
starting switch is in the OFF and ON positions).
Circuit breaker Circuit breaker

Type of power supply Destination of power
No. capacity
Unswitched FUA1 60A Fuse box (BT3) *1

power supply
(Battery output) FUA2 30A Fuse box (BT2) *1
Fuse box (BT1) *1
Fuse box (BT2) *1

FUB1 80A
Accessory Fuse box (BT3) *1
power supply
(Battery relay output) Fuse box (BT4) *1
Fuse box (BT3) *1

FUB2 80A
Fuse box (BT4) *1
Type of power supply Fuse No. Fuse capacity Destination of power
Emergency steering switch connected through fuse box

Unswitched power supply EMPR 10A
(BT2)
(Battery output)
EPP 10A Electric priming pump *2
Accessory power supply Intake air heater (engine) connected through heater relay
INH 120A
(Battery relay output) (HR)
*1: For fuse boxes (BT1) – (BT4), see the following pages.
*2: For "Extra low-grade fuel specification" only.
18 HD785-7
Fuse box (BT1) location and connection table
a The circled numbers are the terminal numbers shown in the circuit diagram of each failure code.
q Fuse box BT1
Type of power Circuit breaker

Fuse No. Fuse capacity Destination of power
supply output
(1) 10A Main lamp and small lamp
(2) 10A Turn signal lamp
(3) 20A Headlamp (Low)
(4) 20A Headlamp (High)
Accessory FUB1 (5) 20A Headlamp (Low) *1

power supply (80A) (6) 20A Headlamp (High) *1
(7) 10A Brake lamp
(8) 20A Backup lamp
(9) 10A Small lamp *1
(10) 20A VHMS controller
*1: These are connected to the corresponding fuses (1), (3) and (4) and lighting switch and then connected
to the fuses again. See troubleshooting of electrical system (E mode), "E-12".
HD785-7 19
q Fuse box BT2

supply output
Key switch
(11) 10A Machine monitor
(ACC)
Key switch (12) 10A Rear view range monitor (if equipped), VHMS download
(BR) (13) 10A Parking brake circuit
(14) 20A Power window (Left)

Accessory
FUB1 (80A) (15) 20A Power window (Right)
power supply
(16) 10A —
Unswitched
FUA2 (30A) (17) 10A Horn
power supply
Accessory
FUB1 (80A) (18) 10A Machine monitor
power supply
(19) 10A Transmission controller
(20) 20A Terminal B
(21) 10A Retarder controller, ABS controller

Unswitched
FUA2 (30A) (22) 20A Hazard lamp
power supply
(23) 10A Emergency steering
(24) 10A Room lamp, radio
(25) 10A Machine monitor, VHMS controller
20 HD785-7
q Fuse box BT3

supply output
Accessory
FUB1 (80A) (26) 20A Fog lamp (if equipped)
power supply
(27) 20A Air conditioner controller
(28) 20A Heater (if equipped)
(29) 20A Heater (if equipped)
Accessory (30) 20A ABS controller

FUB2 (80A)
power supply (31) 20A Retarder controller
(32) 10A Transmission controller, gearshift lever power supply
(33) 10A Emergency steering, parking brake relay
(34) 10A Radio
Key switch
(35) 5A Engine controller
(ACC)
Unswitched
FUA1 (60A) (36) 30A Engine controller
power supply
(37)
Unswitched
FUA1 (60A) (38) 30A Engine controller
power supply
(39)
(40) 2A Spare
HD785-7 21
q Fuse box BT4

supply output
(41) 10A Room lamp
Accessory (42) 10A Engine preheater power supply

FUB2 (80A)
power supply (43) 20A Yellow rotary lamp (if equipped)
(44) 20A Side lamp (if equipped)
Electrical operator's seat heater (if equipped), air

(45) 20A
suspension seat (if equipped)
(46) 10A External indicator lamp of payload meter

Accessory (47) 10A Tachograph (if equipped), cigarette lighter
FUB1 (80A)
power supply
(48) 20A Air conditioner
(49) 20A Spare
(50) 20A Front windshield wiper
22 HD785-7
HD785-7 23
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
24 HD785-7
SEN01937-03
HD785-7

HD785-7 7001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 6
Connection table for connector pin numbers .................................................................................................. 8
T- branch box and T- branch adapter table ................................................................................................... 44
HD785-7 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing testing equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting, 5. Troubleshooting
it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting tion in Items 2 – 4 to narrow down the causes
in accordance with the fixed procedure. of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
of the the failure exactly.
1) Have any other problems occurred apart
a The basic procedure for troubleshooting is
from the problem that has been reported?
as follows.
2) Was there anything strange about the
1] Start from the simple points.
machine before the failure occurred?
2] Start from the most likely points.
3) Did the failure occur suddenly, or were
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure 6. Measures to remove root cause of failure
occur? Even if the failure is repaired, if the root cause
5) Had any repairs been carried out before of the failure is not repaired, the same failure
the failure? When were these repairs car- will occur again.To prevent this, always investi-
ried out? gate why the problem occurred. Then, remove
6) Has the same kind of failure occurred the root cause.
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 HD785-7
Sequence of events in troubleshooting 1
HD785-7 3
Check before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean and drain
3. Check of fuel filter — Replace
4. Check of level and type of hydraulic oil — Add oil
5. Check of hydraulic oil strainer — Clean and drain
6. Check of hydraulic oil filter — Replace
Lubricating 7. Check of level and type of oil in engine oil pan — Add oil
oil/Coolant 8. Check of engine oil filter — Replace
9. Check of coolant level — Add coolant
10. Check of dust indicator for clogging — Clean and replalce
11. Check of power train oil filter — Replace
12. Check of powertrain oil level — Add oil
13. Check of final draive oil level — Add oil
14. Check of differential oil level — Add oil
1. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
2. Check of alternator terminal cables for looseness
Electrical — Retighten or replace
and corrosion
parts
3. Check of starting motor terminal cables for loose-
— Retighten or replace
ness and corrosion
4. Check of operation of instruments — Repair or replace
Hydraulic/ 1. Check for abnormal noise and smell — Repair

Mechanical 2. Check for oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 26 V Replace
2. Check of battery electrolyte level — Retighten or replace
3. Check wires for discoloration, burn, and removal
— Replace
of cover
4. Check for removed wire clamp and drooping wire — Repair
5. Check wiring for wetting with water
Electrical Disconnect and dry
(Check connectors and terminals for wetting with —
equipment connectors
water, in particular)
6. Check of slow-blow fuses and fuses for discon-
— Replace
nection and corrosion
7. Check of alternator voltage After several-minute
Replace
(with engine at medium speed or higher) operation: 27.5 – 29.5 V
8. Check of operating sound of battery relay
— Replace
(Starting switch OFF ON)
4 HD785-7
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
HD785-7 5
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Machine Names of the failure symptoms displayed in the failure history
Machine monitor Trouble
monitor on the machine monitor
display
display
Contents of
State where the machine monitor or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the machine monitor or control-
machine moni-
ler detects a trouble
tor or controller
Problem that
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
appears on
or controller
machine
Related
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value when normal required to judge the possi-
ble cause
• Remarks required to judge whether any cause is right or
1 not
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring har-
ness is disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes
into contact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply
2 (24V) circuit comes into contact with the electric power
supply (24V) circuit.
• Short circuit
Possible causes Cause by which a trouble is A harness abnormally comes into contact with a harness
and standard assumed to be detected of separate circuit.
value in normal (The order number indicates
state a serial number, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling T-
adapter
For troubleshooting, insert or connect the T- adapter as
3 described below unless especially specified.
• When “male“or “female“ is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
adapter in both the male and female.
• When “male“or “female“ is indicated for a connector
number, disconnect the connector, and insert the T-
adapter in only either the male or female.
(2) Pin number description sequence and tester lead han-
dling
For troubleshooting, connect the plus (+) and minus (-)
leads of the tester as described below unless especially
4 specified.
• Connect the plus (+) lead to a pin number or harness
indicated in the front.
• Connect the minus (-) lead to a pin number or harness
indicated in the rear.
6 HD785-7
Circuit diagram related
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• Connector No.: Indicates (Model - Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
HD785-7 7
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 HD785-7
HD785-7 9
10 HD785-7
HD785-7 11
12 HD785-7
HD785-7 13
14 HD785-7
HD785-7 15
16 HD785-7
HD785-7 17
18 HD785-7
HD785-7 19
20 HD785-7
HD785-7 21
22 HD785-7
HD785-7 23
24 HD785-7
HD785-7 25
26 HD785-7
HD785-7 27
28 HD785-7
HD785-7 29
30 HD785-7
HD785-7 31
32 HD785-7
HD785-7 33
34 HD785-7
HD785-7 35
36 HD785-7
HD785-7 37
38 HD785-7
HD785-7 39
40 HD785-7
HD785-7 41
42 HD785-7
HD785-7 43
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
44 HD785-7
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
HD785-7 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
46 HD785-7
HD785-7 47
HD785-7 Dump truck

© 2009 KOMATSU
All Rights Reserved
48 HD785-7
SEN01938-02
HD785-7

HD785-7 7001 and up
Troubleshooting by failure code, Part 1
Failure code [1500L0] Dual engagement........................................................................................................ 3
Failure code [15B0NX] Transmission oil filter: Clogging ................................................................................. 4
Failure code [15F0KM] R o F shifting abuse 1: Mistake in operation ............................................................ 6
Failure code [15F0MB] R o F shifting abuse 2: Mistake in operation ............................................................ 6
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation or setting ....................................... 7
Failure code [15G0MW] R clutch: Slipping ..................................................................................................... 8
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation or setting .................................... 10
Failure code [15H0MW] Hi clutch: Slipping................................................................................................... 12
Failure code [15J0MW] Lo clutch: Slipping................................................................................................... 14
Failure code [15K0MW] 1st clutch: Slipping ................................................................................................. 16
Failure code [15L0MW] 2nd clutch: Slipping................................................................................................. 18
Failure code [15M0MW] 3rd clutch: Slipping ................................................................................................ 20
Failure code [15N0MW] 4th clutch: Slipping ................................................................................................. 22
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when command current is OFF......................... 24
Failure code [15SBMA] R clutch solenoid: Malfunction ................................................................................ 26
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when command current is OFF........................ 28
HD785-7 1
Failure code [15SCMA] Hi clutch solenoid: Malfunction ............................................................................... 31

Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when command current is OFF ....................... 32
Failure code [15SDMA] Lo clutch solenoid: Malfunction............................................................................... 35
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when command current is OFF....................... 36
Failure code [15SEMA] 1st clutch solenoid: Malfunction .............................................................................. 39
2 HD785-7
Failure code [1500L0] Dual engagement 1

Action code Failure code Dual engagement
Trouble
E03 1500L0 (Transmission controller system)
Contents of
• Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
trouble
Action of • Suddenly shifts to Neutral while traveling, and cannot move off again.
controller • Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
appears on • The gear speed is shifted to Neutral.
machine
Related
• Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
information

Clutch pressure control valve
1 system failure code (15S*L1) Troubleshooting by the active failure code.
Possible causes has occurred
and standard
value in normal Defective hydraulic or
Clutch ECMV may be malfunctioning. Carry out troubleshooting of
state 2 mechanical system of clutch
hydraulic and mechanical systems.
ECMV
Defective transmission
3 Troubleshooting by the active failure code.
controller
HD785-7 3
Failure code [15B0NX] Transmission oil filter: Clogging 1

Action code Failure code Transmission oil filter: Clogging
Trouble
E01 15B0NX (Transmission controller system)
Contents of • When the torque converter oil temperature is above 50°C, the signal circuit of the transmission
trouble clogging sensor is opened (disconnected from GND).
Action of
• None in particular.
controller
Problem that
appears on • If the machine is used without repairing, dust may enter the transmission circuit.
machine
• This failure can be checked in the monitoring function (Code: 40905). (Bit [1] [2], normal: 0, clog-
Related ging: 1)
information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to Testing and adjusting, "Inspection of machine monitor".

Clogging of transmission
1 • Clean or replace.
filter
1) Turn the starting switch OFF.
2) Disconnect connector TMF1 and TMF2.
3) Connect T-adapter.
Resis-
Filter is normal Max. 1 z
Between TMF1 tance
Defective transmission filter (male) (1) and (2)
2 Resis-
clogging sensor Filter is clogged Min. 1 Mz
tance
Resis-
Possible causes Filter is normal Max. 1 z
Between TMF2 tance
and standard
(male) (1) and (2) Resis-
value in normal Filter is clogged Min. 1 Mz
state tance
2) Disconnect connectors ATC1, TMF1 and TMF2.
Between ATC1 (female) (11) and TMF2 Resis-
Disconnection in wiring Max. 1 z
(female) (1) tance
harness (Disconnection in
3 Between ATC1 (female) (17) and TMF1 Resis-
wiring or defective contact in Max. 1 z
(female) (1) tance
connector)
Resis-
Between TMF1 (female) (2) and ground Max. 1 z
tance
Resis-
Between TMF2 (female) (2) and ground Max. 1 z
tance
4 HD785-7

If no abnormality was found in the above troubleshooting, the
transmission controller is defective. (Since this is an internal
defect, troubleshooting cannot be performed.)
a Reference
Possible causes 2) Disconnect connectors ATC1.
and standard 3) Insert T-adapter.
value in normal Defective transmission con- 4) Connect conector.
4
state troller 5) Turn the starting switch ON.
Between ATC1 Filter is normal Voltage Max. 1V
(female) (11) and
ground Filter is clogged Voltage 6 – 12 V
Between ATC1 Filter is normal Voltage Max. 1V

(female) (17) and
ground Filter is clogged Voltage 6 – 12 V
HD785-7 5
Failure code [15F0KM] R o F shifting abuse 1: Mistake in operation 1

Action code Failure code R o F shifting abuse 1: Mistake in operation
Trouble
— 15F0KM (Transmission controller system)
Contents of • When output shaft speed is 200 – 300 rpm (about 5 – 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
• Non in particular.
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
machine • Only recorded in failure history.
Related
• Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal A forward-reverse shifting should be performed when the machine
1 Abuse
state is stationary. (Teach the proper operating method.)
Failure code [15F0MB] R o F shifting abuse 2: Mistake in operation 1

Action
code
Failure code R o F shifting abuse 2: Mistake in operation
Trouble
(Transmission controller system)
— 15F0MB
Contents of • When output shaft speed is above 300 rpm (about 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
Related
• Output shaft speed can be checked by monitoring function (code: 31400 (rpm)).
information

and standard
1 Abuse
6 HD785-7
Failure code [15F7KM] Forward clutch disk abuse: Mistake in operation

or setting 1
Action code Failure code Forward clutch disc abuse: Mistake in operation or setting
Trouble
— 15F7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
HD785-7 7
Failure code [15G0MW] R clutch: Slipping 1

Action code Failure code R clutch: Slipping
(R command is holding pressure, R clutch, fill switch is ON, and
Trouble
E03 15G0MW slipping detected)
• When a signal is output to the R clutch ECMV solenoid, the value calculated from the signals of the
Contents of
transmission input shaft speed sensor, transmission intermediate shaft speed sensor, and transmis-
trouble
sion output shaft speed sensor is abnormal.
Action of • Sets gear in neutral.
controller • Turns lockup system OFF.
• Machine cannot travel in reverse.
• If gearshift lever is set in neutral, machine cannot start.
• Operator can move machine by following escape procedure.
Problem that 1) Stop travel and set gearshift lever in N position.
appears on 2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
machine other to set machine in emergency escape mode.
3) Operate gearshift lever and start machine again.
aWhen operating gearshift lever, release accelerator pedal.
aOperate gearshift lever from N to D – L or from N to R.
aMachine is kept in emergency escape mode until starting switch is turned OFF.
• Electric output current to ECMV solenoid can be checked with monitoring function (Code: 31606
(mA)).
• At first, check mechanical system for failure such as defective reverse clutch clogged oil filter of
Related hydraulic pressure control valve, etc.
information • When carrying out emergency escape operation, see "Emergency escape method when electrical
system has trouble".
k Raise the body at the highest position, and set damp lever to "Hold", and install body lock
pin to right and left.

Defective sensing by speed
1 • Troubleshooting by the failure codes of [DL**KA], and [DL**LC].
sensor
2) Disconnect connector R.PS (CN12).
Defective R clutch ECMV
2 Resis-
solenoid Between R.PS (CN12) (male) (1) and (2) 5 – 15 z
Possible causes tance
and standard Between R.PS (CN12) (male) (1) or (2) and Resis-
value in normal Min. 1 Mz
ground tance
state
2) Disconnect connector ATC3.
Disconnection or short circuit a If result is abnormal, disconnect connector J05 and TM3 in
3 order, and troubleshoot similarly. Then isolate defective wiring
in wiring harness
harness.
Between ATC3 (female) (25) and ATC3 Resis-
5 – 15 z
(female) (23) tance
8 HD785-7

a If no abnormality is found in checks on cause 3, this check is not
required.
Disconnection in wiring 2) Disconnect connectors ATC3 and R.PS (CN12).
Possible causes harness 3) Connect T-adapter.
4
and standard (Disconnection or defective
Between ATC3 (female) (25) and R.PS Resis-
value in normal contact) Max. 1 z
(CN12) (female) (1) tance
state
Max. 1 z
If causes are not found by above checks, transmission controller is
Defective transmission con-
5 defective. ( Since this is an internal failure, troubleshooting can not
troller
be performed. )
HD785-7 9
Failure code [15G7KM] Reverse clutch disk abuse: Mistake in operation

or setting 1
Action code Failure code Reverse clutch disc abuse: Mistake in operation or setting
Trouble
— 15G7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has
trouble been detected.
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related
information

and standard
1 Abuse
10 HD785-7
HD785-7 11
Failure code [15H0MW] Hi clutch: Slipping 1

Action code Failure code Hi clutch: Slipping
(Hi command is holding pressure, fill switch is ON, and slipping
Trouble
E03 15H0MW detected)
• When a signal is output to the Hi clutch ECMV solenoid, the value calculated from the signals of the
Contents of
trouble
Action of • Shifts up and keeps gear according to gear speed before trouble and Table 1.
Problem that
appears on • If gearshift lever is set in neutral, machine cannot restart until it stops.
machine
(mA)).
• At first, check mechanical system for failure such as defective Hi clutch, clogged oil filter of hydrau-
Related lic pressure control valve, etc.

sensor
2) Disconnect connector H.PS (CN19).
Defective Hi clutch ECMV
2 Resis-
solenoid Between H.PS (CN19) (male) (1) and (2) 5 – 15 z
tance
Between H.PS (CN19) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
Possible causes Disconnection or short circuit a If result is abnormal, disconnect connector J05 and TM3 in
and standard 3 order, and troubleshoot similarly. Then isolate defective wiring
in wiring harness
value in normal harness.
state Between ATC3 (female) (26) and ATC3 Resis-
5 – 15 z
(female) (3) tance
required.
Disconnection in wiring 2) Disconnect connectors ATC3 and H.PS (CN19).
harness 3) Connect T-adapter.
4
(Disconnection or defective
Between ATC3 (female) (26) and H.PS Resis-
contact) Max. 1 z
Max. 1 z
5 defective. (Since this is an internal failure, troubleshooting can not
troller
be performed.)
12 HD785-7
Table 1
Remedy against trouble
Speed when trouble
Failed clutch Action of controller ON/OFF state of
was detected
(Selected clutch, gear speed) lockup clutch
4th 4th OFF NEUTRAL OFF
F7
High High OFF NEUTRAL OFF
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
Reverse Reverse OFF NEUTRAL OFF
RH
RL
Low Low RH RH OFF
HD785-7 13
Failure code [15J0MW] Lo clutch: Slipping 1

Action code Failure code Lo clutch: Slipping
(Lo command is holding pressure, fill switch is ON, and slipping
Trouble
E03 15J0MW detected)
• When a signal is output to the Lo clutch ECMV solenoid, the value calculated from the signals of the
Contents of
trouble
Action of • Shifts up and keeps gear according to gear speed before trouble and Table 1.
Problem that
appears on • If gearshift lever is set in neutral, machine cannot restart until it stops.
machine
(mA)).
• At first, check mechanical system for failure such as defective Lo clutch, clogged oil filter of hydrau-
Related lic pressure control valve, etc.

sensor
2) Disconnect connector L.PS (CN17).
Defective Lo clutch ECMV
2 Resis-
solenoid Between L.PS (CN17) (male) (1) and (2) 5 – 15 z
tance
Between L.PS (CN17) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
and standard 3 order, and troubleshoot similarly. Then isolate defective wiring
in wiring harness
value in normal harness.
state Between ATC3 (female) (6) and ATC3 Resis-
5 – 15 z
(female) (13) tance
required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L.PS (CN17).
4
Between ATC3 (female) (6) and L.PS Resis-
contact) Max. 1 z
Max. 1 z
troller
be performed.)
14 HD785-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 15
Failure code [15K0MW] 1st clutch: Slipping 1

Action code Failure code 1st clutch: Slipping
(1st command holding pressure, 1st clutch fill switch ON, slipping
Trouble
E03 15K0MW detected)
• During an output to the 1st clutch ECMV solenoid, an abnormality exists in the value calculated
Contents of from the
trouble signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
and transmission output shaft speed sensor.
• Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
Action of
Table 1.
controller
• Turns lock up to OFF.
1) Stop travel and set gearshift lever in N position.
Problem that 2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
appears on other to set machine in emergency escape mode.
machine 3) Operate gearshift lever and start machine again.
• Electric output current to ECMV solenoid can be checked by monitoring function (code: 31602
(mA))
Related • At first, check mechanical system for failure such as defective 1st clutch, clogged oil filter of hydrau-
information lic pressure control valve, etc.

Defective speed sensor
1 • Troubleshooting by failure code [DL**KA], [DL**LC].
detection
1) Turn starting switch OFF.
2) Connect T-adapter to connector 1.PS (CN6) (male).
Defective 1st clutch ECMV Resis-
2 Between 1.PS (CN6) (male) (1) and (2) 5 – 15 z
solenoid tance
Between 1.PS (CN6) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
2) Connect T-adapter to connector ATC3 (female).
a If result is abnormal, disconnect connector J05 and TM3 in
Possible causes Disconnection or short circuit
and standard in wiring harness
harness.
value in normal Resis-
state Between ATC3 (female) (36) and (3) 5 – 15 z
tance
required.
Disconnection in wiring 2) Connect T-adapter to connectors ATC3 (female) and 1.PS
harness (CN6) (female).
4
Between ATC3 (female) (36) and 1.PS Resis-
contact) Max. 1 z
Between ATC3 (female) (3) and 1.PS (CN6) Resis-
Max. 1 z
(female) (2) tance
controller
be performed.)
16 HD785-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 17
Failure code [15L0MW] 2nd clutch: Slipping 1

Action code Failure code 2nd clutch: Slipping
(2nd command holding pressure, 2nd clutch fill switch ON, slipping
Trouble
E03 15L0MW detected)
• During an output to the 2nd clutch ECMV solenoid, an abnormality exists in the value calculated
Action of
Table 1.
controller
(mA))
Related • At first, check mechanical system for failure such as defective 2nd clutch, clogged oil filter of
information hydraulic pressure control valve, etc.

detection
Defective 2nd clutch ECMV Resis-
solenoid tance
Min. 1 Mz
ground tance
Possible causes Disconnection or short circuit order, and troubleshoot similarly. Then isolate defective wiring
3
and standard in wiring harness harness.
tance
required.
4
contact) Max. 1 z
(female) (1) tance
Max. 1 z
controller
be performed.)
18 HD785-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 19
Failure code [15M0MW] 3rd clutch: Slipping 1

Action code Failure code 3rd clutch: Slipping
(3rd command holding pressure, 3rd clutch fill switch ON, slipping
Trouble
E03 15M0MW detected)
• During an output to the 3rd clutch ECMV solenoid, an abnormality exists in the value calculated
Action of • Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
controller Table 1.
(mA))
Related • At first, check mechanical system for failure such as defective 3rd clutch, clogged oil filter of hydrau-

detection
Defective 3rd clutch ECMV Resis-
solenoid tance
Min. 1 Mz
ground tance
Possible causes Disconnection or short circuit order, and troubleshoot similarly. Then isolate defective wiring
3
and standard in wiring harness harness.
tance
required.
4
contact) Max. 1 z
Max. 1 z
controller
be performed.)
20 HD785-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 21
Failure code [15N0MW] 4th clutch: Slipping 1

Action code Failure code 4th clutch: Slipping
(4th command holding pressure, 4th clutch fill switch ON, slipping
Trouble
E03 15N0MW detected)
• During an output to the 4th clutch ECMV solenoid, an abnormality exists in the value calculated
Action of
Table 1.
controller
(mA))
Related • At first, check mechanical system for failure such as defective 4th clutch, clogged oil filter of hydrau-

detection
Defective 4th clutch ECMV Resis-
solenoid tance
Min. 1 Mz
ground tance
Possible causes Disconnection or short circuit
harness.
tance
required.
4
contact) Max. 1 z
Max. 1 z
controller
be performed.)
22 HD785-7
Table 1
Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 23
Failure code [15SBL1] R clutch solenoid: Fill signal is ON when

command current is OFF 1
Action code Failure code R clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • Even when output to the R clutch ECMV solenoid is turned "OFF", the signal from the fill switch
trouble stays "ON" and the clutch is not released.
Action of
controller
Problem that
appears on • Machine cannot restart until it stops.
machine
(mA))
• Fill switch input signal can be checked with code: 38919 (0: OFF, 1: ON).
Related
information • At first, check mechanical systems for failure such as defective R clutch, clogged oil filter of hydrau-
lic pressure control valve, etc.

1) Turn starting switch to OFF position.
2) Disconnect connector R.SW (CN13).
3) Turn starting switch to ON position.
If failure code [15SBL1] is not displayed, R clutch fill switch is
Defective for R clutch fill defective.
1
switch 1) Turn starting switch OFF.
2) Connect T-adapter to connector R.SW (CN13) (male).
Between R.SW (CN13) (male) (1) and
Resis-
ground Min. 1 Mz
tance
Possible causes (Fill switch: OFF)
and standard 1) Turn starting switch to OFF position.
value in normal Ground fault in wiring har- 2) Disconnect connector R.SW (CN13).
state 2 ness or defective transmis- 3) Turn starting switch to ON position.
sion controller If failure code [15SBL1] is displayed yet, ground fault in wiring har-
ness or defective transmission controller.
2) Disconnect connectors ATC3 and R.SW (CN13).
Defective harness grounding 3) Connect T-adapter to ATC3 (female) or R.SW (CN13) (female).
3
(Contact with ground circuit)
Between ATC3 (female) (29) or R.SW Resis-
Min. 1 Mz
(CN13) (female) (1) and ground tance
controller
be performed.)
24 HD785-7
HD785-7 25
Failure code [15SBMA] R clutch solenoid: Malfunction 1

Action code Failure code R clutch solenoid: Malfunction
(R command holding pressure, R clutch fill switch OFF, slipping
Trouble
E03 15SBMA detected)
• The signal from the fill switch stays "OFF" during an output to the R clutch ECMV solenoid and an
Contents of
abnormality exists in the value calculated from the signals of transmission input shaft speed sensor,
trouble
transmission intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of • The controller sets the gear is neutral.
controller • Turns lock up to OFF.
Problem that
appears on • Machine cannot restart until it stops.
machine
(mA))
Related • At first, check mechanical system for failure such as defective R clutch, clogged oil filter of hydraulic
information pressure control valve, etc.

and standard
value in normal Troubleshooting by failure code [15G0MW].
state
26 HD785-7
HD785-7 27
Failure code [15SCL1] Hi clutch solenoid: Fill signal is ON when

Action code Failure code Hi clutch solenoid: Fill signal is ON when command signal is OFF
Trouble
E03 15SCL1 (Transmission controller system)
Contents of • Even when output to the Hi clutch ECMV solenoid is turned "OFF", the signal from the fill switch
Action of
Table 2.
controller
Problem that
• Machine travels at gear speeds which use Hi clutch.
appears on
machine • Machine cannot travel in reverse.
(mA))
Related
information • At first, check mechanical systems for failure such as defective high clutch, clogged oil filter of
hydraulic pressure control valve, etc.

2) Disconnect connector H.SW (CN20).
If failure code [15SCL1] is not displayed, Hi clutch fill switch is
defective.
1 Defective Hi clutch fill switch
2) Connect T-adapter to connector H.SW (CN20) (male).
Between H.SW (CN20) (male) (1) and
Resis-
ground Min. 1 Mz
tance
value in normal Ground fault in wiring har- 2) Disconnect connector H.SW (CN20).
sion controller If failure code [15SCL1] is displayed yet, ground fault in wiring har-
2) Disconnect connectors ATC3 and H.SW (CN20).
Defective harness grounding 3) Connect T-adapter to ATC3 (female) or H.SW (CN20) (female).
3
Between ground and ATC3 (female) (30) or Resis-
Min. 1 Mz
H.SW (CN20) (female) (1) tance
controller
be performed.)
28 HD785-7
HD785-7 29
Table 2
Speed when trouble Failed clutch
was detected (Fill switch ON) Action of controller ON/OFF state of
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
F7 1st OFF NEUTRAL OFF
High
Reverse OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
RH 2nd OFF NEUTRAL OFF
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
RL 2nd OFF NEUTRAL OFF
Low
1st OFF NEUTRAL OFF
High RH RH OFF
N ANY NONE No reaction —
30 HD785-7
Failure code [15SCMA] Hi clutch solenoid: Malfunction 1

Action code Failure code Hi clutch solenoid: Malfunction
(Hi command holding pressure, Hi clutch fill switch OFF, slipping
Trouble
E03 15SCMA detected)
• The signal from the fill switch stays "OFF" during an output to the Hi clutch ECMV solenoid and an
Contents of
trouble
Action of
Table 1. (See failure code [15H0MW].)
controller
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
(mA))
Related • At first, check mechanical system for failure such as defective Hi clutch, clogged oil filter of hydrau-

and standard
value in normal Troubleshooting by failure code [15H0MW].
state
HD785-7 31
Failure code [15SDL1] Lo clutch solenoid: Fill signal is ON when

Action code Failure code Lo clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SDL1 (Transmission controller system)
Contents of • Even when output to the Lo clutch ECMV solenoid is turned "OFF", the signal from the fill switch
• Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before fail-
Action of
ure.
controller
Problem that
appears on • Machine travels at gear speeds which use Lo clutch.
machine
(mA))
Related
information • At first, check mechanical systems for failure such as defective Lo clutch, clogged oil filter of

2) Disconnect connector L.SW (CN18).
If failure code [15SDL1] is not displayed, Lo clutch fill switch is
defective.
1 Defective Lo clutch fill switch
2) Connect T-adapter to connector L.SW (CN18) (male).
Between L.SW (CN18) (male) (1) and
Resis-
ground Min. 1 Mz
tance
value in normal Ground fault in wiring har- 2) Disconnect connector L.SW (CN18).
sion controller If failure code [15SDL1] is displayed yet, ground fault in wiring har-
2) Disconnect connectors ATC3 and L.SW (CN18).
Defective harness grounding 3) Connect T-adapter to ATC3 (female) or L.SW (CN18) (female).
3
Min. 1 Mz
L.SW (CN18) (female) (1) tance
controller
be performed.)
32 HD785-7
HD785-7 33
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
34 HD785-7
Failure code [15SDMA] Lo clutch solenoid: Malfunction 1

Action code Failure code Lo clutch solenoid: Malfunction
(Lo command holding pressure, Lo clutch fill switch OFF, slipping
Trouble
E03 15SDMA detected)
• The signal from the fill switch stays "OFF" during an output to the Lo clutch ECMV solenoid and an
Contents of
trouble
Action of
ure. (See failure code [15J0MW].)
controller
Problem that
appears on • Machine travels at gear speeds which do not use Lo clutch.
machine
(mA))
Related • At first, check mechanical system for failure such as defective Lo clutch, clogged oil filter of hydrau-

and standard
value in normal Troubleshooting by failure code [15J0MW].
state
HD785-7 35
Failure code [15SEL1] 1st clutch solenoid: Fill signal is ON when

Action code Failure code 1st clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • Even when output to the 1st clutch ECMV solenoid is turned "OFF", the signal from the fill switch
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 1st clutch.
appears on
machine • Machine cannot travels in reverse.
(mA))
Related
information • At first, check mechanical systems for failure such as defective 1st clutch, clogged oil filter of

2) Disconnect connector 1.SW (CN7).
If failure code [15SEL1] is not displayed, 1st clutch fill switch is
1 Defective 1st clutch fill switch defective.
2) Connect T-adapter to connector 1.SW (CN7) (male).
Between 1.SW (CN7) (male) (1) and ground Resis-
Min. 1 Mz
(Fill switch: OFF) tance
Possible causes
value in normal Ground fault in wiring har- 2) Disconnect connector 1.SW (CN7).
sion controller If failure code [15SEL1] is displayed yet, ground fault in wiring har-
2) Disconnect connectors ATC3 and 1.SW (CN7).
Defective harness grounding 3) Connect T-adapter to ATC3 (female) or 1.SW (CN7) (female).
3
Min. 1 Mz
1.SW (CN7) (female) (1) tance
controller
be performed.)
36 HD785-7
HD785-7 37
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
38 HD785-7
Failure code [15SEMA] 1st clutch solenoid: Malfunction 1

Action code Failure code 1st clutch solenoid: Malfunction
(1st command holding pressure, 1st clutch fill switch OFF, slipping
Trouble
E03 15SEMA detected)
• The signal from the fill switch stays "OFF" during an output to the 1st clutch ECMV solenoid and an
Contents of
trouble
Action of
ure. (See failure code [15K0MW].)
controller
Problem that
appears on • Machine travels at gear speeds which do not use 1st clutch.
machine
(mA))
Related • At first, check mechanical system for failure such as defective 1st clutch, clogged oil filter of hydrau-

and standard
value in normal Troubleshooting by failure code [15K0MW].
state
HD785-7 39
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
40 HD785-7
SEN01939-03
HD785-7

HD785-7 7001 and up
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF ....................... 4
Failure code [15SFMA] 2nd clutch solenoid: Malfunction ............................................................................... 7
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF........................ 8
Failure code [15SGMA] 3rd clutch solenoid: Malfunction ..............................................................................11
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF ...................... 12
Failure code [15SHMA] 4th clutch solenoid: Malfunction.............................................................................. 15
Failure code [15SJMA] Lockup clutch solenoid: Malfunction........................................................................ 16
Failure code [2F00KM] Parking brake: Mistake in operation or setting ........................................................ 18
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) ........................................................... 21
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) ............................................................ 21
Failure code [989A00] Engine over run prevention command signal: Operating.......................................... 22
Failure code [989D00] Rear section tipping over alarm: Alarm is activated ................................................. 22
Failure code [A570NX] Engine oil filter: Clogging ......................................................................................... 24
Failure code [AA10NX] Air cleaner element: Clogging ................................................................................. 26
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R terminal signal is present and engine is
stopped)................................................................................................................................................. 28
HD785-7 1
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 30

Failure code [AB00MB] Alternator: Failure on battery charge circuit (Absence of R terminal signal and detec-
tion error) ............................................................................................................................................... 32
Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure ..................... 34
Failure code [B@BAZK] Engine oil: Level too low ........................................................................................ 36
Failure code [B@BCNS] Engine: Overheat .................................................................................................. 38
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level ..................................................... 40
Failure code [B@BFZK] Lowering of fuel level ............................................................................................. 42
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) ................................................................... 43
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear).................................................................... 44
Failure code [B@CENS] Overheating of torque converter oil ....................................................................... 46
Failure code [B@GAZK] Battery electrolyte level: Lowering of level ............................................................ 47
Failure code [B@JANS] Steering oil temperature: Overheat ........................................................................ 48
2 HD785-7
HD785-7 3
Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when

Action code Failure code 2nd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SFL1 (Transmission controller system)
Contents of • Even when output to the 2nd clutch ECMV solenoid is turned "OFF", the signal from the fill switch
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 2nd clutch.
appears on
(mA))
• Fill switch input signal can be checked with code: 38919 (0: OFF, 1:ON).
Related
information • At first, check mechanical systems for failure such as defective 2nd clutch, clogged oil filter of

If failure code [15SFL1] is not displayed, 2nd clutch fill switch is
Defective fill switch for 2nd defective.
1
clutch 1) Turn starting switch OFF.
Between 2.SW (CN9) (male) (1) and ground Resis-
Min. 1 Mz
Possible causes (Fill switch: OFF) tance
value in normal Ground fault in wiring har- 2) Disconnect connector 2.SW (CN9).
sion controller If failure code [15SFL1] is displayed yet, ground fault in wiring har-
Ground fault in wiring har- 2) Disconnect connectors ATC3 and 2.SW (CN9).
3 ness (Contact with ground 3) Connect T-adapter to ATC3 (female) or 2.SW (CN9) (female).
circuit) Between ground and ATC3 (female) (9) or Resis-
Min. 1 Mz
controller
be performed.)
4 HD785-7
HD785-7 5
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
6 HD785-7
Failure code [15SFMA] 2nd clutch solenoid: Malfunction 1

Action code Failure code 2nd clutch solenoid: Malfunction
(2nd command holding pressure, 2nd clutch fill switch OFF, slip-
Trouble
E03 15SFMA ping detected)
• The signal from the fill switch stays "OFF" during an output to the 2nd clutch ECMV solenoid and an
Contents of
trouble
Action of
ure.(See failure code [15L0MW].)
controller
Problem that
appears on • Machine travels at gear speeds which do not use 2nd clutch.
machine
(mA))
Related • At first, check mechanical system for failure such as defective 2nd clutch, clogged oil filter of
information hydraulic pressure control valve, etc.

and standard
value in normal Troubleshoot by failure code [15L0MW].
state
HD785-7 7
Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when

Action code Failure code 3rd clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SGL1 (Transmission controller system)
Contents of • Even when output to the 3rd clutch ECMV solenoid is turned "OFF", the signal from the fill switch
Action of
ure.
controller
Problem that
• Machine travels at gear speeds which use 3rd clutch.
appears on
(mA))
• Fill switch input signal can be checked with code: 38919 (0: OFF, 1:ON).
Related
information • At first, check mechanical systems for failure such as defective 3rd clutch, clogged oil filter of

If failure code [15SGL1] is not displayed, 3rd clutch fill switch is
defective.
Defective 3rd clutch fill
1 1) Turn starting switch OFF.
switch
Between 3.SW (CN11) (male) (1) and
Resis-
ground Min. 1 Mz
(Fill switch: OFF)
and standard
value in normal 1) Turn starting switch to OFF position.
state Ground fault in wiring har- 2) Disconnect connector 3.SW (CN11).
2 ness or defective transmis- 3) Turn starting switch to ON position.
sion controller If failure code [15SGL1] is displayed yet, ground fault in wiring har-
Ground fault in wiring har- 2) Disconnect connectors ATC3 and 3.SW (CN11).
3 ness (Contact with ground 3) Connect T-adapter to ATC3 (female) or 3.SW (CN11) (female).
circuit) Between ground and ATC3 (female) (19) or Resis-
Min. 1 Mz
controller
be performed.)
8 HD785-7
HD785-7 9
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
10 HD785-7
Failure code [15SGMA] 3rd clutch solenoid: Malfunction 1

Action code Failure code 3rd clutch solenoid: Malfunction
(3rd command holding pressure, 3rd clutch fill switch OFF, slipping
Trouble
E03 15SGMA detected)
• The signal from the fill switch stays "OFF" during an output to the 3rd clutch ECMV solenoid and an
Contents of
trouble
Action of
ure. (See failure code [15M0MW].)
controller
Problem that
appears on • Machine travels at gear speeds which do not use 3rd clutch.
machine
(mA))
Related • At first, check mechanical system for failure such as defective 3rd clutch, clogged oil filter of hydrau-

and standard
value in normal Troubleshoot by failure code [15M0MW].
state
HD785-7 11
Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when com-
mand current is OFF 1
Action code Failure code 4th clutch solenoid: Fill signal is ON when command current is
Trouble OFF
E03 15SHL1 (Transmission controller system)
Contents of • When output to 4th clutch ECMV solenoid is turned "OFF", signal from fill switch is kept "ON" and
trouble clutch is not disengaged.
Action of
ure.
controller
• Turns lockup system OFF.
Problem that
• Machine travels at gear speeds which use 4th clutch.
appears on
(mA))
Related
information • At first, check mechanical systems for failure such as defective 4th clutch, clogged oil filter of

If failure code [15SHL1] is not displayed, 4th clutch fill switch is
defective.
1 Defective 4th clutch fill switch 1) Turn starting switch OFF.
Between 4.SW (CN15) (male) (1) and
Resis-
ground Min. 1 Mz
(Fill switch: OFF)
and standard
state Ground fault in wiring har- 2) Disconnect connector 4.SW (CN15).
2 ness or defective transmis- 3) Turn starting switch to ON position.
sion controller If failure code [15SHL1] is displayed yet, ground fault in wiring har-
Grounding fault in wiring 2) Disconnect connectors ATC3 and 4.SW (CN15).
3 harness 3) Connect T-adapter to ATC3 (female) or 4.SW (CN15) (female).
(Contact with ground circuit) Between ground and ATC3 (female) (20) or Resis-
Min. 1 Mz
controller
be performed.)
12 HD785-7
HD785-7 13
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
14 HD785-7
Failure code [15SHMA] 4th clutch solenoid: Malfunction 1

Action code Failure code 4th clutch solenoid: Malfunction
(4th command is holding pressure, 4th clutch fill switch is OFF, and
Trouble
E03 15SHMA slipping detected)
• When a signal is output to the 4th clutch ECMV solenoid, the signal from the fill switch is kept "OFF"
Contents of
and the value calculated from the signals of the transmission input shaft speed sensor, transmission
trouble
intermediate shaft speed sensor, and transmission output shaft speed sensor is abnormal.
Action of • The controller sets the gear in Neutral.
Problem that
• The gear is set in Neutral suddenly during travel.
appears on
machine • Machine travels at gear speeds which do not use 4th clutch.
(mA))
Related • At first, check mechanical system for failure such as defective 4th clutch, clogged oil filter of hydrau-

and standard
value in normal Troubleshoot by failure code [15N0MW].
state
HD785-7 15
Failure code [15SJMA] Lockup clutch solenoid: Malfunction 1

Action code Failure code Lockup clutch solenoid: Malfunction
(Lockup command holding pressure is applied and slipping
Trouble
E03 15SJMA detected)
• During an output to the lockup clutch solenoid, an abnormality exists in the value calculated from
Contents of
the signals of engine speed sensor, transmission intermediated shaft speed sensor, and transmis-
trouble
sion output shaft speed sensor.
Action of • Holds gear speed during traveling and turns lock up to "OFF".
controller • Holds neutral when gear shift lever is set to "N".
Problem that
• Lockup is released and gear shift is disabled.
appears on
machine • If gear shift lever is shifted to "N", machine does not start unless it is stopped.
• Electric current of output to solenoid can be checked by monitoring function (code: 31609 (mA))
Related • At first, check mechanical system for failure such as defective lockup clutch, clogged oil filter of
information

detection
2) Disconnect connector L/U.PS (CN16).
3) Connect T-adapter to connector L/U.PS (CN16) (male).
Defective lockup clutch sole-
2 Resis-
noid Between L/U.PS (CN16) (male) (1) and (2) 5 – 15 z
tance
Between L/U.PS (CN16) (male) (1) or (2) Resis-
Min. 1 Mz
and ground tance
harness.
value in normal
state Resis-
Between ATC3 (female) (35) and (23) 5 – 15 z
tance
required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L/U.PS (CN16).
harness 3) Connect T-adapters to connectors ATC3 (female) and L/U.PS
4 (CN16) (female).
contact) Between ATC3 (female) (35) and L/U.PS Resis-
Max. 1 z
Between ATC3 (female) (23) and L/U.PS Resis-
Max. 1 z
controller
be performed.)
16 HD785-7
HD785-7 17
Failure code [2F00KM] Parking brake: Mistake in operation or setting 1

Action code Failure code Parking brake: Mistake in operation or setting
Trouble (Parking brake drags)
— 2F00KM (Retarder controller system)
Contents of • When the output shaft speed is above 200 rpm (approx. 5 km/h), the parking brake or emergency
trouble brake is operated.
Action of
controller
Problem that
appears on • If the machine is used without repairing, it may be broken.
machine
Related • If error in communication between transmission connector and retarder controller (DB1RKR) is dis-
information played, carry out troubleshooting for it first.

• Set the parking brake switch in the FREE position and then start
Mistake in operation of
1 the machine.
parking brake switch
• Do not use parking brake while machine is traveling.
2) Replace R03 with normal one.
When the parking Relay (R03) is
Yes
brake relay (R03) is defective
replaced, is failure Relay (R03) is
repaired? No
normal
2) Disconnect connector R03.
3) Check the relay.
Defective parking brake relay
2 Resis- 200 – 400
(R03) Between R03 (male) (1) and (2)
tance z
3) Check the relay.
4) Apply voltage between R03 (male) (1) and (2).
Possible causes
and standard Apply 24 V between Resis-
Min. 1 Mz
value in normal Between R03 (male) (1) and (2) tance
state (3) and (6) Do not apply 24 V Resis-
Max. 1 z
between (1) and (2) tance
2) Connect T-adapter to connector PSWF (male).
3) Start engine.
Set parking brake
Defective parking brake oil Resis-
3 switch in FREE Min. 1 Mz
pressure switch (front) tance
Between PSWF position
(male) (1) and (2) Set parking brake
Resis-
switch in PARK Max. 1 z
tance
position
2) Connect T-adapter to connector PSWR (male).
3) Start engine.
Set parking brake
Defective parking brake oil Resis-
4 switch in FREE Min. 1 Mz
pressure switch (rear) tance
Between PSWR position
(male) (1) and (2) Set parking brake
Resis-
switch in PARK Max. 1 z
tance
position
18 HD785-7

Mistake in operation of
emergency brake
5 • Operate the emergency brake only when necessary.
(Operation of emergency
brake during travel)
2) Connect T-adapter to connector R03 (female).
Resis-
Between R03 (female) (2), (6) and ground Max. 1 z
tance
2) Connect T-adapter to connectors R03, BT3, PSWR (female), and
Disconnection in wiring PSWR (female).
harness (Disconnection in 3) Check the relay.
6
wiring or defective contact in Between fuse BT3 (16) and PSWF (female) Resis-
Max. 1 z
connector) (1) tance
Between fuse BT3 (16) and PSWR (female) Resis-
Max. 1 z
Possible causes (1) tance
and standard Between R03 (female) (1) and PSWF Resis-
value in normal Max. 1 z
(female) (2) tance
state
Between R03 (female) (1) and PSWR Resis-
Max. 1 z
(female) (2) tance
Ground fault in wiring 2) Disconnect connectors BRC3 and R03.
7 harness (Contact with GND 3) Connect T-adapter.
circuit) Wiring harness between BRC3 (female) (9), Resis-
Min. 1 Mz
R03 (female) (3) and ground tance
2) Disconnect connector BRC3.
3) Insert T-adapter into connector BRC3.
Set parking brake
8 Defective retarder controller
switch in FREE Voltage Max. 1 V
Between BRC3 (9) position
and ground Set parking brake
switch in PARK Voltage 6 – 12 V
position
HD785-7 19
20 HD785-7
Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front) 1

Action code Failure code Accumulator: Oil pressure reduction (Front)
Trouble
E03 2G42ZG (Transmission controller system)
Contents of • Oil pressure reduction (Max. 8.83 MPa {90 kg/cm2}) was detected by signal from accumulator oil
trouble pressure sensor (front).
Action of
• Displays accumulator oil pressure monitor red.
controller
Problem that
appears on • Brake (Retarder) (front) does not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code: 35500 (MPa),
Related
35504 (V)).
information
• Circuit diagram: See [DHU2KX].

Possible causes Hydraulic system (pump, relief valve or piping) may have trouble.
1 Trouble in hydraulic system
and standard If pressure is reduced, remove cause of trouble.
value in normal
• If cause 1 is not detected, accumulator (front) oil pressure sen-
state Defective accumulator (front)
2 sor system may be defective. Carry out troubleshooting for fail-
oil pressure sensor system
ure code [DHU2KX].
Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear) 1

Action code Failure code Accumulator oil pressure reduction (Rear)
Trouble
E03 2G43ZG (Transmission controller system)
Contents of • Oil pressure reduction (Max. 8.83 (MPa) {90 (kg/cm2)}) was detected by signal from accumulator oil
trouble pressure sensor (rear).
Action of
• Displays accumulator oil pressure monitor red.
controller
Problem that
appears on • Brake (Retarder) (rear) does not work.
machine
• Input signal from oil pressure sensor can be checked with monitoring function (Code: 35501 (MPa),
Related
35505 (V)).
information
• Circuit diagram: See [DHU3KX].

Possible causes Hydraulic system (pump, relief valve or piping) may have trouble.
1 Trouble in hydraulic system
and standard If pressure is reduced, remove cause of trouble.
value in normal
• If cause 1 is not detected, accumulator (rear) oil pressure sensor
state Defective accumulator (rear)
2 system may be defective. Carry out troubleshooting for failure
oil pressure sensor system
code [DHU3KX].
HD785-7 21
Failure code [989A00] Engine over run prevention command signal:

Operating 1
Action code Failure code Engine over run prevention command signal: Operating
Trouble
E02 989A00 (Machine monitor system)
Contents of • When gear speed is set at the position other than neutral, transmission input shaft speed signal
trouble exceeds the input shaft speed which is set for each gear speed to prevent over run.
Action of
• Send out command signal to retarder controller and activate brake.
controller
Problem that
appears on • Brake becomes activated and travel speed lowers.
machine
• Input shaft speed can be checked in monitoring function (code: 31200 (rpm)).
Related
information • Information on operation of engine overrun prevention command is obtained from transmission con-
troller through network.

a If machine is so traveling that transmission input shaft speed sig-
Possible causes
1 Engine over run nal exceeds 2,600 rpm (or 2,400 rpm at R2), engine is overrun-
and standard
ning.
value in normal
state • If machine is not so traveling that transmission input shaft speed
2 signal exceeds 2,600 rpm (or 2,400 rpm at R2), transmission
controller
controller is defective.
Failure code [989D00] Rear section tipping over alarm: Alarm is

activated 1
Action code Failure code Rear section tipping over alarm: Alarm is activated
Trouble (Lift operation when machine is inclined)
— 989D00 (Machine monitor system)
Contents of
• Body is lifted when machine is inclined.
trouble
Action of • Turns on inclination caution lamp
machine monitor • Sounds alarm buzzer.
Problem that
appears on • If body is lifted in such condition, machine body may tip over.
machine
• Input signal from pitch angle sensor can be checked with monitoring function (code: 32900 (°),
Related 32903 (V)).
information • Information on operation of inclination alarm activation is obtained from transmission controller
through network.

and standard
value in normal Do not lift body when machine is inclined for more than 15°. (Teach
1 Mistake in operation
state the proper operating method.)
22 HD785-7
HD785-7 23
Failure code [A570NX] Engine oil filter: Clogging 1

Action code Failure code Engine oil filter: Clogging
Trouble
E01 A570NX (Retarder controller system)
• When engine speed is above 500 rpm and torque converter oil temperature is above 50°C, and
Contents of
engine coolant temperature is above 67°C, oil filter circuit is opened (disconnected from ground cir-
trouble
cuit).
Action of
controller
Problem that
appears on • If engine is used for long hours, it may be seized.
machine
Related
information

When maintenance caution lamp
1 Clogged engine oil filter Oil filter is probably clogged
is lighting
2) Disconnect E05.
Resis-
Defective engine oil filter E05 (male) Oil filter
2 tance
clogging switch
When normal Max. 1 z
Between (1) and (2) When clogging
Min. 1 Mz
Possible causes switch is open
and standard 1) Turn starting switch OFF.
value in normal Disconnection in wiring 2) Disconnect connector BRC2 and E05.
state harness 3) Connect T-adapter to BRC2 (female).
3
(Disconnection in wiring or
Resis-
defective contact in connector) Between BRC2 (female) (13) and E05 (1) Max. 1 z
tance
2) Insert T-adapter into connectors BRC2 and BRC3.
3) Turn starting switch ON.
4 Defective retarder controller BRC2 and BRC3 Oil filter Voltage
When normal Max. 1 V
Between BRC2 (13) and BRC3
(21), (31), (32) and (33) When clogging
6 – 12 V
switch is open
24 HD785-7
HD785-7 25
Failure code [AA10NX] Air cleaner element: Clogging 1

Action code Failure code Air cleaner element: Clogging
Trouble
E01 AA10NX (Transmission controller system)
Contents of
• The air cleaner clogging signal circuit is "opened" (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If the machine is used without repairing, the suction performance of the engine may be lowered.
machine
Related
• ATC2 (17) When normal: GND, When clogged: OPEN
information

The dust indicator is not red Air cleaner is normal
1 Clogging of air cleaner
The dust indicator is red Air cleaner is clogged
2) Replace R32 with normal one.
When the dust indicator relay No Relay is normal

(R32) is replaced, is failure
repaired? Yes Relay is defective

Dust indicator relay (R32) 3) Check the relay.
2
defective Resis- 200 – 400
Between R32 (male) (1) – (2)
tance z
Possible causes 3) Check the relay.
and standard 4) Apply voltage between R32 (male) (1) and (2).
value in normal Apply 24 V between Resis-
state Min. 1 Mz
Between R32 (male) (1) and (2) tance
(3) and (6) Do not apply 24 V Resis-
Max. 1 z
between (1) and (2) tance
2) Disconnect connector FR01.
Defective air cleaner clog- 4) Turn the starting switch ON.
3
ging sensor a Inside of air cleaner sensor is consist of electric circuit,so it is
impossible to judge with resistance.
Between FR01 Air cleaner is normal Voltage 20 – 30 V
(male) (1) and (2) Air cleaner is clogged Voltage Max. 10 V
2) Disconnect connectors ATC2, ATC3 and R32.
Disconnection in wiring 3) Connect T-adapters (female).
harness
4 Wiring harness between ATC3 (female) (21) Resis-
(Disconnection or defective Max. 1 z
and R32 (female) (6) tance
contact)
Wiring harness between ATC2 (female) (17) Resis-
Max. 1 z
and R32 (female) (3) tance
26 HD785-7

2) Disconnect connectors R32 and FR01.
Grounding fault of wiring har- 3) Connect T-adapter.
5
Possible causes ness
Between R32 (female) (2) or FR01 (female) Resis-
and standard Min. 1 Mz
(1) and ground tance
value in normal
state 1) Turn starting switch OFF.
2) Insert T-adapter in connectors ATC3 and ATC2.
Defective transmission con- 3) Turn starting switch ON.
6
troller
Between ATC2 (17) Air cleaner is normal Voltage Max. 1 V
and ATC3 (21) Air cleaner is clogged Voltage 6 – 12 V
HD785-7 27
Failure code [AB00L4] Alternator: Failure on battery charge circuit (R

terminal signal is present and engine is stopped) 1
Action code Failure code Alternator: Failure on battery charge circuit (R terminal signal is
Trouble present and engine is stopped)
E01 AB00L4 (Pre-lubrication controller system)
• Engine is not operated normally (500 rpm or lower), due to the CAN communication data with the
Contents of
engine controller. However, the system is judged that charging voltage (12 V or above) from the
trouble
alternator R terminal is present.
Action of
• None in particular
controller
Problem that
appears on
machine
• Starting signal of starting switch: This failure code disappears if the voltage (24 V) is supplied from
C terminal.
• This failure code does not appear if the CAN communication from the engine controller is not possi-
ble.
Related • The engine service monitor carried out troubleshooting in [AB00L6] for a similar error.
information • Judgment of controller pin 13:
Charging voltage from alternator (R terminal) is normal: Min. 12 V
Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V
• The R terminal voltage supplied to the pre-lubrication controller is checked with monitoring code:
04305(V).
Causes Standard value in normal state/Remarks on troubleshooting

2) Disconnect alternator R terminal (E01).
3) Turn the starting switch ON (without starting the engine) and
1 Defective alternator carry out troubleshooting.
Between alternator terminal R
Voltage Max. 5 V
and chassis ground
Possible causes 3) Turn the starting switch ON (without starting the engine) and
and standard carry out troubleshooting.
value in normal Between wiring harness terminal
state Hot short in wiring harness Voltage Max. 1 V
R (E01) and chassis ground
2 (Short circuit with supply
voltage) 1) Turn the starting switch OFF.
2) Disconnect alternator PRE5.
carry out troubleshooting.
Between PRE5 (female) (13)
Voltage Max. 1 V
and chassis ground
If causes 1 – 2 are not detected, engine controller may be defec-
Defective pre-lubrication
3 tive. (Since trouble is in system, troubleshooting cannot be carried
controller
out.)
28 HD785-7
Related electrical circuit diagram
a Prelube controller is the same as pre-lubrication controller.
HD785-7 29
Failure code [AB00MA] Alternator: Malfunction 1

Action code Failure code Alternator: Malfunction
Trouble (Failure in battery charging circuit)
E03 AB00MA (Transmission controller system)
Contents of
• A generation signal is not input from the alternator while the engine is running.
trouble
Action of
controller
Problem that
• If the machine is used without repairing, the source voltage may lower so much that the machine
appears on
cannot travel.
machine
Related
• This failure can be checked in the monitoring function (Code: 04301 (0: OFF, 1:ON)).
information

2) Disconnect connector alternator terminal R.
1 Defective alternator
Between alternator R and E Voltage 20 – 30 V
a If the battery is deteriorated or used in a cold district, the volt-
age may not rise for a while after the engine is started.
Possible causes Disconnection in wiring Between ATC1 (female) (5) and ground Voltage 20 – 30 V
and standard harness
value in normal 2 a If the battery is deteriorated or used in a cold district, the volt-
state age may not rise for a while after the engine is started.
contact)
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M and alternator terminal R tance
3) Insert T-adapter.
Defective transmission con- 4) Start the engine.
3
troller
Between ATC1 (5) and ground Voltage 20 – 30 V
a If the battery is deteriorated or used in a cold district, the volt-
age may not rise for a while after the engine is started.
30 HD785-7
HD785-7 31
Failure code [AB00MB] Alternator: Failure on battery charge circuit

(Absence of R terminal signal and detection error) 1
Action code Failure code Alternator: Failure on battery charge circuit (Absence of R terminal
Trouble signal and detection error)
E01 AB00MB (Pre-lubrication controller system)
• Engine is not operated normally (500 rpm or more), due to the CAN communication data with the
Contents of
engine controller. However, the system is judged that charging voltage (5 V or less) from the alter-
trouble
nator R terminal is present.
Action of
controller
Problem that
appears on
machine
• Starting signal of starting switch: C terminal is irrelevant to this failure code.
• This failure code does not appear if the CAN communication from the engine controller is not possible.
• The engine service monitor diagnoses [AB00MA] for a similar error.
Related • Controller 13 pin monitored the charging voltage from the alternator (R terminal). Hysteresis of :
information Charging voltage from alternator (R terminal) is normal: Min. 12 V
Charging voltage from alternator (R terminal) is not normal: Max. 5 V
• State of R terminal voltage supplied to the pre-lubrication controller is checked with monitoring
code: 04305 (V).

2) Start the engine and carry out troubleshooting.
1 Defective alternator
Between alternator terminal R
Voltage Min. 12 V
and chassis ground
Disconnection in wiring 2) Disconnect alternator R terminal (E01).
harness 3) Disconnect connector PRE5, then carry out troubleshooting with
2 the connector being disconnected.
Possible causes (Disconnection or defective
and standard contact in connector) Between wiring harness termi- Resis-
nals (E01) – PRE5 (female) (13) tance
state
Grounding fault in wiring 3) Disconnect connector PRE5, then carry out troubleshooting with
3 harness (Short circuit with the connector being disconnected.
ground circuit)
Between PRE5 (female) (13) Resis-
Min. 1 Mz
and chassis ground tance
If causes 1 – 3 are not detected, pre-lubrication controller may be
4 defective. (Since trouble is in system, troubleshooting cannot be
controller
carried out.)
32 HD785-7
HD785-7 33
Failure code [B@BAZG] Abnormal lowering of engine oil pressure:

Lowering of oil pressure 1
Action code Failure code Abnormal lowering of engine oil pressure: Lowering of oil pressure
Trouble
E03 B@BAZG (Engine controller system)
Contents of • When engine speed was below 500 rpm for 15 seconds, engine oil pressure became lower than
trouble operating range.
Action of • Limit output for travel (Limit injection rate and engine speed)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitor-
ing function (Code: 37200 (kPa)).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201 (V)).
• Method of reproducing failure code: Start engine.

and standard
value in normal Carry out troubleshooting for failure code [CA135] and [CA141].
state
34 HD785-7
HD785-7 35
Failure code [B@BAZK] Engine oil: Level too low 1

Action code Failure code Engine oil: Level too low
Trouble
E01 B@BAZK (Retarder controller system)
Contents of
• Engine oil level switch circuit has become "OPEN" (disconnected with GND).
trouble
Action of
• Turn on the maintenance caution lamp.
controller
Problem that
appears on • If machine is operated in such a condition, engine may be seized.
machine
Related • This trouble is not detected while engine coolant temperature is above 60°C.
information • This failure code is reset when engine is started.

• Engine oil level is normal.
1 Engine oil level is too low. a If engine oil level is too low, check for an oil leakage around
engine before refilling.
a Prepare with starting switch OFF and troubleshooting with
starting switch still OFF.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between E04 (male) normal tance
(1) and (2) Engine oil level is too Resis-
Min. 1 Mz
Possible causes low tance
and standard a Prepare with starting switch OFF and troubleshooting with
value in normal starting switch still OFF.
state Disconnection in wiring
harness (Disconnection in Between BRC2 (female) (7) and E04 Resis-
3 Max. 1 z
wiring or defective contact in (female) (1) tance
connector) Between BRC3 (female) (21), (31), (32), Resis-
Max. 1 z
(33) and E04 (female) (2) tance
starting switch ON.
Defective retarder Engine oil level is
4 Voltage Max. 1V
controller Between BRC2 (7) normal
and ground Engine oil level is too
Voltage 6 – 12 V
low
36 HD785-7
HD785-7 37
Failure code [B@BCNS] Engine: Overheat 1

Action code Failure code Engine overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of • When engine speed was below 500 rpm for 3 seconds or more, coolant temperature exceeded
trouble operating range.
Action of • Limits output and continues operation.
Problem that
appears on • Engine output drops.
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the moni-
toring function (Code: 04104 (°C)).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105 (V)).
• Method of reproducing failure code: Start engine.

and standard
value in normal Carry out troubleshooting for failure code [CA144] and [CA145].
state
38 HD785-7
HD785-7 39
Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level1

Action code Failure code Lowering of radiator coolant: Lowering of level
Trouble
E01 B@BCZK (Transmission controller system)
Contents of
• The radiator coolant level switch signal circuit is opened (disconnected from GND).
trouble
Action of
controller
Problem that
appears on • If machine is used while coolant level is low, engine may overheat.
machine
Related
information

• The radiator coolant level is normal.
Lowering of radiator coolant
1 a If the radiator coolant level is low, check around the engine
level
and radiator for coolant leakage before adding coolant.
2) Disconnect connector FL02.
3) Connect T-adapter to FL02 (male).
Defective radiator coolant
2 Radiator coolant Resis-
level switch Max. 1 z
Between FL02 (male) level is normal tance
(1) and (2) Radiator coolant Resis-
Min. 1 Mz
level is low tance
Possible causes
and standard a If the radiator coolant level is low, check around the engine
value in normal Disconnection in wiring and radiator for coolant leakage before adding coolant.
state harness Between ATC2 (female) (27) and FL02 Resis-
3 Max. 1 z
(Disconnection or defective (female) (1) tance
contact) Between FL02 (female) (2) and ATC3 Resis-
Max. 1 z
(female) (21) tance
2) Disconnect connectors ATC2 and ATC3.
3) Insert T-adapters into ATC2 and ATC3.
Defective transmission con- 4) Turn the starting switch ON.
4
troller Radiator coolant
Voltage Max. 1V
Between ATC2 (27) level is normal
and ATC3 (21) Radiator coolant
Voltage 6 – 12 V
level is low
40 HD785-7
HD785-7 41
Failure code [B@BFZK] Lowering of fuel level 1

Action code Failure code Lowering of fuel level
Trouble
– B@BFZK (Machine monitor system)
Contents of
• Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 z or higher is detected).
trouble
Action of • Does not display this failure code, if DJF1KA is detected.
machine monitor • Turns fuel level caution lamp ON.
Problem that
appears on • None in particular.
machine
• When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient.
Related • Signal from fuel level sensor can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200 (V) / 04201 (z))
• Method of reproducing failure code: Turn starting switch ON.

Possible causes
Lack of fuel (When system is
and standard 1 Fuel may be insufficient. Check and add fuel, if necessary.
normal)
value in normal
state Carry out troubleshooting for failure code [DJF1KA], if fuel is suffi-
2 Defective fuel level sensor
cient.
42 HD785-7
Failure code [B@C6NS] Brake cooling oil: Overheating (Front) 1

Action code Failure code Brake cooling oil: Overheating (Front)
Trouble
E02 B@C6NS (Machine monitor system)
Contents of • While engine was running, oil overheat was detected by signal from front brake (retarder) oil tem-
trouble perature sensor.
Action of
• Turn on brake oil temperature caution lamp.
machine monitor
Problem that
• Brake (Retarder) (front) comes not to work.
appears on
machine • If machine is used as it is, brake (retarder) (front) may be damaged.
• Input signal from oil temperature sensor can be checked with monitoring function (Code: 30201
Related
(°C), 30204 (V)).
information
• For troubleshooting for brake (retarder) (front) oil temperature sensor, see failure code [DGR4KZ].

Overheat of front brake cool-
1 Front brake may be overloaded. Check related parts.
ing oil
Possible causes
Defective brake oil tempera-
and standard 2 Carry out troubleshooting for [DGR4KB] and [DGR4KZ].
ture sensor
value in normal
state If causes 1 and 2 are not detected, retarder controller may be
defective.
If causes 1 – 3 are not detected, machine monitor may be defec-
4 Defective machine monitor
tive.
HD785-7 43
Failure code [B@C7NS] Brake cooling oil: Overheating (Rear) 1

Action code Failure code Brake cooling oil: Overheating (Rear)
Trouble
E02 B@C7NS (Machine monitor system)
Contents of • While engine was running, oil overheat was detected by signal from rear brake (retarder) oil temper-
trouble ature sensor.
Action of
• Turn on brake oil temperature caution lamp.
machine monitor
Problem that
• Brake (Retarder) (Rear) comes not to work.
appears on
machine • If machine is used as it is, brake (retarder) (rear) may be damaged.
• Input signal from oil temperature sensor can be checked with monitoring function (Code: 30211
Related (°C), 30212 (V)).
information • For troubleshooting for brake (retarder) (rear) oil temperature sensor, see failure code [DGR2KZ].
• If R14 (BCV relay) primary side has trouble, error code [DW78KZ] is displayed.

1) Remove relay cover.
2) Turn starting switch ON (Do not start engine).
1 Defective R14 (BCV relay) 3) Turn retarder brake ON and OFF and carry out troubleshooting.
R14 (BCV relay) Operating sound of relay is heard.
a Turn starting switch OFF and disconnect D12, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
2 Defective diode Forward direction:
Between D12 (male) There is continuity
Continuity
(1) and (2) Backward direction:
There is not continuity
1) Open operator's cab door.
2) Turn starting switch ON (Do not start engine).
3 Defective BCV solenoid 3) Turn retarder brake ON and OFF and carry out troubleshooting.
Operating sound of BCV sole-
BCV solenoid
Possible causes noid is heard.
and standard a Turn starting switch OFF and disconnect R14 (BCV relay) and
value in normal BCVR, then carry out troubleshooting without turning starting
state switch ON.
Disconnection in wiring Between R14 (female) (3) and BCVR Resis-
harness (Disconnection in Max. 1 z
4 (female) (1) tance
wiring or defective contact in
Between T05 (ground) and BCVR (female) Resis-
connector) Max. 1 z
(2) tance
Resis-
Between R14 (female) (5) and BT3 (12) Max. 1 z
tance
a Turn starting switch OFF and disconnect BCVR, then carry out
Grounding fault in wiring troubleshooting without turning starting switch ON.
5 harness (Contact with
ground circuit) Resis-
Between R14 (female) (1) and ground Min. 1 Mz
tance
Trouble in hydraulic system
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
normal)
If causes 1 - 6 are not detected, retarder controller may be defec-
7 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
44 HD785-7
HD785-7 45
Failure code [B@CENS] Overheating of torque converter oil 1

Action code Failure code Overheating of torque converter oil
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• Torque converter oil is overheating.
trouble
Action of
• Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If machine is used as it is, torque converter may be broken.
machine
• Signal of torque converter oil temperature sensor is input to transmission controller and then its
Related information is transmitted to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.
(Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100 (°C) / 30101(V))

Overheating of torque con-
Possible causes Torque converter oil may be overheating. Check for cause and
1 verter oil (When system is
and standard repair.
normal)
value in normal
state Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KX].
46 HD785-7
Failure code [B@GAZK] Battery electrolyte level: Lowering of level 1

Action code Failure code Battery electrolyte level: Lowering of level
Trouble
E01 B@GAZK (Retarder controller system)
Contents of • While engine speed is below 100 rpm, input circuit become "OPEN" (disconnected from ground cir-
trouble cuit).
Action of
controller
Problem that
appears on • If machine is used as it is, battery is deteriorated.
machine
Related
• This code is applied to machine equipped with battery electrolyte level switch (If equipped).
information

Check battery electrolyte level. If it is low, add new electrolyte.
1 Low battery electrolyte level
(If this trouble occurs frequently, check for overcharging.)
2) Connect T-adapter to connector BTL (male).
Defective battery electrolyte Battery electrolyte Resis-
2 BTL (male)
level switch level tance
Possible causes When normal Max. 1 z
Between (1) and ground
and standard When low Min. 1 Mz
value in normal
state Disconnection in wiring 2) Connect T-adapter to connectors BTC2 (female) (38) and BTL
harness (female).
3
(Disconnection in wiring or
defective contact in connector) Wiring harness between BRC2 (female) Resis-
Max. 1 z
(38) and BTL (female) (1) tance
2) Connect T-adapter to connector BRC2 (female).
4 Defective retarder controller 3) Turn starting switch ON.
Between BRC2 (female) (38) and ground Voltage Max. 1 V
HD785-7 47
Failure code [B@JANS] Steering oil temperature: Overheat 1

Action code Failure code Steering oil temperature: Overheat
Trouble
E02 B@JANS (Transmission controller system)
Contents of • Voltage of steering temperature sensor circuit has become below 1.61 V (oil temperature is above
trouble 120°C).
Action of
• Turn on steering oil temperature caution lamp.
controller
• Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If machine is operated in such a condition, it may cause an oil leakage.
machine
Related
• Steering oil temperature can be checked with monitoring function (code: 32701 (°C) and 32702 (V)).
information

Steering oil temperature is
Possible causes overheated. Since the overheat of the steering oil can be suspected, if there is
1
and standard (When the system is operat- an overheat, repair the cause of the failure.
value in normal ing normally)
state If cause 1 is not detected, steering oil temperature sensor system
Defective steering oil
2 may be defective. Carry out troubleshooting for failure code
temperature sensor
[DGR6KX].
48 HD785-7
HD785-7 49
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
50 HD785-7
SEN01940-02
HD785-7

HD785-7 7001 and up
Failure code [CA111] Engine controller (Left bank): Internal abnormality ....................................................... 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality..................................................... 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (Left bank):
Abnormal speed sensor signal ................................................................................................................ 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (Right bank):
Abnormal speed sensor signal ................................................................................................................ 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ......................................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected .......................................................................................................... 12
Failure code [CA131] Throttle sensor high error (At left bank only) .............................................................. 14
Failure code [CA132] Throttle sensor low error (At left bank only) ............................................................... 17
HD785-7 1
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 22
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Low voltage detection ............................................................................................................................ 30
Failure code [CA212] Engine oil temperature sensor abnormally high level (At left bank only):
High voltage detection ........................................................................................................................... 32
Failure code [CA213] Engine oil temperature sensor abnormally low level (At left bank only):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ................................. 44
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ............................................................... 55
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ............................................................. 56
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ........................................................ 57
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection...................................................... 58
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................................... 59
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ............................................................. 60
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ........................................................ 61
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection...................................................... 62
2 HD785-7
HD785-7 3
Failure code [CA111] Engine controller (Left bank): Internal abnormality1

Action code Failure code Engine controller (Left bank): Internal abnormality
Trouble
E03 CA111 (Engine controller system)
Contents of
• Controller has abnormality in it.
trouble
Action of
• Blinks warning lamp and sounds alarm buzzer.
controller
Problem that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appears on
stops.
machine
Related
information

Circuit breaker may be defective. Check it directly. (If fuse is broken
1 Defective circuit breaker
or circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness (Disconnection Wiring harness between J3P (female) (3), (4) Resis-
2 Max. 1 z
in wiring or defective – battery (+) tance
Possible causes contact in connector) Wiring harness between J3P (female) (1), (2) Resis-
and standard Max. 1 z
– ground tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
GND circuit) Wiring harness between J3P (female) (3), (4) Resis-
Min. 1 Mz
– battery (+) tance
a Prepare with starting switch OFF, then turn starting switch ON and
Defective engine carry out troubleshooting.
4
controller J3P Voltage
Between (3), (4) – (1), (2) 20 – 30 V
4 HD785-7
HD785-7 5
Failure code [CB111] Engine controller (Right bank): Internal

abnormality 1
Action code Failure code Engine controller (Right bank): Internal abnormality
Trouble
E03 CB111 (Engine controller system)
Contents of
• Controller has abnormality in it.
trouble
Action of
controller
Problem that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appears on
stops.
machine
Related
information

Circuit breaker may be defective. Check it directly. (If fuse is broken
1 Defective circuit breaker
or circuit breaker is turned OFF, circuit probably has ground fault.)
harness (Disconnection Wiring harness between J3C (female) (3), (4) Resis-
2 Max. 1 z
in wiring or defective – battery (+) tance
Possible causes contact in connector) Wiring harness between J3C (female) (1), (2) Resis-
– ground tance
value in normal
state Ground fault in wiring
without turning starting switch ON.
Wiring harness between J3C (female) (3), (4) Resis-
GND circuit) Min. 1 Mz
– battery (+) and ground tance
Defective engine carry out troubleshooting.
4
controller J3C Voltage
Between (3), (4) – (1), (2) 20 – 30 V
6 HD785-7
HD785-7 7
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors

(Left bank): Abnormal speed sensor signal 1
Action code Failure code Abnormal engine Ne and Bkup speed sensors (Left bank): Abnormal
Trouble
E03 CA115 speed sensor signal (Engine controller system)
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
trouble cuit.
Action of
• Flashes warning lamp and turns on alarm buzzer.
controller
Problem that
• Engine does not start (during engine stop).
appears on
• Engine stops (during engine running).
machine
Related
information

Defective Ne speed
1 Carry out troubleshooting of [CA689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CA778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to be
Defective Ne speed
3 defective, directly check the mounting section. (Defective installation
Possible causes sensor mounting section
of sensor itself, internal defect of flywheel, etc.)
and standard
value in normal Since a mounting section of Bkup speed sensor can be suspected to
Bkup speed sensor
state 4 be defective, directly check the mounting section. (Defective installa-
mounting section
tion of sensor itself, internal defect of supply pump, etc.)
Defective connection of
The defective (wrong) connections of Ne speed sensor and Bkup
5 sensor
speed sensor can be suspected. Directly check them.
(wrong connection)
Engine controller can be suspected to be defective if no problem is
Defective engine
6 found in causes 1 – 5 (since this is an internal defect, it cannot be
controller
diagnosed).
8 HD785-7
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors

(Right bank): Abnormal speed sensor signal 1
Action code Failure code Abnormal engine Ne and Bkup speed sensors (Right bank): Abnormal
Trouble
E03 CB115 speed sensor signal (Engine controller system)
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
trouble cuit.
Action of
controller
Problem that
• Engine does not start (during engine stop).
appears on
• Engine stops (during engine running).
machine
Related
information

Defective Ne speed
1 Carry out troubleshooting of [CB689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CB778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to be
Defective Ne speed
3 defective, directly check the mounting section. (Defective installation
Possible causes sensor mounting section
of sensor itself, internal defect of flywheel, etc.)
and standard
value in normal Since a mounting section of Bkup speed sensor can be suspected to
Bkup speed sensor
state 4 be defective, directly check the mounting section. (Defective installa-
mounting section
tion of sensor itself, internal defect of supply pump, etc.)
Defective connection of
The defective (wrong) connections of Ne speed sensor and Bkup
5 sensor
speed sensor can be suspected. Directly check them.
(wrong connection)
Defective engine
controller
diagnosed).
HD785-7 9
Failure code [CA122] Charge pressure sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Charge pressure sensor too high (At left bank only): Excessively high
Trouble
E03 CA122 voltage detected (Engine controller system)
Contents of
• Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
trouble
Action of • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
controller • Flashes warning lamp and turns on alarm buzzer.
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
• Input state from charge pressure (boost pressure) sensor can be checked with monitoring func-
Related
tion. (Code: 36500 Boost pressure, Code 36502: Boost pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.

Defective sensor power If failure code [CA227] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting switch
ON or with engine started.
PIM Voltage
Defective charge pres-
2 sure (boost pressure) Between (1) – (2) Power source 4.75 – 5.25 V
sensor (internal defect) Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the con-
troller to make it sure if there is no other cause of the trouble, and then
judge the sensor voltage.
a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Disconnection in wiring Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
harness (Disconnection (37) – PIM (female) (1) tance
3
in wiring or defective Wiring harness between PARENT J1 (female) Resis-
contact in connector) Max. 1 z
(44) – PIM (female) (3) tance
Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
(47) – PIM (female) (2) tance
still OFF.
Possible causes
and standard Defective harness Between ground and wiring harness between Resis-
Min. 1 Mz
value in normal grounding PARENT J1 (female) (37) – PIM (female) (1) tance
4
state (Contact with ground Between ground and wiring harness between Resis-
circuit) Min. 1 Mz
PARENT J1 (female) (44) – PIM (female) (3) tance
Between ground and wiring harness between Resis-
Min. 1 Mz
PARENT J1 (female) (47) – PIM (female) (2) tance
still OFF.
Between wiring harness from PARENT J1
(female) (37) to PIM (female) (1) and wiring Resis-
Min. 1 Mz
harness from PARENT J1 (female) (44) to tance
PIM (female) (3)
Harness short Between wiring harness from PARENT J1
5
(Harness internal short) (female) (37) to PIM (female) (1) and wiring Resis-
Min. 1 Mz
PIM (female) (2)
(female) (44) to PIM (female) (3) and wiring Resis-
Min. 1 Mz
PIM (female) (2)
Defective engine ON or with engine started.
6
controller PARENT J1 Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
10 HD785-7
HD785-7 11
Failure code [CA123] Charge pressure sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Charge pressure sensor too low (At left bank only): Excessively low
Trouble
Contents of
• Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
trouble
Action of • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
• Input state from charge pressure (boost pressure) sensor can be checked with monitoring func-
Related
tion. (Code: 36500 Boost pressure, Code 36502: Boost pressure sensor voltage)
information

and standard
value in normal 1
state
12 HD785-7
HD785-7 13
Failure code [CA131] Throttle sensor high error (At left bank only) 1
Action code Failure code Throttle sensor high error (At left bank only)
Trouble
Contents of
• Throttle sensor circuit is abnormally high (Min. 4.5 V)
trouble
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 38% when it is
Action of
ON.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the
monitoring function (Code: 31701 (%)).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function
information
(Code: 31707 (V)).
• Method of reproducing failure code: Turn the starting switch ON.

Defective throttle sensor If failure code [CA2185] or [CA2186] is also indicated, carry out trou-
1
power supply system bleshooting for it first.
carry out troubleshooting
AS1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25V
(Power supply)
Defective accelerator (17 ± 2% of power
2 When released
pedal (Internal defect) supply)*
Between (2) and (3)
(82 ± 2% of power
When pressed
supply)*
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller, too,
for another cause of trouble, and then judge.
Disconnection in wiring Wiring harness between J2P (female) (22) – Resis-
Max. 1 z
Possible causes harness (Disconnection AS1 (female) (1) tance
3
and standard in wiring or defective Wiring harness between J2P (female) (9) – Resis-
value in normal AS1 (female) (2) tance
state Wiring harness between J2P (female) (23) – Resis-
Max. 1 z
AS1 (female) (3) tance
Grounding fault in wiring Wiring harness between J2P (female) (22) – Resis-
Min. 1 Mz
harness AS1 (female) (1) tance
4
(Contact with ground cir- Wiring harness between J2P (female) (9) – Resis-
cuit) Min. 1 Mz
Wiring harness between J2P (female) (23) – Resis-
Min. 1 Mz
J2P Accelerator pedal Voltage
Between All range
Defective engine control- 4.75 – 5.25V
5 (22) and (23) (Power supply)
ler
(17 ± 2% of power
When released
supply)*
Between (9) and (23)
(82 ± 2% of power
When pressed
supply)*
* Refer to Fig. 1
14 HD785-7

Serial No.: 7001 – 7078
HD785-7 15
Fig. 1
Pedal: Stroke of accelerator pedal
Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1
and switch 2
16 HD785-7
Failure code [CA132] Throttle sensor low error (At left bank only) 1
Action code Failure code Throttle sensor low error (At left bank only)
Trouble
Contents of
• Throttle sensor circuit is abnormally low.
trouble
Action of
ON.
controller
Problem that
• Even if the accelerator pedal is depressed, the engine speed does not increase above medium
appears on
speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the
Related
monitoring function (Code: 31701 (%), 31707 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [CA131].
state
HD785-7 17
Excessively high voltage detected 1
Action code Failure code Oil pressure sensor too high (At left bank only): Excessively high volt-
Trouble
E01 CA135 age detected (Engine controller system)
Contents of
• Excessively high voltage is detected at oil pressure sensor circuit.
trouble
Action of • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Problem that
appears on
machine
• Input state from engine oil pressure sensor can be checked with monitoring function.
Related
(Code: 37200 Engine oil pressure, Code 37201: Engine oil pressure sensor voltage)
information

Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
ON or with engine started.
POIL Voltage
Defective oil pressure
2 sensor Between (1) – (2) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being con-
still OFF.
Max. 1 z
harness (Disconnection (37) – POIL (female) (1) tance
3
(47) – POIL (female) (2) tance
Max. 1 z
(13) – POIL (female) (3) tance
still OFF.
Possible causes
and standard Defective harness Between ground and wiring harness between Resis-
Min. 1 Mz
value in normal grounding PARENT J1 (female) (37) – POIL (female) (1) tance
4
state (Contact with ground cir- Between ground and wiring harness between Resis-
cuit) Min. 1 Mz
PARENT J1 (female) (47) – POIL (female) (2) tance
Min. 1 Mz
PARENT J1 (female) (13) – POIL (female) (3) tance
still OFF.
(female) (37) to POIL (female) (1) and wiring Resis-
Min. 1 Mz
POIL (female) (2)
5
(Harness internal short) (female) (37) to POIL (female) (1) and wiring Resis-
Min. 1 Mz
POIL (female) (3)
(female) (47) to POIL (female) (2) and wiring Resis-
Min. 1 Mz
POIL (female) (3)
Defective engine control- ON or with engine started.
6
ler PARENT J1 Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
18 HD785-7
HD785-7 19
Excessively low voltage detected 1
Action code Failure code Oil pressure sensor too low (At left bank only): Excessively low volt-
Trouble
E01 CA141 age detected (At left bank only) (Engine controller system)
Contents of
• Excessively low voltage is detected at oil pressure sensor circuit.
trouble
Action of • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Problem that
appears on • Engine does not start easily at low temperature.
machine
• Input state from engine oil pressure sensor can be checked with monitoring function.
Related
(Code: 37200 Engine oil pressure, Code 37201: Engine oil pressure sensor voltage)
information

and standard
value in normal 1
state
20 HD785-7
HD785-7 21
Failure code [CA144] Coolant temperature sensor too high: Excessively

high voltage detected 1
Action code Failure code Coolant temperature sensor too high: Excessively high voltage
Trouble
E01 CA144 detected (Engine controller system)
Contents of
• Excessively high voltage is detected at signal circuit of coolant temperature sensor.
trouble
Action of • Operates with a fixed coolant temperature (90°C).
Problem that
appears on • Exhaust gas color becomes white.
machine
• Input state from engine coolant temperature sensor can be checked with monitoring function.
Related (Code: 04104 Engine coolant temperature, Code 04105 Engine coolant temperature sensor volt-
information age)

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring still OFF.
harness (Disconnection Wiring harness between PARENT J1 (female) Resis-
2 Max. 1 z
in wiring or defective (15) – TWTR (female) (A) tance
contact in connector) Wiring harness among PARENT J1 (female) Resis-
Max. 1 z
(38) – JB – TWTR (female) (B) tance
Possible causes still OFF.
Harness short
and standard 3 Between PARENT J1 (female) (15) – all pins
(Harness internal short) Resis-
value in normal of PARENT J1 (female) (with all connectors in Min. 1 Mz
tance
state the harness disconnected)
Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
Defective wiring harness
4 • Connector is loose, lock is broken, seal is broken
connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
Defect in other locations still OFF.
5
than engine controller PARENT J1 (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
Defective engine Engine controller is possibly defective if no problem is found in causes
6
controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
22 HD785-7
HD785-7 23
Failure code [CA145] Coolant temperature sensor too low (At left bank
Action code Failure code Coolant temperature sensor too low (At left bank only): Excessively
Trouble
E01 CA145 low voltage detected (Engine controller system)
Contents of
• Excessively low voltage is detected at signal circuit of coolant temperature sensor.
trouble
Action of • Operates with a fixed coolant temperature (90°C).
Problem that
machine
• Input state from engine coolant temperature sensor can be checked with monitoring function.
Related
(Code: 04104 Engine coolant temperature, Code 04105 Engine coolant temperature sensor volt-
information
age)

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Defective harness still OFF.
2 grounding (Contact with Between ground and wiring harness between
Resis-
ground circuit) PARENT J1 (female) (15) – TWTR (female) Min. 1 Mz
tance
(A)
still OFF.
Harness short
Possible causes 3 Between PARENT J1 (female) (15) – all pins
and standard (Harness internal short) Resis-
of PARENT J1 (female) (with all connectors in Min. 1 Mz
value in normal tance
the harness disconnected)
state Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
connector
insulation
5
than engine controller PARENT J1 (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
6
24 HD785-7
HD785-7 25
Failure code [CA153] Charge temperature sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Charge temperature sensor too high (At left bank only): Excessively
Trouble
E01 CA153 high voltage detected. (Engine controller system)
Contents of • Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
trouble sensor.
Action of
• Operates with a fixed charge temperature (boost temperature) (70°C).
controller
Problem that
machine
• Input state from charge temperature (boost temperature) sensor can be checked with monitoring
Related
function. (Code: 18500 Boost temperature, Code: 18501: Boost temperature sensor voltage)
information

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (Internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
2 Max. 1 z
in wiring or defective (23) – TIM (female) (A) tance
contact in connector) Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
(47) – JB – TIM (female) (B) tance
Possible causes still OFF.
and standard Harness short
3 Between PARENT J1 (female) (23) – all pins
value in normal (Harness internal short) Resis-
of PARENT J1 (female) (with all connectors in Min. 1 Mz
state tance
the harness disconnected)
Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
5
than engine controller PARENT J1 (female) Air boost temperature Resistance
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
6
26 HD785-7
HD785-7 27
Failure code [CA154] Charge temperature sensor too low (At left bank
Action code Failure code Charge temperature sensor too low (At left bank only): Excessively
Trouble
Contents of • Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
trouble sensor.
Action of
• Operates with a fixed charge temperature (boost temperature) (70°C).
controller
Problem that
machine
• Input state from charge temperature (boost temperature) sensor can be checked with monitoring
Related
function. (Code: 18500 Boost temperature, Code: 18501: Boost temperature sensor voltage)
information

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (Internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
Defective harness
still OFF.
2 grounding (Contact with
ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
PARENT J1 (female) (23) – TIM (female) (A) tance
still OFF.
Harness short
Possible causes 3 Between PARENT J1 (female) (23) – all pins
(Harness internal short) Resis-
and standard of PARENT J1 (female) (with all connectors in Min. 1 Mz
tance
value in normal the harness disconnected)
state Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
still OFF.
Defect in other locations
5 PARENT J1 (female) Air boost temperature Resistance
than engine controller
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
Between (23) – ground In all range Min. 1 Mz
6
28 HD785-7
HD785-7 29
Failure code [CA187] Sensor power supply (2) abnormally low level
(Left bank): Low voltage detection 1
Action code Failure code Sensor power supply (2) abnormally low level (Left bank): Low voltage
Trouble
E03 CA187 detection (Engine controller system)
Contents of
• Low voltage was detected in sensor power supply (2) (5 V) circuit.
trouble
• Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
continues operation.
• Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Action of
tion.
controller
• Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
• Bkup sensor operates with Ne speed sensor signal.
Problem that
appears on • Output lowers.
machine
Related
information

and standard
state
Failure code [CB187] Sensor power supply (2) abnormally low level
(Right bank): Low voltage detection 1
Action code Failure code Sensor power supply (2) abnormally low level (Right bank): Low volt-
Trouble
E03 CA187 age detection (Engine controller system)
Contents of
trouble
Action of • Bkup sensor operates with Ne speed sensor signal.
controller • Blinks warning lamp and sounds alarm buzzer.
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting for failure code [CB227].
state
30 HD785-7
HD785-7 31
Failure code [CA212] Engine oil temperature sensor abnormally high

level (At left bank only): High voltage detection 1
Action code Failure code Engine oil temperature sensor abnormally high level (At left bank
Trouble
E01 CA212 only): High voltage detection (Engine controller system)
Contents of
• High voltage was detected in engine oil temperature sensor circuit.
trouble
Action of
• Sets oil temperature to default value (100°C) and continues operation.
controller
Problem that
appears on
machine
Related • Input state from engine oil temperature sensor can be checked with monitoring function.
information (Code: 42700 Engine oil temperature, Code 42702: Engine oil temperature sensor voltage)

Defective oil temperature without turning starting switch ON.
1
sensor (Internal defect) TOIL (male) Oil temperature Resistance
Between (A) – (B) 0 – 100°C 0.5 – 36 kz
Possible causes 2 Max. 1 z
in wiring or defective con- (17) – TOIL (female) (A) tance
and standard tact in connector)
value in normal Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
state (47) – TOIL (female) (B) tance
Ground fault in wiring
GND circuit) Wiring harness between PARENT J1 (female) Resis-
Min. 1 Mz
(17) – TOIL (female) (A) tance
Defective engine control- without turning starting switch ON.
4
ler PARENT J1 Oil temperature Resistance
(17) – (47) 0 – 100°C 0.5 – 36 kz
32 HD785-7
HD785-7 33
Failure code [CA213] Engine oil temperature sensor abnormally low

level (At left bank only): Low voltage detection 1
Action code Failure code Engine oil temperature sensor abnormally low level (At left bank only):
Trouble
E01 CA213 Low voltage detection (Engine controller system)
Contents of
• Low voltage was detected in engine oil temperature sensor circuit.
trouble
Action of
• Sets oil temperature to default value (100°C) and continues operation.
controller
Problem that
appears on
machine
Related • Input state from engine oil temperature sensor can be checked with monitoring function.
information (Code: 42700 Engine oil temperature, Code 42702: Engine oil temperature sensor voltage)

and standard
state
34 HD785-7
HD785-7 35
Failure code [CA221] Atmospheric pressure sensor too high (At left
bank only): Excessively high voltage detected 1
Action code Failure code Atmospheric pressure sensor too high (At left bank only): Excessively
Trouble
E01 CA221 high voltage detected (Engine controller system)
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Problem that
appears on • Output decreases.
machine
• Input state from ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37400 Ambient pressure, Code 37402 Ambient pressure sensor voltage)
information

Defective sensor power If failure code [CA352] or [CA386] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
ON.
PAMB Voltage
Defective atmospheric Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.5 – 4.5 V
(Internal defect)
Since the sensor voltage is measured with the harness being con-
still OFF.
Max. 1 z
harness (Disconnection (37) – PAMB (female) (1) tance
3
(3) – PAMB (female) (2) tance
Max. 1 z
(38) – PAMB (female) (3) tance
Possible causes
and standard
still OFF.
value in normal
state Between ground and wiring harness between
Resis-
PARENT J1 (female) (37) – PAMB (female) Min. 1 Mz
Defective harness tance
(1)
ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
PARENT J1 (female) (3) – PAMB (female) (2) tance
Between ground and wiring harness between
Resis-
PARENT J1 (female) (38) – PAMB (female) Min. 1 Mz
tance
(3)
still OFF.
(female) (37) to PAMB (female) (1) and wiring Resis-
Min. 1 Mz
PAMB (female) (2)
5
(Harness internal short) (female) (37) to PAMB (female) (1) and wiring Resis-
Min. 1 Mz
PAMB (female) (3)
(female) (3) to PAMB (female) (2) and wiring Resis-
Min. 1 Mz
PAMB (female) (3)
36 HD785-7

Possible causes a Prepare with starting switch OFF, and diagnose with starting switch
and standard ON or with engine started.
value in normal Defective engine PARENT J1 Voltage
6
state controller
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
HD785-7 37
Failure code [CA222] Atmospheric pressure sensor too low (At left bank
Action code Failure code Atmospheric pressure sensor too low (At left bank only): Excessively
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Problem that
machine
• Input state from ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37400 Ambient pressure, Code 37402 Ambient pressure sensor voltage)
information

and standard
value in normal Carry out troubleshooting of failure code [CA221].
state
38 HD785-7
HD785-7 39
Action code Failure code Sensor power source (2) too high (Left bank): Excessively high volt-
Trouble
Contents of
• Excessively high voltage is detected in sensor power source (2) (5V) circuit.
trouble
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Action of
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
controller
• Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
Problem that
machine
Related
information

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
ON.
Bkup speed sensor G connector
Disconnect the
Engine oil pressure
Defective sensor devices on the right POIL connector
2 sensor
(Internal defect) one at a time.
If the code disap- Atmospheric pressure
PAMB connector
sensor
pears, that device is
internally defective. Charge pressure sen-
PIM connector
sor
3 Max. 1 z
in wiring or defective (37) – each sensor (female) tance
Possible causes contact in connector) Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
and standard (47) – each sensor (female) tance
value in normal a Prepare with starting switch OFF and diagnose with starting switch
state still OFF.
Defective harness Between ground and wiring harness between
Resis-
grounding PARENT J1 (female) (37) – each sensor Min. 1 Mz
4 tance
(Contact with ground cir- (female)
cuit) Between ground and wiring harness between
Resis-
PARENT J1 (female) (47) – each sensor Min. 1 Mz
tance
(female)
still OFF.
5
(Harness internal short) (female) (37) to each sensor (female) and wir- Resis-
Min. 1 Mz
ing harness from PARENT J1 (female) (47) to tance
each sensor (female)
Defective engine control- ON.
6
Between (37) – (47) 4.75 – 5.25 V
40 HD785-7
HD785-7 41
Failure code [CB227] Sensor power supply (2) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Sensor power supply (2) abnormally high level (Right bank): High volt-
Trouble
E03 CB227 age detection (Engine controller system)
Contents of
• High voltage was detected in sensor power supply (2) (5 V) circuit.
trouble
Action of
• Bkup speed sensor operates with Ne speed sensor signal.
controller
Problem that
machine
Related
information

1 Related defective system If another code is also displayed, carry out troubleshooting for it.
Defective sensor (Inter- When device at right
2 is disconnected, if
nal defect) Bkup speed
error code disappears, G connector
sensor
that device has defect
in it.
harness (Disconnection Wiring harness between CHILD J1 (female) Resis-
3 Max. 1 z
in wiring or defective con- (37) – each sensor (female) tance
tact in connector) Wiring harness between CHILD J1 (female) Resis-
Possible causes Max. 1 z
(47) – each sensor (female) tance
and standard
value in normal
state Ground fault in wiring
Wiring harness between CHILD J1 (female) Resis-
4 harness (Contact with Min. 1 Mz
GND circuit)
Min. 1 Mz
Short circuit in wiring har-
5 ness (With another wiring Between wiring harness from CHILD J1
(female) (37) to each sensor (female) and wir- Resis-
harness) Min. 1 Mz
ing harness from CHILD J1 (female) (47) to tance
each sensor (female)
Defective engine control- carry out troubleshooting.
6
ler CHILD J1 Voltage
Between (37) – (47) 4.75 – 5.25 V
42 HD785-7
HD785-7 43
Failure code [CA234] Engine over speed (At left bank only): Excessively
high speed 1
Action code Failure code Engine over speed (At left bank only): Excessively high speed
Trouble
Contents of
• The engine speed exceeds upper control limit speed.
trouble
Action of • Stops operation of injector until the engine speed drops to the normal speed.
Problem that
appears on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
Related
(Code: 01002 Engine speed)
information
• Duplication of failure code: Start engine and operate at high idle.

Possible causes 1 Defective related circuits
and standard
value in normal 2 Improper usage Operation may be improper. Teach proper operation.
state Engine controller can be suspected to be defective if no problem is
Defective engine
controller
diagnosed).
44 HD785-7
HD785-7 45
Failure code [CA238] Abnormal power source for Ne speed sensor (At
left bank only): Excessively low voltage detected 1
Action code Failure code Abnormal power source for Ne speed sensor (At left bank only):
Trouble
E03 CA238 Excessively low voltage detected (Engine controller system)
Contents of
• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
trouble
Action of • Controls using Bkup speed sensor signal.
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
Related
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(Internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
2 Max. 1 z
in wiring or defective (16) – Ne (female) (1) tance
contact in connector) Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
Possible causes (48) – Ne (female) (2) tance
and standard a Prepare with starting switch OFF and diagnose with starting switch
value in normal Defective harness still OFF.
state grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground cir- PARENT J1 (female) (16) – Ne (female) (1) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
PARENT J1 (female) (48) – Ne (female) (2) tance
still OFF.
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from PARENT J1 (female) (48) to Ne tance
(female) (2)
5
Between (16) – (48) 4.75 – 5.25 V
46 HD785-7
HD785-7 47
Failure code [CB238] Abnormal power source for Ne speed sensor (At
right bank only): Excessively low voltage detected 1
Action code Failure code Abnormal power source for Ne speed sensor (At right bank only):
Trouble
E03 CB238 Excessively low voltage detected (Engine controller system)
Contents of
• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
trouble
Action of • Controls using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(Internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
2 Max. 1 z
in wiring or defective (16) – Ne (female) (1) tance
contact in connector) Wiring harness between CHILD J1 (female) Resis-
Max. 1 z
Possible causes (48) – Ne (female) (2) tance
and standard a Prepare with starting switch OFF and diagnose with starting switch
value in normal Defective harness still OFF.
state grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground cir- PARENT J1 (female) (16) – Ne (female) (1) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
CHILD J1 (female) (48) – Ne (female) (2) tance
still OFF.
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from CHILD J1 (female) (48) to Ne tance
(female) (2)
5
ler Between PARENT J1 (16) – Voltage
CHILD J1 (48) 4.75 – 5.25 V
48 HD785-7
HD785-7 49
Action code Failure code Fuel temperature sensor too high (Left bank): Excessively high volt-
Trouble
Contents of
• Excessively high voltage is detected at fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95°C).
controller
Problem that
appears on
machine
• Input state from engine fuel temperature sensor can be checked with monitoring function.
Related
(Code: 04204 Fuel temperature (Left bank), Code 14201 Fuel temperature sensor voltage (Left
information
bank))

Defective fuel tempera- still OFF.
1 ture sensor (Internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
2 Max. 1 z
Possible causes in wiring or defective (30) – TFUEL (female) (A) tance
and standard contact in connector) Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
value in normal (47) – TFUEL (female) (B) tance
state a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective harness
grounding Resis-
3 PARENT J1 (female) (30) – TFUEL (female) Min. 1 Mz
(Contact with ground cir- tance
(A)
cuit)
still OFF.
Defective engine control- PARENT J1 (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
50 HD785-7
HD785-7 51
Action code Failure code Fuel temperature sensor too high (Right bank): Excessively high volt-
Trouble
E01 CB263 age detected (Engine controller system)
Contents of
• Excessively high voltage is detected at fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95°C).
controller
Problem that
appears on
machine
Related
(Code: 04205 Fuel temperature (Right bank), Code 14202 Fuel temperature sensor voltage (Right
information
bank))

Defective fuel tempera- still OFF.
1 ture sensor (Internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Possible causes 2 Max. 1 z
in wiring or defective (30) – TFUEL (female) (A) tance
and standard
contact in connector) Wiring harness between CHILD J1 (female) Resis-
(47) – TFUEL (female) (B) tance
state
Defective harness still OFF.
grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground cir- CHILD J1 (female) (30) – TFUEL (female) (A) tance
cuit) a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective engine control- CHILD J1 (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
52 HD785-7
HD785-7 53
Failure code [CA265] Fuel temperature sensor abnormally low level

Action code Failure code Fuel temperature sensor abnormally low level (Left bank): Low volt-
Trouble
Contents of
• Low voltage was detected in fuel temperature sensor circuit.
trouble
• Substitutes coolant temperature sensor.
Action of
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
controller
Problem that
appears on
machine
Related
(Code: 04204 Fuel temperature (Left bank), Code 14201 Fuel temperature sensor voltage (Left
information
bank))

and standard
state
Failure code [CB265] Fuel temperature sensor abnormally low level

Action code Failure code Fuel temperature sensor abnormally low level (Right bank): Low volt-
Trouble
Contents of
• Low voltage was detected in fuel temperature sensor circuit.
trouble
• Substitutes coolant temperature sensor.
Action of
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
controller
Problem that
appears on
machine
Related
information

and standard
state
54 HD785-7
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 1
Action code Failure code PCV1 short circuit (Left bank): Short circuit
Trouble
Contents of
• Short circuit occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related • While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1) but it cannot
information be measured with circuit tester since it is a pulse voltage.

Defective supply pump
1 PCV1 PCV1 (male) Resistance
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
(4) – PCV1 (female) (1) tance
Possible causes GND circuit)
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Contact with
Wiring harness between PARENT J1 (female)
3 24V circuit) in wiring Voltage Max. 1 V
(4) – PCV1 (female) (1)
harness
Voltage Max. 1 V
(5) – PCV1 (female) (2)
Defective engine PARENT J1 (female) Resistance
4
controller
Between (4) – (5) 2.3 – 5.3 z
HD785-7 55
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 1
Action code Failure code PCV1 short circuit (Right bank): Short circuit
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

value in normal
Wiring harness between CHILD J1 (female)
(4) – PCV1 (female) (1)
harness
Voltage Max. 1 V
(5) – PCV1 (female) (2)
Defective engine CHILD J1 (female) Resistance
4
controller
Between (4) – (5) 2.3 – 5.3 z
56 HD785-7
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 1

Action code Failure code PCV1 disconnection (Left bank): Disconnection
Trouble
Contents of
• Disconnection occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective (4) – PCV1 (female) (1) tance
Possible causes contact in connector) Wiring harness between PARENT J1 (female) Resis-
value in normal
GND circuit)
Min. 1 Mz
4
controller
Between (4) – (5) 2.3 – 5.3 z
HD785-7 57
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1

Action code Failure code PCV1 disconnection (Right bank): Disconnection
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective (4) – PCV1 (female) (1) tance
Possible causes contact in connector) Wiring harness between CHILD J1 (female) Resis-
value in normal
GND circuit)
Min. 1 Mz
4
controller
Between (4) – (5) 2.3 – 5.3 z
58 HD785-7
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 1
Action code Failure code PCV2 short circuit (Left bank): Short circuit
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

value in normal
(9) – PCV2 (female) (1)
harness
Voltage Max. 1 V
(10) – PCV2 (female) (2)
4
controller
Between (9) – (10) 2.3 – 5.3 z
HD785-7 59
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 1
Action code Failure code PCV2 short circuit (Right bank): Short circuit
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

value in normal
(9) – PCV2 (female) (1)
harness
Voltage Max. 1 V
(10) – PCV2 (female) (2)
4
controller
Between (9) – (10) 2.3 – 5.3 z
60 HD785-7
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 1

Action code Failure code PCV2 disconnection (Left bank): Disconnection
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

Defective supply pump without turning starting switch ON.
1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- (9) – PCV2 (female) (1) tance
Possible causes tact in connector) Wiring harness between PARENT J1 (female) Resis-
Max. 1 z
and standard (10) – PCV2 (female) (2) tance
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
GND circuit)
Min. 1 Mz
Defective engine control- PARENT J1 (female) Resistance
4
ler
Between (9) – (10) 2.3 – 5.3 z
HD785-7 61
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1

Action code Failure code PCV2 disconnection (Right bank): Disconnection
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

Defective supply pump without turning starting switch ON.
1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- (9) – PCV2 (female) (1) tance
Possible causes tact in connector) Wiring harness between CHILD J1 (female) Resis-
Max. 1 z
and standard (10) – PCV2 (female) (2) tance
state without turning starting switch ON.
GND circuit)
Min. 1 Mz
Defective engine control- CHILD J1 (female) Resistance
4
ler
Between (9) – (10) 2.3 – 5.3 z
62 HD785-7
HD785-7 63
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
64 HD785-7
SEN01941-02
HD785-7

HD785-7 7001 and up
Disconnection, short circuit...................................................................................................................... 4
Disconnection, short circuit.................................................................................................................... 10
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ............................................ 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch .......................................... 16
Failure code [CA351] Abnormal injector drive circuit (Left bank): Abnormal circuit ...................................... 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ............................ 20
HD785-7 1
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
Failure code [CA431] Trouble in idle validation switch.................................................................................. 28
Failure code [CA432] Idle validation action error .......................................................................................... 32
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence .................................................................................................. 35
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence ................................................................................................... 35
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection .......................................................................................................... 40
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection .......................................................................................................... 40
Excessively high pressure detected....................................................................................................... 41
Excessively high pressure detected....................................................................................................... 42
Failure code [CA554] In-range error in common rail pressure sensor (Left bank): In-range error ................ 43
Failure code [CB554] In-range error in common rail pressure sensor (Right bank): In-range error.............. 43
Loss of pressure feed detected.............................................................................................................. 44
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank): Abnormal signal .............................. 52
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank): Abnormal signal............................ 54
Failure code [CA691] Intake air temperature sensor abnormally high level (At left bank only):
Failure code [CA692] Intake air temperature sensor abnormally low level (At left bank only):
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left bank): Abnormal phase ............... 59
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right bank): Abnormal phase............. 59
2 HD785-7
HD785-7 3
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or

short circuit (Left bank): Disconnection, short circuit 1
Action code Failure code Injector No. 1 (L/B No.1) system disconnection or short circuit (Left
Trouble
E03 CA322 bank): Disconnection, short circuit (Engine controller system)
Contents of
• A disconnection or short circuit has occurred in injector No. 1 circuit.
trouble
Action of
controller
Problem that
• Output decreases.
appears on
• Speed is not stable.
machine
Related • While engine is running normally, pulse voltage of about 70 V is applied to injector (+) side but it
information cannot be measured with circuit tester since it is a pulse voltage.

a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Defective injector No. 1 CN1 (male) Resistance
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) and ground Min. 1 Mz
Disconnection in wiring switch still OFF.
harness (Disconnection in Wiring harness between PARENT J1 Resis-
2 Max. 1 z
wiring or defective contact (female) (45) – CN1 (female) (1) tance
in connector) Wiring harness between PARENT J1 Resis-
(female) (53) – CN1 (female) (2) tance
and standard
value in normal
state switch still OFF.
Defective harness
3 grounding (Contact with Min. 1 Mz
PARENT J1 (female) (45) – CN1 (female) (1) tance
ground circuit)
Min. 1 Mz
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
switch still OFF.
5 Defective engine controller PARENT J1 (female) Resistance
Between (45) – (53) 0.4 – 1.1 z
4 HD785-7
HD785-7 5

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

switch still OFF.
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
and standard
value in normal
Defective harness
3 grounding (Contact with Min. 1 Mz
ground circuit)
Min. 1 Mz
4
switch still OFF.
Between (46) – (60) 0.4 – 1.1 z
6 HD785-7
HD785-7 7

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

switch still OFF.
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
and standard
value in normal
Defective harness ground-
3 ing (Contact with ground Min. 1 Mz
circuit)
Min. 1 Mz
4
switch still OFF.
Between (55) – (52) 0.4 – 1.1 z
8 HD785-7
HD785-7 9

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

switch still OFF.
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
and standard
value in normal
circuit)
Min. 1 Mz
4
switch still OFF.
Between (57) – (59) 0.4 – 1.1 z
10 HD785-7
HD785-7 11

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

switch still OFF.
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
and standard
value in normal
circuit)
Min. 1 Mz
4
switch still OFF.
Between (54) – (51) 0.4 – 1.1 z
12 HD785-7
HD785-7 13

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

switch still OFF.
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
and standard
value in normal
circuit)
Min. 1 Mz
4
switch still OFF.
Between (56) – (58) 0.4 – 1.1 z
14 HD785-7
HD785-7 15
Failure code [CA342] Engine controller data mismatch (Left bank):

Mismatch 1
Action code Failure code Engine controller data mismatch (Left bank): Mismatch
Trouble
Contents of
• Data mismatch occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine cannot be started or operated.
machine
Related
information

and standard
state
Failure code [CB342] Engine controller data mismatch (Right bank):

Mismatch 1
Action code Failure code Engine controller data mismatch (Right bank): Mismatch
Trouble
Contents of
• Data mismatch occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine cannot be started or operated.
machine
Related
information

and standard
state
16 HD785-7
HD785-7 17
Failure code [CA351] Abnormal injector drive circuit (Left bank):

Abnormal circuit 1
Action code Failure code Abnormal injector drive circuit (Left bank): Abnormal circuit
Trouble
Contents of
• Abnormality has occurred in injector drive circuit.
trouble
Action of • Operates with limited output. (Limits common rail pressure.)
Problem that
machine
Related
information

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a fuse or breaker of equipped machine side can be suspected
to be defective, directly check them.
2 Defective breaker
(If fuse is blown, or breaker is shut off, it is highly possible that a
defective grounding, etc. has occurred in the circuit.)
Possible causes Disconnection in wiring switch still OFF.
and standard harness (Disconnection in Wiring harness between J3P (female) (3) (4) Resis-
3 Max. 1 z
value in normal wiring or defective contact – battery (+) tance
state in connector) Wiring harness between J3P (female) (1) (2) Resis-
Max. 1 z
and ground tance
Defective harness
switch still OFF.
ground circuit) Min. 1 Mz
J3P (female) (3) (4) – battery (+)Resistance tance
switch ON.
5 Defective engine controller
J3P Voltage
Between (3), (4) – (1), (2) 20 – 30 V
18 HD785-7
HD785-7 19
Failure code [CB351] Injector drive circuit abnormality (Right bank):

Circuit abnormality 1
Action code Failure code Injector drive circuit abnormality (Right bank): Circuit abnormality
Trouble
Contents of
• Abnormality occurred in injector drive circuit.
trouble
Action of • Limits output and continues operation (Limits common rail pressure).
Problem that
machine
Related
information

If another code (code of injector system abnormality) is also dis-
1 Related defective system
played, carry out troubleshooting for it.
Fuse or circuit breaker on applicable machine side may be defective.
2 Defective circuit breaker Check them directly. (If fuse is broken or circuit breaker is turned
OFF, circuit probably has ground fault.)
Possible causes harness (Disconnection in Wiring harness between J3C (female) (3), (4) Resis-
3 Max. 1 z
and standard wiring or defective contact – battery (+) tance
value in normal in connector) Wiring harness between J3C (female) (1), (2) Resis-
Max. 1 z
state – ground tance
GND circuit) Wiring harness between J3C (female) (3), (4) Resis-
Min. 1 Mz
J3C Voltage
Between (3), (4) – (1), (2) 20 – 30 V
20 HD785-7
HD785-7 21
Failure code [CA352] Sensor power supply (1) abnormally low level
Action code Failure code Sensor power supply (1) abnormally low level (Left bank): Low volt-
Trouble
Contents of
trouble
Action of • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
Problem that
machine
Related
information

and standard
state
Failure code [CB352] Sensor power supply (1) abnormally low level
Action code Failure code Sensor power supply (1) abnormally low level (Right bank): Low volt-
Trouble age detection
Contents of
trouble
Problem that
machine
Related
information

and standard
state
22 HD785-7
HD785-7 23
Failure code [CA386] Sensor power supply (1) abnormally high level
(Left bank): High voltage detection 1
Action code Failure code Sensor power supply (1) abnormally high level (Left bank): High volt-
Trouble
Contents of
trouble
Problem that
machine
Related
information

Defective sensor When device at right
(Internal defect) Left common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Disconnection in wiring Wiring harness between PARENT J1 Resis-
Max. 1 z
harness (Disconnection in (female) (33) – PFUEL (female) (1) tance
3
wiring or defective contact Wiring harness between PARENT J1 Resis-
Max. 1 z
in connector) (female) (25) – PFUEL (female) (2) tance
Wiring harness between PARENT J1 Resis-
Max. 1 z
(female) (47) – PFUEL (female) (3) tance
Possible causes Ground fault in wiring Min. 1 Mz
and standard 4 harness (Contact with
value in normal GND circuit) Wiring harness between PARENT J1 Resis-
Min. 1 Mz
state (female) (25) – PFUEL (female) (2) tance
Min. 1 Mz
Between wiring harness between PARENT
J1 (female) (33) – PFUEL (female) (1) and Resis-
Min. 1 Mz
wiring harness between PARENT J1 (female) tance
(25) – PFUEL (female) (2)
Short circuit in wiring
5 harness (with another Between wiring harness between PARENT
wiring harness) J1 (female) (33) – PFUEL (female) (1) and Resis-
Min. 1 Mz
Between wiring harness between PARENT
J1 (female) (25) – PFUEL (female) (2) and Resis-
Min. 1 Mz
PARENT J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
24 HD785-7
HD785-7 25
Failure code [CB386] Sensor power supply (1) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Sensor power supply (1) abnormally high level (Right bank): High
Trouble voltage detection
E03 CB386
(Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

Defective sensor When device at right
(Internal defect) Right common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Disconnection in wiring Wiring harness between CHILD J1 (female) Resis-
Max. 1 z
harness (Disconnection in (33) – PFUEL (female) (1) tance
3
wiring or defective contact Wiring harness between CHILD J1 (female) Resis-
in connector) Max. 1 z
(25) – PFUEL (female) (2) tance
Max. 1 z
Possible causes Ground fault in wiring har- Min. 1 Mz
and standard 4 ness (Contact with GND
value in normal circuit) Wiring harness between CHILD J1 (female) Resis-
Min. 1 Mz
state (25) – PFUEL (female) (2) tance
Min. 1 Mz
Between wiring harness between CHILD J1
(female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
ing harness between CHILD J1 (female) (25) tance
– PFUEL (female) (2)
5 ness (with another wiring Between wiring harness between CHILD J1
harness) (female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
Min. 1 Mz
CHILD J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
26 HD785-7
HD785-7 27
Failure code [CA431] Trouble in idle validation switch 1

Action code Failure code Trouble in idle validation switch
Trouble
Contents of
• Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit.
trouble
Action of
• Operates normally according to throttle sensor (E01 Testing and maintenance)
controller
Problem that
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring
function (Code: 18300).
Related
information
Serial No.: 7001 – 7078
AS1 Signal name Voltage
Defective accelerator Between (5) – (4) Signal 1
1 See Fig. 1
pedal (Internal defect) Between (6) – (4) Signal 2
Max. 1 z
harness (Disconnection AS1 (female) (4) tance
2
in wiring or defective con- Wiring harness between J2P (female) (11) – Resis-
tact in connector) Max. 1 z
Max. 1 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between J2P (female) (32) – Resis-
state Grounding fault in wiring Min. 1 Mz
AS1 (female) (4) and chassis ground tance
3 harness (Short circuit
with ground circuit) Wiring harness between J2P (female) (11) – Resis-
Min. 1 Mz
Min. 1 Mz
Wiring harness between J2P (female) (32) –
Hot short (Short circuit Voltage Max. 1 V
AS1 (female) (4) and chassis ground
4 with 24V circuit) in wiring
harness Wiring harness between J2P (female) (11) –
Voltage Max. 1 V
Voltage Max. 1 V
Defective engine control- J2P Signal name Voltage
5
ler
Between (11) – (32) Signal 1
See Fig. 1
28 HD785-7
Fig. 1
and switch 2
HD785-7 29

AS1 Signal name Voltage
Defective accelerator See Fig. 1
1 Between (6) – (4) Signal 2
pedal (Internal defect)
Between AS2 (1) – (2) Voltage 5V
Max. 1 z
Max. 1 z
harness (Disconnection AS1 (female) (5) tance
2
in wiring or defective con- Wiring harness between J2P (female) (1) – Resis-
tact in connector) Max. 1 z
Wiring harness between ATC1 (female) (4) – Resis-
Max. 1 z
Wiring harness between ATC3 (female) (34) – Resis-
Max. 1 z
Possible causes AS2 (female) (1) tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
Grounding fault in wiring Min. 1 Mz
3 harness (Short circuit
with ground circuit) Wiring harness between J2P (female) (11) – Resis-
Min. 1 Mz
Min. 1 Mz
Hot short (Short circuit Voltage Max. 1 V
4 with 24V circuit) in wiring
harness Wiring harness between J2P (female) (11) –
Voltage Max. 1 V
Voltage Max. 1 V
Defective engine control- J2P Signal name Voltage
5
ler
See Fig. 1
Defective transmission carry out troubleshooting.
6
controller
Between ATC3 (34) – ATC1 (4) Voltage 5V
30 HD785-7
Fig. 1
and switch 2
HD785-7 31
Failure code [CA432] Idle validation action error 1

Action code Failure code Idle validation action error
Trouble
Contents of
• Action error was detected in idle validation switch circuit.
trouble
Action of • Operates at position of throttle of accelerator pedal (throttle sensor).
Problem that
appears on
machine
Related
information

and standard
state
32 HD785-7
Failure code [CA441] Power supply voltage abnormally low level (Left
bank): Low voltage detection 1
Action code Failure code Power supply voltage abnormally low level (Left bank): Low voltage
Trouble
Contents of
• Low voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appears on
it stops.
machine
Related
information

and standard
state
Failure code [CB441] Power supply voltage abnormally low level (Right
bank): Low voltage detection 1
Action code Failure code Power supply voltage abnormally low level (Right bank): Low voltage
Trouble
E03 CB441 detection (Engine controller system)
Contents of
• Low voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
it stops.
machine
Related
information

and standard
state
HD785-7 33
Failure code [CA442] Power supply voltage abnormally high level (Left
bank): High voltage detection 1
Action code Failure code Power supply voltage abnormally high level (Left bank): High voltage
Trouble
Contents of
• High voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
it stops.
machine
Related
information

and standard
state
Failure code [CB442] Power supply voltage abnormally high level (Right
bank): High voltage detection 1
Action code Failure code Power supply voltage abnormally high level (Right bank): High volt-
Trouble
Contents of
• High voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
it stops.
machine
Related
information

and standard
state
34 HD785-7
Failure code [CA449] Common rail abnormally high pressure (2) (Left
bank): Abnormally high pressure occurrence 1
Action code Failure code Common rail abnormally high pressure (2) (Left bank): Abnormally
Trouble
E03 CA449 high pressure occurrence (Engine controller system)
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
trouble
Problem that
machine
Related
information

and standard
state
Failure code [CB449] Common rail abnormally high pressure (2) (Right
bank): Abnormally high pressure occurrence 1
Action code Failure code Common rail abnormally high pressure (2) (Right bank): Abnormally
Trouble
E03 CB449 high pressure occurrence (Engine controller system)
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
trouble
Problem that
machine
Related
information

and standard
state
HD785-7 35
Action code Failure code Common rail pressure sensor too high (Left bank): Excessively high
Trouble
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor circuit.
trouble
Action of • Operates with limited output.(Limits common rail pressure.)
Problem that
machine
• Input state from common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36400 Common rail pressure (Left bank), Code 36402 Common rail pressure sensor volt-
information
age (Left bank))

Defective sensor power If failure code [CA352] or [CA386] is displayed, carry out trouble-
1
source circuit shooting for it first.
a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
(Internal defect)
Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the
controller to make it sure if there is no other cause of the trouble, and
then judge the sensor voltage.
switch still OFF.
Max. 1 z
harness (Disconnection in (female) (33) – PFUEL (female) (1) tance
3
Max. 1 z
Possible causes a Prepare with starting switch OFF and diagnose with starting
and standard switch still OFF.
value in normal Between ground and wiring harness between
state Resis-
PARENT J1 (female) (33) – PFUEL (female) Min. 1 Mz
tance
Defective harness ground- (1)
4 ing (Contact with ground Between ground and wiring harness between
circuit) Resis-
tance
(2)
Resis-
tance
(3)
switch still OFF.
(female) (33) to PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
PFUEL (female) (2)
5
(Harness internal short) (female) (33) to PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
PFUEL (female) (3)
(female) (25) to PFUEL (female) (2) and wir- Resis-
Min. 1 Mz
PFUEL (female) (3)
36 HD785-7

Possible causes a Prepare with starting switch OFF, and diagnose with starting
and standard switch ON or with engine started.
value in normal 6 Defective engine controller PARENT J1 Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
HD785-7 37
Failure code [CB451] Common rail pressure sensor abnormally high

level (Right bank): High voltage detection 1
Action code Failure code Common rail pressure sensor abnormally high level (Right bank):
Trouble
E03 CB451 High voltage detection (Engine controller system)
Contents of
• High voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
(Code: 36403 Common rail pressure (Right bank), Code 36404 Common rail pressure sensor volt-
information
age (Right bank))

Defective sensor power If code [CB352] or [CB386] is displayed, carry out troubleshooting
1
supply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
Between (1) – (3) Power supply 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (2) – (3) Signal 0.25 – 4.6 V
Max. 1 z
harness (Disconnection in (33) – PFUEL (female) (1) tance
3
Max. 1 z
in connector) (25) – PFUEL (female) (2) tance
Max. 1 z
Possible causes (47) – PFUEL (female) (3) tance
state Wiring harness between CHILD J1 (female) Resis-
Ground fault in wiring har- (33) – PFUEL (female) (1) Min. 1 Mz
tance
4 ness (Contact with GND
circuit) Wiring harness between CHILD J1 (female) Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
harness) (female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
Min. 1 Mz
38 HD785-7

Possible causes a Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal 6 Defective engine controller CHILD J1 Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
HD785-7 39
Failure code [CA452] Common rail pressure sensor abnormally low

level (Left bank): Abnormally low voltage detection 1
Action code Failure code Common rail pressure sensor abnormally low level (Left bank):
Trouble
E03 CA452 Abnormally low voltage detection (Engine controller system)
Contents of
• Low voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information
age (Left bank))

and standard
state
Failure code [CB452] Common rail pressure sensor abnormally low

level (Right bank): Abnormally low voltage detection 1
Action code Failure code Common rail pressure sensor abnormally low level (Right bank):
Trouble
E03 CB452 Abnormally low voltage detection (Engine controller system)
Contents of
• Low voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information
age (Right bank))

and standard
state
40 HD785-7
Excessively high pressure detected 1
Action code Failure code Common rail pressure high trouble (1) (Left bank): Excessively high
Trouble
E03 CA553 pressure trouble occurred (Engine controller system)
Contents of
• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information
age (Left bank))

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible causes sensor [CA451]
and standard
value in normal Defective mechanical sys-
Since a mechanical defect of common rail pressure sensor is sus-
4 tem of common rail pres-
state pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
HD785-7 41
Excessively high pressure detected 1
Action code Failure code Common rail pressure high trouble (1) (Right bank): Excessively
Trouble
E03 CB553 high pressure trouble occurred (Engine controller system)
Contents of
• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information
age (Right bank))

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible causes sensor [CB451]
and standard
value in normal Defective mechanical sys-
Since a mechanical defect of common rail pressure sensor is sus-
4 tem of common rail pres-
state pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
42 HD785-7
Failure code [CA554] In-range error in common rail pressure sensor

(Left bank): In-range error 1
Action code Failure code In-range error in common rail pressure sensor (Left bank): In-range
Trouble
E03 CA554 error occurred (Engine controller system)
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting of [CA451].
state
Failure code [CB554] In-range error in common rail pressure sensor

(Right bank): In-range error 1
Action code Failure code In-range error in common rail pressure sensor (Right bank): In-range
Trouble
E03 CB554 error occurred (Engine controller system)
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting of [CB451].
state
HD785-7 43
Failure code [CA559] Loss of pressure feed from supply pump (1) (Left
bank): Loss of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (1) (Left bank): Loss of
Trouble
E03 CA559 pressure feed detected (Engine controller system)
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of • Limits common rail pressure.
Problem that
machine
Related
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See "Note 1" for the contents of diagnosis. See Testing and
adjusting "Testing fuel pressure" for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See "Note 2" for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
Defective electrical system
5 out troubleshooting for the following codes.
of supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
Possible causes Defective common rail Since a defect of common rail pressure sensor is suspected, check
and standard 6
pressure sensor for a damage in harnesses.
value in normal a As for testing an amount of pressure limiter leak, see testing and
state
adjusting "Testing fuel return and leak amount".
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting "Testing fuel return and leak amount".
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for no-
pressure feed".
44 HD785-7
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
HD785-7 45
Check sheet for no-pressure feed
Model HD785-7 Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 625 – 675
*1 Engine speed High idle rpm 2,200 – 2,300
Equivalent to rating rpm 1,900
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
46 HD785-7
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
HD785-7 47
Failure code [CB559] Loss of pressure feed from supply pump (1) (Right
Action code Failure code Loss of pressure feed from supply pump (1) (Right bank): Loss of
Trouble
E03 CB559 pressure feed detected (Engine controller system)
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of • Limits common rail pressure.
Problem that
machine
Related
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See "Note 1" for the contents of diagnosis. See Testing and
adjusting "Testing fuel pressure" for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See "Note 2" for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
5 out troubleshooting for the following codes.
of supply pump PCV
[CB271], [CB272], [CB273], and [CB274]
Possible causes Defective common rail Since a defect of common rail pressure sensor is suspected, check
and standard 6
pressure sensor for a damage in harnesses.
value in normal a As for testing an amount of pressure limiter leak, see testing and
state
adjusting "Testing fuel return and leak amount".
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting "Testing fuel return and leak amount".
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for no-
pressure feed".
48 HD785-7
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
HD785-7 49
Check sheet for no-pressure feed
Model HD785-7 Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 625 – 675
*1 Engine speed High idle rpm 2,200 – 2,300
Equivalent to rating rpm 1,900
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
50 HD785-7
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
HD785-7 51
Failure code [CA689] Abnormal engine Ne speed sensor (Left bank):

Abnormal signal 1
Action code Failure code Abnormal engine Ne speed sensor (Left bank): Abnormal signal
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of • Operates using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

1
switch still OFF.
Max. 1 z
harness (Disconnection in (female) (16) – NE (female) (1) tance
2
Max. 1 z
in connector) (female) (48) – NE (female) (2) tance
Max. 1 z
(female) (27) – NE (female) (3) tance
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing PARENT J1 (female) (16) – NE (female) (1) tance
3
(Contact with ground cir- Between ground and wiring harness between Resis-
Min. 1 Mz
cuit) PARENT J1 (female) (48) – NE (female) (2) tance
Min. 1 Mz
PARENT J1 (female) (27) – NE (female) (3) tance
value in normal
state
(female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
NE (female) (2)
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
NE (female) (3)
Min. 1 Mz
NE (female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
7 Defective engine controller found in causes 1 – 6 (since this is an internal defect, it cannot be
diagnosed).
52 HD785-7
HD785-7 53
Failure code [CB689] Abnormal engine Ne speed sensor (Right bank):

Abnormal signal 1
Action code Failure code Abnormal engine Ne speed sensor (Right bank): Abnormal signal
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of • Operates using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

Defective sensor power If failure code [CB238] is displayed at the same time, carry out trou-
1
switch still OFF.
Max. 1 z
harness (Disconnection in (female) (16) – NE (female) (1) tance
2
Max. 1 z
in connector) (48) – NE (female) (2) tance
Max. 1 z
(27) – NE (female) (3) tance
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing PARENT J1 (female) (16) – NE (female) (1) tance
3
(Contact with ground cir- Between ground and wiring harness between Resis-
Min. 1 Mz
cuit) CHILD J1 (female) (48) – NE (female) (2) tance
Min. 1 Mz
CHILD J1 (female) (27) – NE (female) (3) tance
value in normal
state
Min. 1 Mz
harness from CHILD J1 (female) (48) to NE tance
(female) (2)
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
Between wiring harness from CHILD J1
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
speed sensor
diagnosed).
54 HD785-7
HD785-7 55
Failure code [CA691] Intake air temperature sensor abnormally high

level (At left bank only): High voltage detection 1
Action code Failure code Intake air temperature sensor abnormally high level (At left bank
Trouble
E01 CA691 only): High voltage detection (Engine controller system)
Contents of
• Intake air temperature sensor circuit detected high voltage.
trouble
Action of
• Fixes intake air temperature (25°C) and continues operation.
controller
Problem that
appears on
machine
Related • Input state from intake air temperature sensor can be checked with monitoring function.
information (Code: 18400 Intake air temperature, Code: 18401 Intake air temperature sensor voltage)

Defective charge tempera- without turning starting switch ON.
1 ture sensor (Internal TAMB Intake air temperature Resistance
defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground All range Min. 1 Mz
Possible causes harness (Disconnection in Wiring harness between PARENT J1 Resis-
2 Max. 1z
and standard wiring or defective contact (female) (43) – TAMB (female) (A) tance
value in normal in connector) Wiring harness between PARENT J1 Resis-
state Max. 1z
(female) (47) – TAMB (female) (B) tance
Ground fault in wiring har-
circuit) Min. 1 Mz
(female) (43) – TAMB (female) (A) tance
PARENT J1 (female) Intake air temperature Resistance
Between (43) – (47) 10 – 100°C 0.5 – 20 kz
56 HD785-7
HD785-7 57
Failure code [CA692] Intake air temperature sensor abnormally low level
(At left bank only): Low voltage detection 1
Action code Failure code Intake air temperature sensor abnormally low level (At left bank
Trouble
E01 CA692 only): Low voltage detection (Engine controller system)
Contents of
• Intake air temperature sensor circuit detected low voltage.
trouble
Action of
• Fixes intake air temperature (25°C) and continues operation.
controller
Problem that
appears on
machine
Related • Input state from intake air temperature sensor can be checked with monitoring function.
information (Code: 18400 Intake air temperature, Code: 18401 Intake air temperature sensor voltage)

and standard
state
58 HD785-7
Failure code [CA731] Abnormal engine Bkup speed sensor phase (Left
bank): Abnormal phase 1
Action code Failure code Abnormal engine Bkup speed sensor phase (Left bank): Abnormal
Trouble
E03 CA731 phase (Engine controller system)
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of • Operates using engine Ne speed sensor signal.
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
Related
information

Since a defect of engine Ne speed sensor can be suspected, carry
Possible causes Defective engine Ne
1 out troubleshooting for the following code.
and standard speed sensor circuit
[CA689]
value in normal
state Since a defect of engine Bkup speed sensor can be suspected, carry
Defective engine Bkup
speed sensor system
[CA778]
Failure code [CB731] Abnormal engine Bkup speed sensor phase (Right
bank): Abnormal phase 1
Action code Failure code Abnormal engine Bkup speed sensor phase (Right bank): Abnormal
Trouble
E03 CB731 phase (Engine controller system)
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of • Operates using engine Ne speed sensor signal.
Problem that
appears on
machine
Related
information

Since a defect of engine Ne speed sensor can be suspected, carry
Possible causes Defective engine Ne
and standard speed sensor circuit
[CB689]
value in normal
state Since a defect of engine Bkup speed sensor can be suspected, carry
speed sensor system
[CB778]
HD785-7 59
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
60 HD785-7
SEN01942-02
HD785-7

HD785-7 7001 and up
Failure code [CA757] Loss of all engine controller data (Left bank): Loss of all data ..................................... 3
Failure code [CB757] Loss of all engine controller data (Right bank): Loss of all data................................... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup signal ................... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error..................... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error ............... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error .......... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error.......................................................................................................................................11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error...................................................................................................................................... 12
Disconnection/Short circuit .................................................................................................................... 14
HD785-7 1
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error......................................... 26
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 28
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 30
Failure code [CA2555] Intake heater relay voltage low error (Left bank) ...................................................... 32
Failure code [CA2556] Intake heater relay voltage high error (Left bank)..................................................... 34
2 HD785-7
Failure code [CA757] Loss of all engine controller data (Left bank): Loss
of all data 1
Action code Failure code Loss of all engine controller data (Left bank): Loss of all data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on • The engine cannot be started, or cannot be operated.
machine
Related
information

and standard
value in normal Carry out troubleshooting of [CA111].
state
Failure code [CB757] Loss of all engine controller data (Right bank): Loss
of all data 1
Action code Failure code Loss of all engine controller data (Right bank): Loss of all data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on • The engine cannot be started, or cannot be operated.
machine
Related
information

and standard
value in normal Carry out troubleshooting of [CB111].
state
HD785-7 3
Failure code [CA778] Abnormal engine Bkup speed sensor (Left bank):
Abnormal Bkup signal 1
Action code Failure code Abnormal engine Bkup speed sensor (Left bank): Abnormal Bkup
Trouble
E03 CA778 signal (Engine controller system)
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
Action of • Operates using Ne speed sensor signal.
Problem that
appears on
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
source circuit shooting for it first.
switch still OFF.
Max. 1 z
harness (Disconnection in (female) (37) – left G (female) (1) tance
2
(female) (47) – left G (female) (2) tance
Max. 1 z
(female) (26) – left G (female) (3) tance
switch still OFF.
Resis-
PARENT J1 (female) (37) – left G (female) Min. 1 Mz
tance
Defective harness (1)
3 grounding (Contact with Between ground and wiring harness between
ground circuit) Resis-
PARENT J1 (female) (47) – left G (female) Min. 1 Mz
tance
(2)
Resis-
Possible causes PARENT J1 (female) (26) – left G (female) Min. 1 Mz
tance
and standard (3)
value in normal a Prepare with starting switch OFF and diagnose with starting
(female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
harness from PARENT J1 (female) (47) to left tance
G (female) (2)
4
(Harness internal short) (female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
G (female) (3)
(female) (47) to left G (female) (2) and wiring Resis-
Min. 1 Mz
G (female) (3)
Defective mounting of sen- Since defective mounting of Bkup speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (in supply pump) can be sus-
speed detection pected, directly check it.
Engine Bkup speed sensor can be suspected to be defective if no
speed sensor
diagnosed).
4 HD785-7
HD785-7 5
Failure code [CB778] Engine Bkup speed sensor abnormality (Right

bank): Bkup signal error 1
Action code Failure code Engine Bkup speed sensor abnormality (Right bank): Bkup signal
Trouble
E03 CB778 error (Engine controller system)
Contents of
• Engine Bkup speed sensor signal detected abnormality.
trouble
Action of • Operates with Ne speed sensor signal
Problem that
• If engine has been running, it stops (when Ne speed sensor is also defective).
appears on
• If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
machine
Related
information

Defective sensor power If failure code [CB187] or [CB227] is displayed, carry out trouble-
1
supply system shooting for it first.
Max. 1 z
harness (Disconnection in (37) – right G (female) (1) tance
2
Max. 1 z
in connector) (47) – right G (female) (2) tance
Max. 1 z
(26) – right G (female) (3) tance
Ground fault in wiring har- Min. 1 Mz
circuit) Min. 1 Mz
Min. 1 Mz
Possible causes (26) – right G (female) (3) tance
state Between wiring harness between CHILD J1
(female) (37) – right G (female) (1) and wiring Resis-
Min. 1 Mz
harness between CHILD J1 (female) (47) – tance
right G (female) (2)
harness) Min. 1 Mz
Min. 1 Mz
Defective sensor installa- Bkup speed sensor may be installed defectively (improper clear-
5 tion or defective speed ance) or speed sensing part (in supply pump) may be defective.
sensing part Check them directly.
If causes 1 – 5 are not detected, engine Bkup speed sensor may be
speed sensor
carried out.)
If causes 1 – 6 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
6 HD785-7
HD785-7 7
Failure code [CA781] Inter-multicontroller communication error (Left

bank): Communication error 1
Action code Failure code Inter-multicontroller communication error (Left bank): Communica-
Trouble
E03 CA781 tion error (Engine controller system)
Contents of
• Communication error occurred between engine controllers (Left bank).
trouble
Action of
controller
Problem that
• During operation: Engine continues operation with 1 bank.
appears on
• When key is ON: Engine cannot be started.
machine
Related
information

1 Max. 1 z
wiring or defective contact (female) (8) – CHILD J1 (female) (8) tance
Max. 1 z
(female) (6) – CHILD J1 (female) (6) tance
and standard without turning starting switch ON.
value in normal Wiring harness between PARENT J1 Resis-
state (female) (8) – CHILD J1 (female) (8) tance
GND circuit)
Min. 1 Mz
(female) (6) – CHILD J1 (female) (6) tance
Between (8) – (6) 54 – 66 z
8 HD785-7
HD785-7 9
Failure code [CB781] Inter-multicontroller communication error (Right

bank): Communication error 1
Action code Failure code Inter-multicontroller communication error (Right bank): Communica-
Trouble
E03 CB781 tion error (Engine controller system)
Contents of
• Communication error occurred between engine controllers (Right bank).
trouble
Action of
controller
Problem that
• During operation: Engine continues operation with 1 bank.
appears on
• When key is ON: Engine cannot be started.
machine
Related
information

and standard
state
10 HD785-7
Failure code [CA1257] Multicontroller distinction wiring harness key

error (Left bank): Distinction error 1
Action code Failure code Multicontroller distinction wiring harness key error (Left bank): Dis-
Trouble
E03 CA1257 tinction error (Engine controller system)
Contents of
• Controller of each bank disagrees with distinction wiring harness (Left bank).
trouble
Action of • Stops operation.
Problem that
appears on • When key is ON: Engine cannot be started.
machine
Related
information

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch ON.
1
wiring or defective contact Wiring harness between J2P (female) (7) – Resis-
Max. 1 z
in connector) (34) tance
Possible causes Ground fault in wiring har-
and standard 2 ness (Contact with GND
Resis-
value in normal circuit) Between J2P (female) (8) – ground Min. 1 Mz
state tance
Resis-
3 Defective engine controller Between J2P (female) (7) – ground Max. 1 z
tance
Resis-
Between J2P (female) (8) – ground Min. 1 Mz
tance
HD785-7 11
Failure code [CB1257] Multicontroller distinction wiring harness key

error (Right bank): Distinction error 1
Action code Failure code Multicontroller distinction wiring harness key error (Right bank): Dis-
Trouble
E03 CB1257 tinction error (Engine controller system)
Contents of
• Controller of each bank disagrees with distinction wiring harness (Right bank).
trouble
Action of • Stops operation.
Problem that
appears on • When key is ON: Engine cannot be started.
machine
Related
information

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness (Disconnection in without turning starting switch ON.
1
wiring or defective contact Wiring harness between J2C (female) (8) – Resis-
Max. 1 z
in connector) (34) tance
Possible causes
and standard Ground fault in wiring har-
value in normal 2 ness (Contact with GND
state Resis-
circuit) Between J2C (female) (8) – ground Max. 1 z
tance
Resis-
Between J2C (female) (8) – ground Max. 1 z
tance
12 HD785-7
HD785-7 13
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short

circuit (Right bank): Disconnection/Short circuit 1
Action code Failure code Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Trouble
E03 CB1548 Disconnection/Short circuit (Engine controller system)
Contents of
• Disconnection or short circuit occurred in injector #7 circuit.
trouble
Action of
controller
Problem that
• Output lowers.
appears on
• Engine speed is unstable.
machine
Related
information

Defective injector #7 CN1 (male) Resistance
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnection in Wiring harness between CHILD J1 (female) Resis-
2 Max. 1 z
wiring or defective contact (45) – CN1 (female) (1) tance
in connector) Wiring harness between CHILD J1 (female) Resis-
Max. 1 z
Possible causes (53) – CN1 (female) (2) tance
state Ground fault in wiring har-
3 ness (Contact with GND Min. 1 Mz
(45) – CN1 (female) (1) tance
circuit)
Min. 1 Mz
Defective injector of
If failure codes of 1 or more injectors are displayed, carry out trou-
4 another cylinder or defec-
bleshooting for them.
tive wiring harness
5 Defective engine controller CHILD J1 (female) Resistance
Between (45) – (53) 0.4 – 1.1 z
14 HD785-7
HD785-7 15

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (54) – (51) 0.4 – 1.1 z
16 HD785-7
HD785-7 17

Action code Failure code Injector #10 (R/B #4) system disconnection/short circuit (Right
Trouble
E03 CB1551 bank): Disconnection/Short circuit (Engine controller system)
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (56) – (58) 0.4 – 1.1 z
18 HD785-7
HD785-7 19

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (46) – (60) 0.4 – 1.1 z
20 HD785-7
HD785-7 21

Action code Failure code Injector #12 (R/B #6) system disconnection/short circuit (Right
Trouble
E03 CB1553 bank): Disconnection/Short circuit (Engine controller system)
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (57) – (59) 0.4 – 1.1 z
22 HD785-7
HD785-7 23

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (55) – (52) 0.4 – 1.1 z
24 HD785-7
HD785-7 25
Failure code [CA1633] KOMNET abnormality (Left bank):

Communication error 1
Action code Failure code KOMNET abnormality (Left bank): Communication error
Trouble
Contents of
• Abnormality occurred in KOMNET communication circuit to engine controller (Left bank).
trouble
Action of • Continues operation in default mode or maintains condition when trouble occurred.
Problem that
• Information may not be transmitted or received normally through KOMNET communication system
appears on
and machine may not operate normally.
machine
Related
information

Max. 1 z
harness (Disconnection in J2C (female) (46) tance
1
wiring or defective contact Wiring harness between J2P (female) (47) – Resis-
Max. 1 z
in connector) J2C (female) (47) tance
54 – 66 z
J2P (female) (47) tance
Possible causes
and standard
value in normal Ground fault in wiring har-
J2C (female) (46) tance
circuit)
Min. 1 Mz
3 Defective engine controller 54 – 66 z
J2P (female) (47) tance
Wiring harness between J2C (female) (46) – Resis-
54 – 66 z
26 HD785-7
HD785-7 27
Failure code [CA2185] Throttle sensor supply voltage high error 1

Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• Voltage of throttle sensor power supply (5V) circuit is high.
trouble
Action of
ON.
controller
Problem that
appears on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
Related
information

Disconnect device
Defective accelerator suggested on the
1
pedal (Internal defect) right. At this time, if
Accelerator pedal AS1 connector
failure code is not indi-
cated, the device is
defective.
harness (Disconnection Wiring harness between J2P (female) (22) – Resis-
2 Max. 1 z
in wiring or defective AS1 (female) (1) tance
contact in connector) Wiring harness between J2P (female) (23) – Resis-
and standard AS1 (female) (3) tance
state Grounding fault in wiring without turning starting switch ON.
harness Wiring harness between J2P (female) (22) – Resis-
3 Min. 1 Mz
(Contact with ground cir- AS1 (female) (1) tance
cuit) Wiring harness between J2P (female) (23) – Resis-
Min. 1 Mz
ness
4 Wiring harness between J2P (female) (22) –
(with another wiring har- Resis-
ness) AS1 (female) (1) and J2P (female) (23) – AS1 Min. 1 Mz
tance
(female) (3)
Defective engine control- carry out troubleshooting
5
ler J2P Voltage
Between (22) and (23) 4.75 – 5.25 V
28 HD785-7

Serial No.: 7001 – 7078
HD785-7 29
Failure code [CA2186] Throttle sensor power supply low error 1

Action code Failure code Throttle sensor power supply low error
Trouble
Contents of
• Voltage of throttle sensor power supply (5V) circuit is low.
trouble
Action of
ON.
controller
Problem that
appears on • When accelerator pedal is pressed fully, engine speed does not rise above medium level.
machine
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and the
standard values Carry out troubleshooting for failure code [CA2185].
when normal
30 HD785-7
Failure code [CA2249] Loss of pressure feed from supply pump (2) (Left
Action code Failure code Loss of pressure feed from supply pump (2) (Left bank): Loss of
Trouble
E03 CA2249 pressure feed detected (Engine controller system)
Contents of
• Loss of pressure feed (level 2) occurred in the common rail circuit.
trouble
Action of • Operates with limited output.
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.
Related
(Code: 36400 Common rail pressure (Left bank), Code: 36402 Common rail pressure sensor volt-
information
age (Left bank))

and standard
value in normal 1 Carry out troubleshooting of [CA559].
state
Failure code [CB2249] Loss of pressure feed from supply pump (2)
(Right bank): Loss of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (2) (Right bank): Loss of
Trouble
E03 CB2249 pressure feed detected (Engine controller system)
Contents of
• Loss of pressure feed (level 2) occurred in the common rail circuit.
trouble
Action of • Operates with limited output.
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.
Related
information
age (Right bank))

and standard
value in normal 1 Carry out troubleshooting of [CB559].
state
HD785-7 31
Failure code [CA2555] Intake heater relay voltage low error (Left bank) 1
Action code Failure code Intake heater relay voltage low error (Left bank)
Trouble
Contents of
• Disconnection error was detected in intake air heater relay circuit.
trouble
Action of • Automatic preheating (to be started when engine coolant temperature is below -5 °C) is not
controller started.
Problem that
machine
Related
information

and standard
state
32 HD785-7
HD785-7 33
Failure code [CA2556] Intake heater relay voltage high error (Left bank)1
Action code Failure code Intake heater relay voltage high error (Left bank)
Trouble
Contents of
• Short circuit was detected in intake heater relay circuit.
trouble
Action of • Automatic preheating (to be started when engine coolant temperature is below -5 °C) is not
controller started.
Problem that
machine
Related
information

Defective intake heater without turning starting switch ON.
1
relay (Internal defect) R37 (male) Resistance
Between (1) and (2) 200 – 400 z
harness (Disconnection Wiring harness between J2P (female) (40) – Resis-
2 Max. 1 z
in wiring or defective R37 (female) (1) tance
Possible causes contact in connector) Wiring harness between J2P (female) (42) – Resis-
Max. 1 z
and standard R37 (female) (2) tance
state Grounding fault in wiring without turning starting switch ON.
harness Wiring harness between J2P (female) (40) – Resis-
3 Min. 1 Mz
(Contact with ground cir- R37 (female) (1) tance
cuit) Wiring harness between J2P (female) (42) – Resis-
Min. 1 Mz
R37 (female) (2) tance
Defective engine control-
4 J2P Heater relay Voltage
ler
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V
34 HD785-7
HD785-7 35
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
36 HD785-7
SEN01943-03
HD785-7

HD785-7 7001 and up
Failure code [D180KA] Preheating relay output system: Disconnection......................................................... 3
Failure code [D180KB] Preheating relay output system: Grounding fault....................................................... 4
Failure code [D180KY] Preheating relay output system: Hot short circuit ...................................................... 6
Failure code [D19HKB] Stop lamp relay output system: Short circuit ............................................................. 8
Failure code [D1EFKA] Pre-lubrication start relay output system: Disconnection ........................................ 10
Failure code [D1EFKB] Pre-lubrication start relay output system: Grounding fault ...................................... 12
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot short circuit ...................................... 14
Failure code [DAF9KM] Wrong connection of connector .............................................................................. 16
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication...... 17
Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage ... 18
Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller .................. 20
Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low ..... 22
Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection.................................... 24
Failure code [DAQRKR] Abnormality in CAN communication (Transmission).............................................. 25
Failure code [DAQRMA] Transmission controller option setting: Malfunction............................................... 30
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller .......................... 30
Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble .............. 31
HD785-7 1
Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low ...... 33
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 35
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled ...................... 36
Failure code [DB1RMA] Disagreement of option setting (Retarder controller) ............................................. 40
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled........................ 41
Failure code [dB2RKR] CAN communication (engine controller): Communication disabled ........................ 47
Failure code [DBB0KK] or VHMS_LED display: "n9" o "01" ........................................................................ 54
Failure code [DBB0KQ] (or VHMS_LED display: "nF" o "11") VHMS controller: Disagreement of model
selection signals..................................................................................................................................... 56
Failure code [DBB3KK] (or VHMS_LED display: "n9" o "05") VHMS controller battery power supply: Low
power supply voltage (input) .................................................................................................................. 58
Failure code [DBB5KP] (or VHMS_LED display: "n9" o "04") VHMS controller 5 V power supply output: Low
output voltage ........................................................................................................................................ 60
Failure code [DBB6KP] (or VHMS_LED display: "n9" o "02") VHMS controller 24 V power supply output:
Low output voltage................................................................................................................................. 62
Failure code [DBB7KP] (or VHMS_LED display: "n9" o "03") VHMS controller 12 V power supply output:
Low output voltage................................................................................................................................. 64
Failure code [DBBQKR] (or VHMS_LED display: "n8" o "02") VHMS controller CAN communication: Defec-
tive communication (Abnormality in target component system)............................................................. 65
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) ......................................................... 65
Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble .................... 66
Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low ............ 68
Failure code [DBC9KQ] Disagreement of model selection (ABS controller)................................................. 70
Failure code [DBCRKR] Abnormality in CAN communication (ABS) ............................................................ 71
Failure code [DBCRMA] Disagreement of option setting (ABS controller).................................................... 75
Failure code [DBG2KK] Solenoid power supply: Low voltage ...................................................................... 76
Failure code [DBG3KK] Battery direct power supply: Low voltage ............................................................... 78
Failure code [DBG9KQ] Model selection signal: Abnormal........................................................................... 80
Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range ............... 82
Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped) .................................... 84
Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped)........................................ 86
Failure code [DDD9KA] ABS system switch system: Disconnection ............................................................ 88
Failure code [DDD9KB] ABS system switch system: Short circuit................................................................ 90
Failure code [DDDAKA] ASR system switch: Disconnection ........................................................................ 92
Failure code [DDDAKB] ASR system switch: Short circuit............................................................................ 94
Failure code [DDE2KB] Engine oil pressure switch error: Grounding fault ................................................... 96
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection or hot short circuit ........................ 98
Failure code [DDP6L4] Service brake pressure switch trouble (Rear)........................................................ 100
Failure code [DDTHKA] Hi clutch fill switch: Disconnection........................................................................ 102
Failure code [DDTJKA] Lo clutch fill switch: Disconnection ........................................................................ 104
Failure code [DDTKKA] 1st clutch fill switch: Disconnection....................................................................... 106
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection...................................................................... 108
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection.......................................................................110
Failure code [DDTNKA] R clutch fill switch: Disconnection..........................................................................112
Failure code [DDTPKA] 4th clutch fill switch: Disconnection .......................................................................114
Failure code [DF10KA] Gear shift lever: Disconnection ...............................................................................116
Failure code [DF10KB] Gear shift lever: Short circuit ................................................................................. 120
.
Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range........................... 126
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear wheel) system (Disconnection and
short circuit) ......................................................................................................................................... 128
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear wheel) system (Ground fault).... 130
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front wheel) system (Disconnection and
short circuit) ......................................................................................................................................... 131
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front wheel) system (Ground fault) ... 132
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range ................................... 134
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range ..................... 136
2 HD785-7
Failure code [D180KA] Preheating relay output system: Disconnection 1

Action code Failure code Preheating relay output system: Disconnection
Trouble
E01 D180KA (Pre-lubrication controller system)
• When preheating engine, pre-lubrication controller first turns the preheating relay ON.
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as disconnection.
trouble
(Preheat relay (R37) primary coil side: Disconnection)
Action of
• Turns the preheat relay output OFF.
controller
Problem that
appears on • Preheating disabled
machine
Related • The output state of the preheating relay controller can be checked with the monitoring code:
information 40974 "D-OUT-0" (1: ON, 0: OFF).

Defective preheating relay 2) Disconnect preheating relay (R37) and carry out troubleshooting.
1
(R37) Between preheating relay (R37) (male) (1) – Resis- 290 z
Possible causes (2) tance ± 10%
and standard Disconnection in wiring har- 1) Turn the starting switch OFF.
value in normal ness 2) Disconnect connector PRE5 and carry out troubleshooting.
state 2
(Disconnection or defective Resis- 290 z
contact in connector) Between PRE5 (female) (9) – (40)
tance ± 10%
controller
carried out.)
HD785-7 3
Failure code [D180KB] Preheating relay output system: Grounding fault 1

Action code Failure code Preheating relay output system: Grounding fault
Trouble
E01 D180KB (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as grounding fault.
trouble
(Preheat relay (R37) primary coil side: Grounding fault)
Action of
• Turns the preheating relay output OFF.
controller
Problem that
appears on • Preheating disabled
machine
Related • The output state of the preheating relay controller can be checked with the monitoring code:
information 40974 "D-OUT-0" (1: ON, 0: OFF).

1
(R37) Between preheating relay (R37) (male) (1) – Resis- 290 z
(2) tance ± 10%
Possible causes
and standard 1) Turn the starting switch OFF.
value in normal Grounding fault in wiring har- 2) Disconnect connector PRE5 and R37, then carry out trouble-
state 2 ness shooting.
(Contact with ground circuit) Between PRE5 (female) (9) and chassis Resis- Min. 1
ground tance Mz
controller
carried out.)
4 HD785-7
HD785-7 5
Failure code [D180KY] Preheating relay output system: Hot short circuit 1
Action code Failure code Preheating relay: Hot short circuit
Trouble
E01 D180KY (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the preheat relay ON, and it was judged as hot short circuit.
trouble
(Preheat relay (R37) primary coil side: Hot short circuit)
Action of
• Turns the preheating relay output OFF.
controller
Problem that
appears on • Preheating constantly in operation.
machine
• The output state of the preheating relay controller can be checked with the monitoring code:
Related
40974 "D-OUT-0" (1: ON, 0: OFF).
information
• Heater coil may be burnt out due to overheated preheating coil.

1
(R37) Between preheating relay (R37) (male) (1) – Resis- Min. 1
(3) tance Mz
2) Disconnect connector PRE5 and carry out troubleshooting.
Resis- Min. 1
Between PRE5 (female) (9) – (1)
tance Mz
Resis- Min. 1
Possible causes Between PRE5 (female) (9) – (2)
tance Mz
and standard
Grounding fault in wiring Resis- Min. 1
value in normal Between PRE5 (female) (9) – (30)
2 harness tance Mz
state
(Contact with ground circuit) 1) Turn the starting switch OFF.
2) Disconnect PRE5 and connect T-branch.
a When preheating in cold weather, turn the starting switch ON
and wait for a while, then check the preheating relay.
Between PRE5 (female) (9) and chassis
Voltage Max. 1 V
ground
controller
carried out.)
6 HD785-7
HD785-7 7
Failure code [D19HKB] Stop lamp relay output system: Short circuit 1
Action code Failure code Stop lamp relay output system: Short circuit
Trouble
E01 D19HKB (Retarder controller system)
Contents of
• When signal was output to stop lamp relay, abnormal current flowed.
trouble
Action of • Turns output to stop lamp relay OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Stop lamp does not light up.
machine
Related
information

3) Connect T-adapter to connector R08 (male).
R08 (male) Resistance
1 Defective stop lamp relay
Between (1) and (2) 250 – 350 z
Between (1) and ground Min. 1 Mz
Relay may be checked by exchanging it with another relay
Possible causes (5-pole relay).
value in normal Grounding fault in wiring har- 2) Disconnect connectors BRC2 and R08.
state 2 ness 3) Connect T-adapter to BRC2 or R08 (female).
(Contact with ground circuit) Between BRC2 (female) (18) and R08 Resis-
Min. 1 Mz
(female) (2) and ground tance
2) Insert T-adapter in connector BRC2.
3 Defective retarder controller BRC2 Brake pedal Voltage
Between (18) and When pressed Max. 1 V
ground When in neutral 20 – 30 V
8 HD785-7
HD785-7 9
Failure code [D1EFKA] Pre-lubrication start relay output system:

Disconnection 1
Action code Failure code Pre-lubrication start relay output system: Disconnection
Trouble
E01 D1EFKA (Pre-lubrication controller system)
• When pre-lubricating engine, pre-lubrication controller first turns the pre-lubrication start relay ON.
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as discon-
trouble
nection (Pre-lubrication start relay (connector PRE7) primary (coil) side: Disconnection).
• Turns the pre-lubrication relay output OFF.
Action of • Turns the preheating relay output OFF.
controller • Turns the engine start relay OFF.
• After detecting error, the relay will not reset itself unless starting switch is turned OFF once.
Problem that • Pre-lubrication disabled
appears on • The engine does not start.
machine • Preheating disabled
• Engine can be started by bypassing pre-lubrication controller.
1) Disconnect connectors PER1 and PRE2 from near pre-librication controller.
Related
2) Connect PRE1 (male) connector and PRE2 (female) connector.
information
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

2) Disconnect pre-lubrication start relay (PRE7) and carry out trou-
Defective pre-lubrication start bleshooting.
1
relay
Between pre-lubrication start relay PRE7 Resis- 290 z
Possible causes (male) (1) – (2) tance ± 10%
and standard
value in normal Disconnection in wiring 1) Turn the starting switch OFF.
state harness 2) Disconnect connector PRE5 and carry out troubleshooting.
2
(Disconnection or defective Resis- 290 z
contact in connector) Between PRE5 (female) (19) – (40)
tance ± 10%
controller
carried out.)
10 HD785-7
HD785-7 11
Failure code [D1EFKB] Pre-lubrication start relay output system:

Grounding fault 1
Action code Failure code Pre-lubrication start relay output system: Grounding fault
Trouble
E01 D1EFKB (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as ground-
trouble
ing fault (Pre-lubrication start relay (connector PRE7) primary (coil) side: Grounding fault).
Problem that • Pre-lubrication disabled
Related
information
• The output state of the pre-lubrication start relay output can be checked with the monitoring code:
40974, "D-OUT-1" (1: ON, 0: OFF).

1
relay
Between pre-lubrication start relay PRE7 Resis- 290 z
Possible causes (male) (1) – (2) tance ± 10%
value in normal 2) Disconnect connectors PRE5 and PRE7 and carry out trouble-
state Ground fault in wiring harness shooting.
2
Between PRE5 (female) (19) and chassis Resis- Min. 1
ground tance Mz
controller
carried out.)
12 HD785-7
HD785-7 13
Failure code [D1EFKY] Pre-lubrication start relay output system: Hot

short circuit 1
Action code Failure code Pre-lubrication start relay output system: Hot short circuit
Trouble
E01 D1EFKY (Pre-lubrication controller system)
Contents of
However, the controller failed to turn the pre-lubrication start relay ON, and it was judged as hot
trouble
short circuit (Pre-lubrication start relay (connector PRE7) primary (coil) side: Hot short circuit).
Problem that • Pre-lubrication does not stop
Related
information
• The output state of the pre-lubrication start relay output can be checked with the monitoring code:
40974, "D-OUT-1" (1: ON, 0: OFF).

1
relay
Between pre-lubrication start relay PRE7 Resis- Min. 1
(male) (1) – (3) tance Mz
2) Disconnect connector PRE5 and carry out troubleshooting.
Resis- Min. 1
tance Mz
Possible causes
and standard Resis- Min. 1
value in normal tance Mz
Hot short in wiring harness
state 2 (Contact with power supply Resis- Min. 1
circuit) tance Mz
1) Starting switch OFF
2) Disconnect PRE5 and connect T-branch.
Voltage Max. 1 V
ground
controller
carried out.)
14 HD785-7
HD785-7 15
Failure code [DAF9KM] Wrong connection of connector 1

Action code Failure code Wrong connection of connector
Trouble
E03 DAF9KM (Machine monitor system)
Contents of
• Check signal of connector is different from internal setting of machine monitor.
trouble
Action of • Detects only at start.
machine monitor • Keeps trouble condition until starting switch is turned OFF.
Problem that
• Machine monitor mode selector switch cannot be selected.
appears on
• Headlamp high beam pilot lamp, turn signal pilot lamp, and output mode pilot lamp do not operate.
machine
Related
information

Wrong connection of connec- Connector DPC2A (female) may be connected to DPC3A (male)
1
tor by mistake. Check and connect it correctly, if connected wrongly.
1) Starting switch OFF.
Disconnection in wiring har- 2) Inseret T-adapter into DPC2A.
Possible causes ness (Disconnection in wiring 3) Turn starting switch ON
2
and standard or defective contact in con-
DPC2A Voltage
value in normal nector)
state Between (5) and ground 20 – 30 V
Short circuit in wiring har- ing without turning starting switch ON.
3 ness (with another wiring
harness) Between DPC3A (female) (5) and each pin Resis-
Min. 1 Mz
other than DPC3A (female) (5) tance
4 Defective machine monitor Check by replacing machine monitor.
16 HD785-7
Failure code [DAFRKR] Abnormal CAN communication

(machine monitor): Abnormal communication 1
Action code Failure code Abnormal CAN communication (machine monitor): Abnormal com-
Trouble munication
E03 DAFRKR (Transmission controller system)
Contents of • Transmission controller can not receive the data from the machine monitor with CAN communica-
trouble tion.
Action of • Keep the information at the time when abnormality occurred.
controller • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
• When the network is abnormal, the machine monitor can not correctly display the data from each
appears on
controller.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is notified to each controller by ACC signal from starting switch.
• Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN commu-
Related nication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it can
information be observed only through KOMTRAX system.
• Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
• Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

Possible causes Defective power supply to
and standard 1 Perform troubleshooting for E mode, "E-3".
machine monitor
value in normal
state Defective CAN communica- Perform troubleshooting for failure code [DAQRKR], cause 2 and
2
tion after.
HD785-7 17
Failure code [DAQ0KK] Transmission controller direct power supply:

Lowering of power supply voltage 1
Action code Failure code Transmission controller direct power supply: Lowering of power
Trouble supply voltage
E03 DAQ0KK (Transmission controller system)
Contents of
• While engine was running, controller direct power supply circuit voltage lowered below 18 V.
trouble
Action of • Keeps current gear speed.
controller • If gearshift lever is set in N, transmission is set in neutral.
• If there is not power supply voltage (there is disconnection), transmission is set in neutral suddenly
Problem that during travel and machine cannot restart until voltage becomes normal.
appears on • The gear is set in Neutral suddenly during travel and the machine cannot start again until the volt-
machine age rises to the normal level.
• If power supply voltage is low, machine can move but transmission may slip because of load.
• If failure code "AB00MA" (Malfunction of alternator) is indicated, perform troubleshooting for it first.
Related
information • If the fuse is broken, check the line between the fuse and ATC3 (female) (1) and (11) for grounding
fault.

a Test the battery voltage and specific gravity of the battery fluid.
Battery voltage Voltage Min. 24 V
1 Defective battery
Specific
Specific gravity of battery fluid Min. 1.26
gravity
Defective circuit breaker
When circuit breaker FuA2 is tripped or fuse BT2 (17) and (18) is
2 FuA2 or defective fuse BT2
blown, a ground fault may have occurred in the circuit.
(17) and (18)
2) Disconnect negative (–) terminal of battery and connect T-
adapter to ATC3 (female).
3) Connect negative (–) terminal of battery.
Between battery relay terminal B – ground Voltage 20 – 30 V
Possible causes Between ATC3 (female) (1), (11) – ground Voltage 20 – 30 V
and standard Disconnection in wiring har-
value in normal ness If there is voltage between battery relay terminal B and ground and
3 there is not voltage between ATC3 (1) and (11), wiring harness
state (Disconnection or defective
contact) between them has disconnection.
2) Disconnect negative (–) terminal of battery, and connector ATC
3 and connect T-adapter to ATC3 (female)
Between ATC3 (female) (21), (31), (32), (33)
Resis-
and ground Max. 1 z
tance
a Looseness or rusting on ER1 terminal
2) Disconnect negative (–) terminal of battery and insert T-adapter
in ATC3.
Defective transmission con- 3) Connect negative (–) terminal of battery.
4
troller 4) Turn starting switch ON.
Between ATC3 (1), (11) and (21), (31), (32),
Voltage 20 – 30 V
(33)
18 HD785-7
HD785-7 19
Failure code [DAQ0KT] Transmission controller nonvolatile memory:

Abnormality in controller 1
Action code Failure code Transmission controller nonvolatile memory: Abnormality in con-
Trouble
E01 DAQ0KT troller (Transmission controller system)
• An abnormality has occurred in the nonvolatile memory inside the controller.

Contents of
trouble • Just after starting switch was turned OFF, there was not battery direct power supply and finishing
operation was not carried out normally.
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine control parameter may change and transmission gear shift shock may get worse.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard Since this is an internal defect, it cannot be diagnosed.
value in normal Defective transmission
1 (It is no problem to keep using controller unless any visible trouble
state controller
symptom appears on machine.)
20 HD785-7
HD785-7 21
Failure code [DAQ2KK] Transmission controller solenoid power supply:

Power supply voltage too low 1
Action code Failure code Transmission controller solenoid power supply: Power supply volt-
Trouble
E03 DAQ2KK age too low (Transmission controller system)
Contents of • Battery direct power supply voltage of transmission controller has dropped to above 20 V, and sole-
trouble noid power supply voltage has dropped to below 18 V.
Action of • Holds the gear speed.
controller • Keeps neutral with shift lever neutral.
Problem that
appears on • Suddenly shifts to neutral while traveling, and the machine cannot move off again.
machine
Related
• When the fuse is blown, check for ground fault of line from fuse – ATC3 (female) (2), (12), (22).
information

when circuit breaker FuB2 is tripped or fuse BT3 (13) and (14) is
1 FuB2 or defective fuse BT3
(13) and (14)
2) Disconnect negative (–) terminal of battery and connector ATC3,
and connect T-adapter to ATC3.
Between battery relay terminal M and
Voltage 20 – 30 V
ground
Disconnection in wiring Between ATC3 (female) (2), (12), (22) and
Voltage 20 – 30 V
harness ground
Possible causes 2
(Disconnection or defective If there is voltage between battery relay terminal M and ground and
and standard
contact) there is not voltage between ATC3 (2), (12), (22) and ground, wir-
value in normal
state ing harness between them has disconnection.
5) Turn the starting switch to OFF position.
6) Disconnect battery (-) terminal and connector ATC3, and con-
nect the T-adapter to the female side of ATC3.
Between ground and ATC3 (female) (21),
Resis-
(31), (32), (33) Max. 1 z
tance
in ATC3.
Defective transmission 3) Connect negative (–) terminal of battery.
3
controller 4) Turn starting switch ON.
Between ATC3 (2), (12), (22) and (21), (31),
Voltage 20 – 30 V
(32), (33)
22 HD785-7
HD785-7 23
Failure code [DAQ9KQ] Transmission controller: Disagreement of

model selection 1
Action code Failure code Transmission controller: Disagreement of model selection
Trouble
E03 DAQ9KQ (Machine monitor system)
Contents of • Machine model information from machine monitor is different from machine model information
trouble saved in transmission controller.
Action of
machine monitor
Problem that
appears on • Machine cannot travel.
machine
Related
information

Failure code [DAQ9KQ] is not displayed (Code is not displayed).
Possible causes Wrong setting of machine
1
model by machine monitor a When machine monitor or transmission controller is replaced,
and standard
set them according to Testing and adjusting.
value in normal
state Controller of correct part No. is mounted.
Installation of wrong trans-
2
mission controller a Check part No. If it is wrong, replace transmission controller
with correct one.
24 HD785-7
Failure code [DAQRKR] Abnormality in CAN communication (Transmis-

sion) 1
Action code Failure code Abnormality in CAN communication (Transmission)
Trouble
E03 DAQRKR (Machine monitor system)
Contents of • Machine monitor cannot obtain information from transmission controller through CAN communica-
trouble tion circuit.
Action of
• Keeps information at time of occurrence of abnormality.
controller
Problem that
• System may not operate normally.
appears on
machine • Information from transmission controller is not displayed on machine monitor.
• Method of reproducing failure code: Turn the starting switch to ON position.

• Start of CAN communication is recognized by each controller when the ACC signal of the starting
switch is received.
• If a failure code for [DBBQKR] is additionally displayed, CAN communication is established
between the machine monitor and at least VHMS controller. Therefore, there is no short circuit,
ground fault or hot short circuit in the CAN communication line.
• If [DAQRKR] is the only failure code displayed and [DBBQKR] is not displayed, CAN communica-
tion may not be established with any controller.
Related
Namely, a short circuit, ground fault or hot short circuit may have occurred in the CAN communica-
information
tion line.
• Since this is the only CAN communication error able to be recognized by the machine monitor, dis-
play of this code does not necessarily mean that the transmission controller is defective.
• A certain defective controller can make the entire CAN communication impossible.
• Since power to each controller and machine monitor is supplied directly from the battery, their
power is supplied even when the starting switch is turned OFF.
• Since the signals in operation are constructed with pulse voltage, they cannot be measured by
using a multimeter.

Defective power supply to
1 Perform troubleshooting for failure code [DAQ0KK].
the transmission controller
Possible causes 1) Turn the starting switch to OFF position.
and standard 2) Disconnect connector CAN2 and CAN3, and connect the T-
value in normal Defective CAN terminating adapter to male side.
state resistor
2 Between CAN3 (male) (A) and (B) (engine Resis-
(Internal open or short cir- 120 ± 12 z
side) tance
cuit)
Between CAN2 (male) (A) and (B) (inside Resis-
120 ± 12 z
cab) tance
HD785-7 25

• CAN communication line
a CAN terminating resistors of 120 z are connected in parallel.
Therefore, an disconnection has not occurred in the communi-
cation line when the combined resistance of 60 z is measured
from any connector.
1) Turn the starting switch to OFF position and disconnect the bat-
tery ground cable.
2) Disconnect either one of the following connectors ATC2, J2P,
J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
adapter to the female side of the disconnected connector.
a If a short circuit is detected (resistance between terminals is 1
z or less), disconnect all CAN communication connectors on
each controller. Then, identify whether the failure is short circuit
between wiring harnesses or inside the controller.
Disconnection or short circuit
3 Resis- Approx. 60
in wiring harness Between ATC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
Between J2P (female) (46) and (47)
tance Mz
Resis- Approx. 60
Between J2C (female) (46) and (47)
tance Mz
Resis- Approx. 60
Between DPC4 (female) (3) and (8)
tance Mz
Resis- Approx. 60
Between BRC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
Between HM-CN4A (female) (4) and (12)
tance Mz
Possible causes
Resis- Approx. 60
and standard Between ABS2 (female) (32) and (22)
tance Mz
value in normal
state 1) Turn the starting switch to OFF position and disconnect the bat-
tery ground cable.
2) Insert the T-adapter into connectors ATC3, J2P, J3P, J2C, J3C,
DPC1, BRC3, HM-CN1 and ABS3.
3) Connect the battery ground cable and turn the starting switch to
ON position.
Between ATC3(14) and (21) Voltage 20 - 30 V
Defective ACC signal from Between J2P (39) and J3P (1) Voltage 20 - 30 V
starting switch
4
(Start of CAN communication Between J2C (39) and J3C (1) Voltage 20 - 30 V
is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Between DPC1 (7) and (10) Voltage 20 - 30 V
Between BRC3 (14) and (21) Voltage 20 - 30 V
Between HM-CN1 (17) and (19) Voltage 20 - 30 V
Between ABS3 (14) and (21) Voltage 20 - 30 V
a If no failure is found by check on cause 4, this check is not
required.
Disconnection in wiring har- tery ground cable.
ness 2) Disconnect the connectors ATC2, J2P, J2C, DPC4, BRC2, HM-
5 (Wire breakage or defective
CN4A, CAN2, CAN3 and ABS2, and connect the T-adapter to
contact of connector)
their female side.
Between ATC2 (female) (32) and CAN2 Resis-
Max. 1 z
(female) (A) tance
26 HD785-7

Max. 1 z
(female) (B) tance
Between ATC2 (female) (32) and BRC2 Resis-
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Between ATC2 (female) (32) and DPC4 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Between ATC2 (female) (32) and J2P Resis-
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Between ATC2 (female) (32) and J2C Resis-
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Between ATC2 (female) (32) and DL (male) Resis-
Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
and standard Disconnection in wiring har- (female) (B) tance
value in normal ness Between ATC2 (female) (32) and ABS2 Resis-
5
(Wire breakage or defective Max. 1 z
state (female) (32) tance
Between ATC2 (female) (22) and ABS2 Resis-
Max. 1 z
(female) (22) tance
Between ATC2 (female) (32) and HM-CN4A Resis-
Max. 1 z
(female) (4) tance
Between ATC2 (female) (22) and HM-CN4A Resis-
Max. 1 z
(female) (12) tance
required.
tery ground cable.
2) Disconnect connectors ATC3, J2P, J2C, DPC1, BRC3, HM-CN1
and ABS3, and connect the T-adapter to their female side.
Between starting switch (ACC) and ATC3 Resis-
Max. 1 z
(female) (14), (24) tance
Between starting switch (ACC) and DPC1 Resis-
Max. 1 z
Between starting switch (ACC) and J2P Resis-
Max. 1 z
(female) (39) tance
Between starting switch (ACC) and J2C Resis-
Max. 1 z
(female) (39) tance
Between starting switch (ACC) and BRC3 Resis-
Max. 1 z
Between starting switch (ACC) and HM- Resis-
Max. 1 z
CN1 (female) (17) tance
Between starting switch (ACC) and ABS3 Resis-
Max. 1 z
HD785-7 27

a If no failure is found by check on cause 4 (no disconnection is
found), taking a measurement in only one location is sufficient.
tery ground cable.
2) Disconnect the connectors ATC2, J2P, J2C, DPC4, BRC2, HM-
CN4A and ABS2, and connect the T-adapter to their female
Ground fault in wiring har- side.
6 ness Between ground and either J2P (female)
(Contact with ground circuit) (46), J2C (female) (46), ATC2 (female) (32), Resis-
Min. 1 z
DPC4(female) (3), BRC2 (female) (32), HM- tance
CN4A (female) (4), or ABS2 (female) (32)
Between ground and either J2P (female)
(47), J2C (female)(47), ATC2 (female) (22), Resis-
Min. 1 z
DPC4(female) (8), BRC2 (female) (22), HM- tance
a If no failure is found by check on cause 4 (no open circuit is
found), taking a measurement in only one location is sufficient.
tery ground cable.
CN4A and ABS2, and connect the T-adapter to their female
side.
3) Connect the battery ground cable.
4) Turn the starting switch to ON position.
Short circuit or hot short cir- a Since voltages of CAN (+) and CAN (-) are 2.5 ± 1 V even while
7 cuit in wiring harness (con- communication is continued, they are judged to be normal if
tact with 24 V circuit) they are 1 - 4 V.
Possible causes Between ground and either J2P (female)
and standard (46), J2C (female) (46), ATC2 (female) (32),
Voltage 1-4V
value in normal DPC4(female) (3), BRC2 (female) (32), HM-
state CN4A (female) (4), or ABS2 (female) (32)
Between ground and either J2P (female)
(47), J2C (female)(47), ATC2 (female) (22),
Voltage 1-4V
DPC4(female) (8), BRC2 (female) (22), HM-
• When the above checks are normal and a failure code for
[DBBQKR] is additionally displayed, transmission controller may
be deffective.
• When the above checks are nomal and failure code for
[DBBQKR] is not displayed
a Identify which controller is defective by disconnecting the con-
nector one by one from the CAN communication by repeating
the following steps 1) through 3).
Either the engine controller
(right and left bank), the
tery ground cable.
transmission controller, the
8 2) Disconnect CAN communication connector of the engine con-
retarder controller, the VHMS
troller (right and left bank), the transmission controller, the
& PLM controller or the ABS
retarder controller, the VHMS & PLM controller and the ABS
controller is defective
controller one by one sequentially (see the related circuit dia-
gram).
3) Connect the battery ground cable, turn the starting switch to ON
position and perform troubleshooting.
4) Return to Step 1 to troubleshoot the next controller.
Did failure code for [DAQRKR] change to If YES, the controller
[D**RKR] (other than [DAQRKR]), that was removed is
[DBBQKR] or [dB2RKR]? defective.
a If no abnormality is found in the above troubleshooting, the
9 Defective machine monitor machine monitor may be defective. (Since this is an internal
28 HD785-7
HD785-7 29
Failure code [DAQRMA] Transmission controller option setting:

Malfunction 1
Action code Failure code Transmission controller option setting: Malfunction
Trouble (Machine monitor-transmission controller)
E03 DAQRMA (Machine monitor system)
Contents of • Option setting signals inputted from machine monitor with the starting switch ON are different from
trouble the option settings that controller memorizes.
• Holds the gear speed in neutral.
Action of
• Controls with the option setting that the controller memorizes.
machine monitor
• It does not return normal unless the starting switch is turned OFF.
Problem that
appears on • The gear speed becomes neutral and the machine cannot move off again.
machine
Related
• Perform initial setting and initial adjustment as when transmission controller is replaced.
information

and standard
value in normal Defective option setting of machine monitor or internal defect of
state monitor
Failure code [DB10KT] Retarder controller nonvolatile memory:

Abnormality in controller 1
Action code Failure code Retarder controller nonvolatile memory: Abnormality in controller
Trouble
E01 DB10KT (Retarder controller system)
Contents of
• An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine parameter may change and power may increase or decrease.
machine
Related
information

and standard
value in normal Since this is an internal defect, it cannot be diagnosed.
state Replace to controller.
30 HD785-7
Failure code [DB12KK] Retarder controller solenoid power supply:

Power supply system trouble 1
Action code Failure code Retarder controller solenoid power supply: Power supply system
Trouble trouble
E03 DB12KK (Retarder controller system)
Contents of • While controller direct power supply voltage is normal, solenoid power supply voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power supply.
Problem that • All systems of retarder controller do not operate. (retarder, dump, automatic suspension, ARSC and
appears on ASR)
machine • Failure code (DHU2KX and DHU3KX) are displayed at the same time.
• If the fuse is blown, check for ground fault of line from fuse – BRC3 (female) (2), (12), (22).
Related
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power supply) is displayed, carry
out troubleshooting for it first.

When circuit breaker FuB2 is tripped or fuse BT3 (11) and (12) is
1 FuB2 or defective fuse BT3
(11) and (12)
2) Disconnect negative (–) terminal of battery and connector BRC3
(female) and connect T-adapter to BRC3.
Between battery terminal M and ground Voltage 20 – 30 V
Disconnection in wiring Between BRC3 (female) (2), (12), (22) and
Voltage 20 – 30 V
Possible causes harness ground
2
and standard (Disconnection or defective If voltage at fuse BT3 (12) is normal and voltage at BRC3 (2), (12),
value in normal contact) (22) is abnormal, wiring harness between fuse (12) and BRC3
state (female) (2), (12), (22) has disconnection.
2) Disconnect negative (–) terminal of battery and connector
BRC3, and connect T-adapter to BRC3 (female).
Between BRC3 (female) (21), (31), (32), Resis-
Max. 1 z
(33) and ground tance
into BRC3.
3 Defective retarder controller 3) Connect negative (–) terminal of battery.
Between BRC3 (2), (12), (22) and ground Voltage 20 – 30 V
HD785-7 31
32 HD785-7
Failure code [DB13KK] Retarder controller battery direct power supply:

Action code Failure code Retarder controller battery direct power supply: Power supply volt-
Trouble age too low
E03 DB13KK (Retarder controller system)
Contents of
• Controller power supply voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • Retarder does not operate.
machine
• When the fuse is blown, check the short circuit of line from fuse – BRC3 (female) (1), (11), (2), (12),
Related (22).
information • If failure code "DAQ0KK" or "DAQ2KK" (transmission controller power supply) is displayed, carry

a Check battery voltage and electrolyte specific gravity.
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
When circuit breaker FuA2 is tripped or fuse BT2 (21) and (22) is
2 FuA2 or defective fuse
BT2(21) and (22)
2) Disconnect battery (–) terminal and connector BRC3 and con-
nect T-adapter to BRC3 (female).
Between BRC3 (female) (21), (31), (32),
Resis-
(33) and ground Max. 1 z
tance
Possible causes a Looseness or rusting on ER1 terminal
value in normal Disconnection in wiring har- 2) Disconnect battery (–) terminal and insert T-adapter in BRC3.
state ness 3) Connect battery (–) terminal.
3 (Disconnection in wiring or
Between battery relay terminal B and
defective contact in connec- Voltage 20 – 30 V
ground
tor)
Between BRC3 (1), (11) and ground Voltage 20 – 30 V
2) Disconnect battery (–) terminal and connect T-adapter to BRC3
(female).
If there is voltage between battery relay terminal B and ground but
not between BRC3 (1), (11) and ground, wiring harness or fuse is
broken.
Defective transmission con- 2) Disconnect battery (–) terminal and insert T-adapter in BRC3.
4 3) Connect battery (–) terminal.
troller
Between BRC3 (1), (11) and ground Voltage 20 – 30 V
HD785-7 33
34 HD785-7
Failure code [DB19KQ] Disagreement of model selection (Retarder

controller) 1
Action code Failure code Disagreement of model selection (Retarder controller)
Trouble
E03 DB19KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in retarder controller.
Action of • Turns all outputs OFF.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • When operator performs starting operation, machine does not start.
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.
information • Method of reproducing failure code: Turn starting switch ON.

Failure code [DB19KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
machine monitor After replacing machine monitor or retarder controller, set them
value in normal
correctly according to Testing and adjusting volume.
state
Defective transmission con- Wrong reterder controller may be installed. Check its part No. and
2
troller install correct reterder controller.
HD785-7 35
Failure code [DB1RKR] CAN communication (retarder controller):

Communication disabled 1
Action code Failure code Abnormal CAN communication (retarder controller): Communication
disabled
Trouble
E03 DB1RKR (Between retarder controller – transmission controller)
Contents of
trouble • Updating of received data from retarder controller has stopped.
• AISS is locked in LOW. (until starting switch is turned OFF.)

Action of
controller • Keep the information at the time when abnormality occurred.
Problem that
appears on • The information and special functions which are retrieved from retarder controller do not work or
machine display.

switch is received.
• If a failure code for [D**RKR], [dB2RKR] or [DBBQKR] is additionally displayed, write down every
failure code displayed.
Related • The fact that a failure code for [DB2RKR] is displayed means that CAN communication is estab-
information lished at least between the transmission controller and the machine monitor.
Therefore, there is no short circuit, ground fault or hot short circuit in the CAN communication line.
• Since power to each controller and machine monitor is fed directly from the battery, supply of their
power remains uninterrupted even when the starting switch is turned OFF.
using a multimeter.

1 Perform troubleshooting for [DB13KK]
retarder controller
1) Turn the starting switch to OFF position
2) Disconnect connector CAN2 and CAN3, and connect the T-adpter
Defective CAN terminating to male side.
resistor
(Internal open or short cir- side) 120 ± 12 z
tance
cuit)
Between CAN2 (male) (A) and (B) (engine Resis-
120 ± 12 z
cab) tance
Possible causes Therefore, an disconnection has not occurred in the communica-
and standard
tion line when the combined resistance of 60 z is measured
value in normal
state from any connector.
tery ground cable.
Disconnection or short cir- J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
3 adapter to the female side of the disconnected connector.
cuit in wiring harness
a If a short circuit is detected (resistance between terminals is 1 z
or less), disconnect all CAN communication connectors on each
controller. Then, identify whether the failure is short circuit
Resis- Approx. 60
Between ATC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
tance Mz
36 HD785-7

Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Disconnection or short cir- Resis- Approx. 60
3 Between BRC2 (female) (32) and (22)
cuit in wiring harness tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
Between ABS2 (female) (32) and (22)
tance Mz
1) Turn the starting switch to OFF position and disconnect the battery
ground cable.
ON position.
starting switch
4
(Start of CAN communica- Between J2C (39) and J3C (1) Voltage 20 - 30 V
tion is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Possible causes
and standard Between BRC3 (24) and (31) Voltage 20 - 30 V
value in normal Between HM-CN1 (17) and (19) Voltage 20 - 30 V
state
required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
Disconnection in wiring har- (female) (B) tance
ness
5 (Wire breakage or defective Between ATC2 (female) (32) and BRC2 Resis-
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
HD785-7 37

Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Between ATC2 (female) (32) and HM- Resis-
Max. 1 z
CN4A (female) (4) tance
Disconnection in wiring har- Between ATC2 (female) (22) and HM- Resis-
ness Max. 1 z
5
(Wire breakage or defective
Possible causes a If no failure is found by check on cause 5, this check is not
and standard required.
value in normal 1) Turn the starting switch to OFF position and disconnect the bat-
state tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
Max. 1 z
(female) (39) tance
Max. 1 z
Max. 1 z
Max. 1 z
Defective retarder control-
6 machine monitor may be defective. (Since this is an internal
ler
38 HD785-7
HD785-7 39
Failure code [DB1RMA] Disagreement of option setting (Retarder

controller) 1
Action code Failure code Disagreement of option setting (Retarder controller)
Trouble
E03 DB1RMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in retarder controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.

Possible causes Option may be set wrongly in machine monitor. When machine
Wrong option setting in
and standard 1 monitor or retarder controller is replaced, set it correctly according
machine monitor
value in normal to Testing and adjusting.
state If cause 1 is not detected, machine monitor may be defective.
40 HD785-7
Failure code [DB2RKR] CAN communication (engine controller):

Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 DB2RKR (Transmission controller system)
• Updating of received data from engine controller has stopped.
Contents of • The transmission controller cannot recognize the engine controller of left bank in the CAN commu-
trouble nication.
1) CAN communication circuit error
• keep the current gear speed.
Action of • Set the gearshift lever in the "N" position to keep the transmission in neutral.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.

switch is received.
• The fact that a failure code for [DB2RKR] is displayed means that CAN communication is estab-
Related
lished at least between the transmission controller and the machine monitor.
information
Therefore, there is no short circuit, ground fault or hot short circuit in the CAN communi-
cation line.
using a multimeter.

2) Remove fuses at the 5th and 6th from the bottom of BT3 and
1 Blowout of fuse the top fuse of BT2.
Between fuse terminals Continuity
a If fuse is not brown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J3P and connect T-adapter to male side.
Defective engine controller of a Measured value: Approx. 9-20 kz
2 left bank a If measured value is below 10 kz, engine controller is defec-
Possible causes (Internal short circuit) tive (internal short circuit).
and standard
Resis-
value in normal Between J3P (male) (3) and (1) Max. 10 z
tance
state
tery ground cable.
2) Insert the T-adapter into connector J3P
3) Perform troubleshooting by connecting the battery ground
Defective power supply to cable.
3
engine controller a If abnormality is found, perform troubleshooting for Detail of
failure 2) "Abnormality in input power supply circuit for engine
controller of left bank".
Between J3P (3) and (1) Voltage 20 - 30 V
Between J3P (4) and (2) Voltage 20 - 30 V
HD785-7 41

2) Disconnect connector CAN2 and CAN3, and connect the T-
Defective CAN terminating adapter to male side.
resistor
side) tance
cuit)
120 ± 12 z
cab) tance
from any connector.
tery ground cable.
each controller. Then, identify whether the failure is short cir-
cuit between wiring harnesses or inside the controller.
5 Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Possible causes Resis- Approx. 60
and standard tance Mz
value in normal
Resis- Approx. 60
state Between DPC4 (female) (3) and (8)
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
6
42 HD785-7

required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Max. 1 z
(female) (46) tance
Possible causes Between ATC2 (female) (22) and J2C Resis-
Disconnection in wiring har- Max. 1 z
and standard (female) (47) tance
value in normal ness
7 (Wire breakage or defective Between ATC2 (female) (32) and DL (male) Resis-
state Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Max. 1 z
required.
tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
HD785-7 43

Max. 1 z
(female) (39) tance
ness (female) (14), (24) tance
7
(Wire breakage or defective Between starting switch (ACC) and HM- Resis-
contact of connector) Max. 1 z
Possible causes
value in normal (female) (14), (24) tance
state a If no abnormality is found in the above check and in the trou-
bleshooting for Detail of failure 2, "Abnormality in input power
8 Defective engine controller supply circuit for engine controller of left bank", the engine con-
troller may be defective. (Since this is an internal defect, trou-
bleshooting cannot be performed.)
44 HD785-7
HD785-7 45
Contents of • The transmission controller cannot recognize the engine controller in the CAN communication.
trouble 2) Abnormality in input power supply circuit for engine controller of left bank.

Defective circuit breaker (60 If a circuit breaker is tripped, the circuit probably has a ground
1
A) fault. (See cause 3.)
2 Blowout of fuse 2) Remove the 5th fuse from the bottom of BT3.
tery ground cable.
2) Perform troubleshooting with the switch turned OFF.
Possible causes Disconnection in wiring har-
Between circuit breaker (60 A) terminal and Resis-
and standard ness Max. 1 z
3 BT3 (21) tance
value in normal (Wire breakage or defective
Between BT3(22) and J3P (female) (3) or Resis-
state contact of connector) Max. 1 z
(4) tance
Between J3P (female) (1), (2) and ground Resis-
Max. 1 z
(GS) tance
tery ground cable.
Ground fault in wiring har- 2) Perform troubleshooting with the switch turned OFF.
4 ness Resis-
Between ground and BT3 (21) Min. 1 z
(Contact with ground circuit) tance
Between ground and BT3 (22) or J3P Resis-
Min. 1 z
(female) (3) or (4) tance
46 HD785-7
Failure code [dB2RKR] CAN communication (engine controller):

Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 dB2RKR (Transmission controller system)
• Updating of received data from engine controller has stopped.
Contents of • The transmission controller cannot recognize the engine controller of right bank in the CAN commu-
trouble nication.
1) CAN communication circuit error
• keep the current gear speed.
Action of • Set the gearshift lever in the "N" position to keep the transmission in neutral.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.

switch is received.
• If a failure code for [D**RKR] or [DBBQKR] is additionally displayed, write down every failure code
displayed.
Related
information
cation line.
using a multimeter.

2) Remove fuses at the 3th and 6th from the bottom of BT3 and
1 Blowout of fuse the top fuse of BT2.
a If fuse is not brown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J3C and connect T-adapter to male side.
Defective engine controller of a Measured value: Approx. 9-20 kz
2 right bank a If measured value is below 10 kz, engine controller is defec-
Possible causes (Internal short circuit) tive (internal short circuit).
and standard
Resis-
value in normal Between J3C (male) (3) and (1) Max. 10 z
tance
state
tery ground cable.
2) Insert the T-adapter into connector J3C
3) Perform troubleshooting by connecting the battery ground
Defective power supply to cable.
3
engine controller a If abnormality is found, perform troubleshooting for Detail of
failure 2) "Abnormality in input power supply circuit for engine
controller of right bank".
Between J3C (3) and (1) Voltage 20 - 30 V
Between J3C (4) and (2) Voltage 20 - 30 V
HD785-7 47

Defective CAN terminating adapter to male side.
resistor
side) tance
cuit)
120 ± 12 z
cab) tance
from any connector.
tery ground cable.
each controller. Then, identify whether the failure is short cir-
cuit between wiring harnesses or inside the controller.
5 Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Possible causes Resis- Approx. 60
and standard tance Mz
value in normal
Resis- Approx. 60
state Between DPC4 (female) (3) and (8)
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
6
48 HD785-7

required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Max. 1 z
(female) (46) tance
Possible causes Between ATC2 (female) (22) and J2C Resis-
and standard (female) (47) tance
value in normal ness
7 (Wire breakage or defective Between ATC2 (female) (32) and DL (male) Resis-
state Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Max. 1 z
required.
tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
HD785-7 49

Max. 1 z
(female) (39) tance
ness (female) (14), (24) tance
7
(Wire breakage or defective Between starting switch (ACC) and HM- Resis-
contact of connector) Max. 1 z
Possible causes
value in normal (female) (14), (24) tance
state a If no abnormality is found in the above check and in the trou-
bleshooting for Detail of failure 2, "Abnormality in input power
8 Defective engine controller supply circuit for engine controller of right bank", the engine
controller may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
50 HD785-7
HD785-7 51
Contents of • The transmission controller cannot recognize the engine controller in the CAN communication.
trouble 2) Abnormality in input power supply circuit for engine controller of right bank.

Defective circuit breaker (60 If a circuit breaker is tripped, the circuit probably has a ground
1
A) fault. (See cause 3.)
2 Blowout of fuse 2) Remove the 3th fuse from the bottom of BT3.
tery ground cable.
2) Perform troubleshooting with the switch turned OFF.
Possible causes Disconnection in wiring har-
Between circuit breaker (60 A) terminal and Resis-
and standard ness Max. 1 z
3 BT3 (25) tance
value in normal (Wire breakage or defective
Between BT3(26) and J3C (female) (3) or Resis-
state contact of connector) Max. 1 z
(4) tance
Between J3C (female) (1), (2) and ground Resis-
Max. 1 z
(GS) tance
tery ground cable.
Ground fault in wiring har- 2) Perform troubleshooting with the switch turned OFF.
4 ness Resis-
Between ground and BT3 (25) Min. 1 z
Between ground and BT3 (26) or J3C Resis-
Min. 1 z
(female) (3) or (4) tance
52 HD785-7
HD785-7 53
Failure code [DBB0KK] or VHMS_LED display: "n9" o "01" 1

VHMS controller: Low power supply voltage (input)
Action code Failure code VHMS controller: Low power supply voltage (input)
Trouble
– DBB0KK (VHMS controller system) (Display: PLM)
Contents of
• Voltage of VHMS controller switch fell to below 19.5 V while the engine speed is above 500 rpm.
trouble
Action of • None in particular.
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays "n9" o "01".
• Method of reproducing failure code: Start engine and raise the engine speed above 500 rpm

Defective fuse No.(19), (20) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT1 (See cause 3.)
Disconnection in wiring har- ing without turning starting switch ON.
ness Between fuse No.10 (20) of fuse box BT1 Resis-
2 Max. 1 z
(Disconnection or defective and HM-CN1 (female) (8), (9) tance
contact) Between HM-CN1 (female) (11), (12), (19), Resis-
(20) and chassis ground tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state Grounding fault in wiring har- ing without turning starting switch ON.
3 ness Between fuse No.10 (20) of fuse box BT1 or
(Contact with ground circuit) HM-CN1 (female) (8), (9) and chassis Resis- Min. 1
tance Mz
ground
ing after starting engine and raising the engine speed above
Defective VHMS & PLM con- 500 rpm
4
troller
Between HM-CN1 (8), (9) and (11), (12),
Voltage 20 – 30 V
(19), (20) or chassis ground
54 HD785-7
HD785-7 55
Failure code [DBB0KQ] (or VHMS_LED display: "nF" o "11")

VHMS controller: Disagreement of model selection signals 1
Action code Failure code VHMS controller: Disagreement of model selection signals
Trouble
— DBB0KQ (VHMS controller system) (Display: PLM)
Contents of
• Improperly connected connectors were detected.
trouble
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The system may not work properly.
machine
information • The LED of the VHMS controller displays "nF" o "11".

Possible Improperly connected con-
Check connection between HM-CN2A and HM-CN3A connectors,
causes and 1 nectors in VHMS controller
and HM-CN2B and HM-CN3B connectors for abnormality.
standard value (when the system is normal)
in normal state Defective VHMS & PLM If the above is normal, VHMS & PLM controller may be defective.
2
controller (Since trouble is in system, troubleshooting cannot be carried out.)
56 HD785-7
HD785-7 57

VHMS controller battery power supply: Low power supply voltage (input) 1
Action code Failure code VHMS controller: Low power supply voltage (input)
Trouble
Contents of
• Constant voltage of VHMS controller fell to below 10 V.
trouble
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on –
machine
• Method of reproducing failure code: Keep the starting switch turned OFF

Defective fuse No.(29), (30) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT2 (See cause 3.)
Disconnection in wiring har- ing without turning starting switch ON.
ness Between fuse No.25 (30) of fuse box BT2 Resis-
2 Max. 1 z
(Disconnection or defective and HM-CN1 (female) (6), (7) tance
Possible causes contact) Between HM-CN1 (female) (11), (12), (19), Resis-
Max. 1 z
and standard (20) and chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Grounding fault in wiring har-
3 ness Between fuse No.25 (30) of fuse box BT2 or
(Contact with ground circuit) HM-CN1 (female) (6), (7) and chassis Resis- Min. 1
tance Mz
ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective VHMS & PLM con- and carry out troubleshooting
4
troller Between HM-CN1 (6), (7) and (11), (12),
Voltage 20 – 30 V
(19), (20) or chassis ground
58 HD785-7
HD785-7 59

VHMS controller 5 V power supply output: Low output voltage 1
Action code Failure code VHMS controller 5 V power supply output: Low output voltage
Trouble
Contents of
• VHMS controller 5 V sensor power supply is shorted with the chassis ground.
trouble
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked
Related by downloading data stored in the VHMS controller).

Grounding fault in wiring har- ing without turning starting switch ON.
Possible causes 1 ness
and standard (Contact with ground circuit) Between HM-CN1 (female) (4), (5) or HM12 Resis- Min. 1 Mz
(female) (B) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
2
troller Between HM-CN1 (female) (4), (5) and
Voltage 4.5 – 5.5 V
HMCN2A (female) (12) or chassis ground
60 HD785-7
HD785-7 61

Trouble
– DBB6KP (VHMS controller system) (Display: PLM)
Contents of • VHMS controller 24 V sensor and VHMS indicator lamp power supply is shorted with the chassis
trouble ground.
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked
Related by downloading data stored in the VHMS controller).

Possible causes 1 ness Between HM-CN1 (female) (2) or HN25
(Contact with ground circuit) (female) (2), or HM-23A (female) (A), or Resis-
tance
value in normal HM-23B (female) (A) and chassis ground
2
troller Between HM-CN1 (2) and (11), (12), (19),
Voltage 20 – 30 V
(20) or chassis ground
62 HD785-7
HD785-7 63

Trouble
– DBB7KP (VHMS controller system) (Display: PLM)
Contents of
• VHMS controller 12 V indicator lamp power supply is shorted with the chassis ground.
trouble
Problem that
appears on –
machine

Possible causes 1 ness
and standard (Contact with ground circuit) Between HM-CN1 (female) (3) or LM1 and Resis-
Min. 1 Mz
chassis ground tance
value in normal
2
troller Between HM-CN1 (3) and (11), (12), (19), 11.5 – 12.5
Voltage
(20) or chassis ground V
64 HD785-7
Failure code [DBBQKR] (or VHMS_LED display: "n8" o "02")

VHMS controller CAN communication: Defective communication
(Abnormality in target component system) 1
Action code Failure code VHMS controller CAN communication: Defective communication
Trouble (Abnormality in target component system)
– DBBQKR (VHMS controller system) (Display: PLM)
Contents of
• CAN communication information from each controller cannot be received.
trouble
Action of
machine monitor
Problem that
appears on • The system may not work properly.
machine

and standard
value in normal Carry out troubleshooting for failure code [DAQRKR], [DB1RKR], [DB2RKR] or [DBCRKR].
state
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 1

Action code Failure code Abnormality in CAN communication (VHMS)
Trouble
E03 DBBRKR (Machine monitor system)
Contents of • Machine monitor cannot obtain information from VHMS controller through CAN communication cir-
trouble cuit.
Action of
machine monitor
Problem that
appears on
machine • Information from VHMS controller is not displayed.
Related
information

and standard Defetive power supply for Carry out troubleshooting for failure code [DBB0KK] and
1
value in normal VHMS controller [DBB3KK].
state 2 Carry out troubleshooting for failure code [DAQRKR] (Cause 2 and after)
HD785-7 65
Failure code [DBC2KK] ABS controller solenoid power supply: Power

supply system trouble 1
Action code Failure code ABS controller solenoid power supply: Power supply system trou-
Trouble ble
E03 DBC2KK (ABS controller system)
Contents of • While controller direct power supply voltage is normal, solenoid power supply voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power supply.
Problem that
appears on • All systems of ABS controller do not operate.
machine
Related
• If the fuse is blown, check for ground fault of line between fuse and ABS3 (female) (2), (12), (22).
information

Defective circuit breaker If a circuit breaker is tripped, the circuit probably has a ground
1
(FuB2) fault. (See cause 4.)
2) Remove No.30 of fuse BT3 (5th fuse from the top).
2 Defective No.30 of fuse BT3
If the fuse is blown, the circuit probably has a ground fault. (See
cause 4).
2) Disconnect negative (–) terminal of battery and connector ABS3
and connect T-adapter to ABS3 (female).
Between battery terminal M and ground Voltage 20 – 30 V
Disconnection in wiring Between ABS3 (2), (12), (22) and ground Voltage 20 – 30 V
harness If voltage at fuse BT3 No.30 (9) is normal and voltage at ABS3 (2),
3
(Disconnection or defective (12), (22) is abnormal, wiring harness between fuse No.30 (10)
Possible causes contact) and ABS3 (female) (2), (12), (22) has disconnection.
and standard
value in normal
2) Disconnect negative (–) terminal of battery and connector ABS3,
state
and connect connect T-adapter to ABS3 (female).
Between ABS3 (female) (21), (31), (32),
Resis-
tance
tery ground cable.
Ground fault in wiring har- 2) If No.30 of fuse BT3 is blown, replace it with a new one.
4 ness 3) Disconnect connector ABS3 and connect the T-adapter to
(Contact with ground circuit) female side.
Between ground and ABS3 (female) (2), Resis-
Min. 1 z
(12), (22) tance
in ABS3.
5 Defective ABS controller 3) Connect negative (–) terminal of battery.
Between ABS3 (2), (12), (22) and ground Voltage 20 – 30 V
66 HD785-7
HD785-7 67
Failure code [DBC3KK] ABS controller battery direct power supply:

Action code Failure code ABS controller battery direct power source: Power supply voltage
Trouble too low
E03 DBC3KK (ABS controller system)
Contents of
• Controller power supply voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • ABS does not operate.
machine
Related
• When the fuse is blown, check the ground faulf of line between fuse and ABS3 (female) (1), (11).
information

a Check battery voltage and electrolyte specific gravity.
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
Defective circuit breaker If a circuit breaker is tripped, the circuit probably has a ground
2
(FuA2) fault. (See cause 4.)
2) Remove No.21 of fuse BT2 (5th fuse from the bottom).
3 Defective No. 21 of fuse BT2
If the fuse is blown, the circuit probably has a ground fault. (See
cause 4).
2) Disconnect battery (–) terminal and connector ABS3, and con-
nect T-adapter to ABS3 (female).
Between ABS3 (female) (21), (31), (32),
Resis-
tance
Possible causes Disconnection in wiring har- 1) Turn starting switch OFF.
and standard ness 2) Disconnect battery (–) terminal and connector ABS3, and con-
value in normal 4 (Disconnection in wiring or nect T-adapter in ABS3 (female).
state defective contact in connec- 3) Connect battery (–) terminal.
tor)
Between battery relay terminal B and
Voltage 20 – 30 V
ground
Between ABS3 (1), (11) and ground Voltage 20 – 30 V
If there is voltage between battery relay terminal B and ground but
not between ABS3 (1), (11) and ground, wiring harness or fuse is
broken.
tery ground cable.
Ground fault in wiring har- 2) If No.21 of fuse BT2 is blown, replace it with a new one.
5 ness 3) Disconnect connector ABS3 and connect the T-adapter to
(Contact with ground circuit) female side.
Between ground and ABS3 (female) (1), Resis-
Min. 1 z
(11) tance
Defective transmission con- 2) Disconnect battery (–) terminal and insert T-adapter to ABS3.
6 3) Connect battery (–) terminal.
troller
Between ABS3 (1), (11) and ground Voltage 20 – 30 V
68 HD785-7
HD785-7 69
Failure code [DBC9KQ] Disagreement of model selection (ABS

controller) 1
Action code Failure code Disagreement of model selection (ABS controller)
Trouble
E03 DBC9KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in ABS controller.
Action of • Turns all outputs OFF.
Problem that
• ABS does not operate.
appears on
• All ABS output is turned OFF.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBC9KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
Installation of wrong ABS Wrong ABS controller may be installed. Check part No. of installed
2
controller ABS controller and install normal ABS controller.
70 HD785-7
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1

Action code Failure code Abnormality in CAN communication (ABS)
Trouble
E03 DBCRKR (Transmission controller system)
Contents of • Machine monitor cannot obtain information from ABS controller through CAN communication cir-
trouble cuit.
Action of
machine monitor
Problem that
appears on
• Information from ABS controller is not displayed.
machine
switch is received.
Related
information
cation line.
using a multimeter.

1 Perform troubleshooting for [DB13KK]
retarder controller
1) Turn the starting switch to OFF position
Defective CAN terminating adpter to male side.
resistor
side) tance
cuit)
Between CAN2 (male) (A) and (B) (engine Resis-
120 ± 12 z
cab) tance
Possible causes Therefore, an disconnection has not occurred in the communi-
and standard
value in normal
state from any connector.
tery ground cable.
Disconnection or short cir- J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
3 adapter to the female side of the disconnected connector.
cuit in wiring harness
each controller. Then, identify whether the failure is short circuit
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
HD785-7 71

Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
Disconnection or short cir- Resis- Approx. 60
3 Between BRC2 (female) (32) and (22)
cuit in wiring harness tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
4 Between J2C (39) and J3C (1) Voltage 20 - 30 V
(Start of CAN communica-
tion is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Possible causes
and standard Between BRC3 (24) and (31) Voltage 20 - 30 V
value in normal Between HM-CN1 (17) and (19) Voltage 20 - 30 V
state
required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
ness
5 (Wire breakage or defective Between ATC2 (female) (32) and BRC2 Resis-
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
72 HD785-7

Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Between ATC2 (female) (32) and DL Resis-
Max. 1 z
(male) (3) tance
Between ATC2 (female) (22) and DL Resis-
Max. 1 z
(male) (10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Disconnection in wiring har- Between ATC2 (female) (22) and HM- Resis-
ness Max. 1 z
5
Possible causes a If no failure is found by check on cause 5, this check is not
value in normal 1) Turn the starting switch to OFF position and disconnect the bat-
state tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
Max. 1 z
(female) (39) tance
Max. 1 z
Max. 1 z
Max. 1 z
6 Defective ABS controller ABS controller may be defective. (Since this is an internal
HD785-7 73
74 HD785-7
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1

Action code Failure code Disagreement of option setting (ABS controller)
Trouble
E03 DBCRMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in ABS controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
Problem that
appears on • Non in particular.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBCRMA] is not displayed.
Possible causes
Wrong option setting in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
If cause 1 is not detected, machine monitor may be defective.
HD785-7 75
Failure code [DBG2KK] Solenoid power supply: Low voltage

Action code Failure code Solenoid power supply: Low voltage
Trouble
E03 DBG2KK (Pre-lubrication controller system)
Contents of
• During starting switch is ON, solenoid supply voltage below 18 V is detected.
trouble
• Turns pre-lubrication relay output OFF.
Action of
• Turns pre-heating relay output OFF.
controller
• Turns engine start relay output OFF.
Problem that • The engine does not start.
appears on • No pre-lubrication effected
machine • No pre-heating effected
Related
information
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power sup- 2) Disconnect PRE5 and connect T-branch.
1
ply pin voltage is 3) Start the engine and carry out troubleshooting.
normal) Between PRE5 (30) – (31) Voltage 20 – 30 V
2 Fuse disconnection Fuse box BT2: Fuse (11) Continuity Yes
3 Circuit breaker operated Between circuit breaker (62) – (63) Continuity Yes
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect PRE5 and alternator terminal B and carry out trou-
Disconnection in wiring har- bleshooting.
value in normal ness (Disconnection or
state 4 Between PRE5 (female) (30) – alternator Resis-
defective contact in Max. 1 z
terminal B tance
connector)
Between PRE5 (female) (21), (31) and Resis-
Max. 1 z
Ground fault in wiring 2) Disconnect PRE5 and alternator terminal B and carry out trou-
5 harness (Contact with bleshooting.
ground circuit) Between PRE5 (female) (30) and chassis Resis- Min. 1
ground tance Mz
76 HD785-7
HD785-7 77
Failure code [DBG3KK] Battery direct power supply: Low voltage

Action code Failure code Battery direct power supply: Low voltage
Trouble
E03 DBG3KK (Pre-lubrication controller system)
Contents of
• Supply voltage of controller is low.
trouble
Action of
• Stops judging other errors caused by low voltage
controller
Problem that
appears on • Engine may not be able to start.
machine
Related
information
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power 2) Disconnect PRE5 and connect T-branch.
supply pin (40) voltage is 3) Start the engine and carry out troubleshooting.
normal)
1
a Check which path Between PRE5 (1) and (11) – (31) Voltage 20 – 30 V
poses problem since
each pin (1) and pin (2) Between PRE5 (2) and (12) – (31) Voltage 20 – 30 V
have different path.
Fuse box BT2: Fuse (19) Continuity Yes
2 Fuse disconnection
Fuse box BT2: Fuse (29) Continuity Yes
Circuit breaker(30A) oper- Directly check circuit breaker (30A). (If the circuit breaker is shut
3
ated down, the circuit probably has a grounding fault, etc.)
1) Check starting switch unit.
4 Defective starting switch 2) Turn starting switch ON position,Then carry out troubleshooting.
Possible causes Between terminal B – terminal ACC Continuity Yes
value in normal 2) Disconnect PRE5.
state 3) Turn starting switch ON and carry out troubleshooting.
Between PRE5 (female) (1), (11) and chassis
Disconnection in wiring Voltage 20 – 30 V
ground
harness (Disconnection or
5 Between PRE5 (female) (2), (12) and chassis
defective contact in Voltage 20 – 30 V
ground
connector)
2) Disconnect PRE5.
Between PRE5 (female) (21), (26), (31) and Resis-
Max. 1 z
2) Disconnect battery ground and PRE6.
Ground fault in wiring 3) Turn starting switch OFF and carry out troubleshooting.
6 harness (Contact with Between PRE5 (female) (1), (11) and chassis Resis-
Min. 1 Mz
ground circuit) ground tance
Between PRE5 (female) (2), (12) and chassis Resis-
Min. 1 Mz
ground tance
78 HD785-7
HD785-7 79
Failure code [DBG9KQ] Model selection signal: Abnormal

Action code Failure code Model selection signal: Abnormal
Trouble
E01 DBG9KQ (Pre-lubrication controller system)
Contents of • Because pre-lubrication controller model selection signal is not specified as GND, the system
trouble judged the signal as for different model.
Action of
• Pre-lubrication controller operates under the program for a different model.
controller
Problem that
appears on
machine
• Input state of model selection signal can be checked with monitoring code: 40973 (1: 24 V, 0:
GND)
Related
[D-IN-4]: PRE5 (35)=Machine select1
information
[D-IN-5]: PRE5 (26)=Machine select2 (NC: Internal pull-up)
[D-IN-6]: PRE5 (36)=Machine select3 (NC: Internal pull-up)

False connection of the
1 Choice and connect the connector for HD785-7.
machine select connector
2) Disconnect PRE5 and carry out troubleshooting.
Possible causes Disconnection in wiring Between connectors PRE5 (female) (35) – Resis-
Min. 1 Mz
and standard harness (Disconnection or (21), (26), (31) tance
2
value in normal defective contact in Between connectors PRE5 (female) (36) – Resis-
state connector) Min. 1 Mz
(21), (26), (31) tance
Between connectors PRE5 (female) (21), Resis-
Max. 1 z
(26), (31) – ground tance
If causes 1, 2 is not detected, the pre-lubrication controller may be
3 defective. (Since trouble is in system, troubleshooting cannot be car-
controller
ried out.)
80 HD785-7
HD785-7 81
Failure code [DDD7KX] Trouble in travel speed setting switch system:

Out of input signal range 1
Action code Failure code Trouble in travel speed setting switch system: Out of input signal
range
Trouble
E03 DDD7KX (When ARSC is set and ARSC system switch is ON)
(Retarder controller system)
Contents of
trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of
controller • When ARSC operates, the controller releases the brake gradually.
Problem that
appears on • This failure does not have a serious effect on the machine.
machine
Related
information • None in particular.

2) Replace the travel speed set switch (ARSC SET switch).
Defective travel speed set
1 Replace the travel Failure is not
switch (ARSC SET switch) Switch is normal
speed set switch repaired.
(ARSC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Defective register (250 z) 3) Connect T-adapter (female).
Resis- 250 ± 25
Between RE3 (female) (1) and (2)
tance z
Possible causes 2) Disconnect connector RE4.
and standard 3 Defective resistor (1,020 z) 3) Connect T-adapter (female).
value in normal Resis- 1,020 ±
state Between RE4 (female) (1) and (2)
tance 102 z
2) Disconnect connectors BRC1, ARC, RE3, and RE4.
3) Connect T-adapter to BRC1 (female), ARC (female), RE3 (male)
and RE4 (male).
Between BRC1 (female) (22) and RE3 Resis-
ness (male) (1) tance
4
(Disconnection or defective Between BRC1 (female) (13) and RE3 Resis-
Max. 1 z
contact) (male) (2) and ARC (female) (1) tance
Between RE4 (male) (1) and ARC (female) Resis-
Max. 1 z
(3) tance
Between RE4 (male) (2) and ARC (female) Resis-
Max. 1 z
(2) tance
82 HD785-7

Between BRC1 (22) and (21) Voltage Approx. 5 V
2) Disconnect connectors BRC1.
3) Connect T-adapter (female).
When set switch is Resis- 1,020 ±
ON tance 102 z
When set switch is Resis- 68 ± 6.8
Between BRC1 TOUCH UP tance z
(female) (13) – (21) When set switch is Resis- 198 ±
TOUCH DOWN tance 19.8 z
When set switch is Resis- 418 ±
CANCEL tance 41.8 z
HD785-7 83
Failure code [DDD8KA] ARSC system switch system: Disconnection (If

equipped) 1
Action code Failure code ARSC system switch system: Disconnection
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KA (Retarder controller system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
ness 3) Connect T-adapter (female).
1
Between DPC2B (female) (1) and ARSC Resis-
contact) Max. 1 z
(female) (3) tance
2) Replace the ARSC system switch with normal one.
Defective ARSC system
2 System switch is nor-
Possible causes switch When the ARSC system switch No
mal
and standard is replaced with normal one, is
value in normal failure repaired? System switch is
Yes
state defective
2) Disconnect connector DPC2B.
Turn the ARSC sys-
tem switch ON Voltage 20 – 30 V
Between DPC2B (1) (Press it up).
and ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).
84 HD785-7
HD785-7 85
Failure code [DDD8KB] ARSC system switch system: Short circuit

(If equipped) 1
Action code Failure code ARSC system switch system: Short circuit
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KB (Machine monitor system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

2) Disconnect connectors ARSC and DPC2B.
Hot short in wiring harness 3) Connect T-adapter (female).
1 4) Turn the starting switch ON.
(Contact with 24V circuit)
Between ARSC (female) (3) and ground Voltage Max. 1 V
Between ARSC (female) (2) and ground Voltage Max. 1 V
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec-
and standard tive When the ARSC system switch No
mal
value in normal is replaced with normal one, is
failure repaired? System switch is
state Yes
defective
Turn the ARSC sys-
3 Machine monitor defective
– ground Turn the ARSC sys-
(Press it down).
86 HD785-7
HD785-7 87
Failure code [DDD9KA] ABS system switch system: Disconnection 1

Action code Failure code ABS system switch system: Disconnection
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KA (ABS controller system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
information

2) Disconnect connectors ABS and DPC2B.
Disconnection in wiring har- 3) Connect T-adapter (female).
ness
1 Between DPC2B (female) (2) and ABS Resis-
(female) (3) tance
contact)
Between DPC2B (female) (8) and ABS Resis-
Max. 1 z
(female) (2) tance
2) Replace the ABS system switch with normal one.
Possible causes
and standard 2 Defective ABS system switch System switch is nor-
When the ABS system switch is No
value in normal mal
replaced with normal one, is fail-
state ure repaired? System switch is
Yes
defective
Turn the ABS sys-
and ground Turn the ABS sys-
(Press it down).
88 HD785-7
HD785-7 89
Failure code [DDD9KB] ABS system switch system: Short circuit 1

Action code Failure code ABS system switch system: Short circuit
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KB (Machine moniter system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
machine moniter
Problem that
machine
Related
information

2) Disconnect connectors ABS.
Between ground and ABS (female) (3) Voltage Max. 1 V
Between ground and ABS (female) (2) Voltage Max. 1 V
2) Replace the ABS system switch with normal one.
Possible causes 2 Defective ABS system switch System switch is nor-
and standard When the ABS system switch is No
mal
value in normal replaced with normal one, is fail-
ure repaired? System switch is
state Yes
defective
Turn the ABS sys-
and ground Turn the ABS sys-
(Press it down).
90 HD785-7
HD785-7 91
Failure code [DDDAKA] ASR system switch: Disconnection 1

Action code Failure code ASR system switch: Disconnection
Trouble
E01 DDDAKA (Machine monitor system)
Contents of
• The ON input of the ASR system switch is OFF and the OFF input of the system switch is OFF.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected seriously.
appears on
machine • ASR control cannot be continued.
Related
information

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring har- Between DPC2B (female) (3) and ASR Resis-
ness Max. 1 z
(female) (3) tance
defective contact in connec- 1) Turn starting switch OFF.
tor) 2) Disconnect connectors ASR and DPC2B.
Between DPC2B (female) (9) and ASR Resis-
Max. 1 z
(female) (2) tance
2) Replace ASR system switch with normal switch.
Possible causes 3) Turn starting switch ON.
Defective ASR system
and standard 2 System switch is nor-
switch When ASR system switch is No
value in normal mal
state replaced with normal switch,
does condition become normal? System switch is
Yes
abnormal
ASR system switch
Voltage 20 – 30 V
Between DPC2B (3) "ON"
3 Defective machine monitor and ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
and ground ASR system switch
Voltage 20 – 30 V
"OFF"
92 HD785-7
HD785-7 93
Failure code [DDDAKB] ASR system switch: Short circuit 1

Action code Failure code ASR system switch system: Short circuit
Trouble
E01 DDDAKB (Machine monitor system)
Contents of
• ASR system switch ON input is turned ON and system switch OFF input is turned ON.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected particularly.
appears on
Related
information

2) Disconnect connectors ASR.
1 4) Turn starting switch ON.
Between ground and ASR (female) (3) Voltage Max. 1 V
Between ground and ASR (female) (2) Voltage Max. 1 V
2) Replace ASR system switch with normal switch.
Defective ASR system
switch When ASR system switch is No
Possible causes mal
replaced with normal switch, is
and standard System switch is
condition normal? Yes
value in normal defective
state
ASR system switch
Voltage 20 – 30 V
3 Defective machine monitor and ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
and ground ASR system switch
Voltage 20 – 30 V
"OFF"
94 HD785-7
HD785-7 95
Failure code [DDE2KB] Engine oil pressure switch error: Grounding

fault
Action code Failure code Engine oil pressure switch: Grounding fault
Trouble
E01 DDE2KB (Pre-lubrication controller system)
Contents of • Engine oil pressure switch detected low oil pressure (switch closed) when engine speed is Min.
trouble 500 rpm and engine oil pressure is over 100 kPa (communication from engine controller).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related
• Engine oil pressure: 37200 (kPa)
information
• State of the engine oil pressure switch can be monitored with 40973 "D-IN-1" (ON: 1, OFF: 0).

Ground fault in wiring 2) Disconnect connector PRE5 and terminal PRE16, then carry out
1 harness (Contact with troubleshooting.
ground circuit) Between terminal PRE16 (harness side) and Resis-
Min. 1 Mz
Possible causes 2) Disconnect terminal PRE16.
and standard 3) Start the engine and carry out troubleshooting.
value in normal Between terminal PRE16 (oil pressure switch Resis-
state Defective engine oil Min. 1 Mz
2 side) and chassis ground tance
pressure switch
2) Disconnect terminal PRE16 and carry on troubleshooting.
Between terminal PRE16 (oil pressure switch Resis-
Max. 1 z
side) and chassis ground tance
controller
ried out.)
96 HD785-7
HD785-7 97
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection

or hot short circuit
Action code Failure code Engine oil pressure switch error: Disconnection or hot short circuit
Trouble
E01 DDE2L6 (Pre-lubrication controller system)
• After starting switch is ON, no terminal C signal is input and engine oil pressure switch detected
Contents of
"OPEN" state although the engine speed is under 500 rpm (communication from engine control-
trouble
ler).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related • Engine oil pressure switch: 40973 "D-IN-1" (ON: 1, OFF: 0).
information • Oil pressure can be monitored with engine starting switch terminal C signal: 40973 "D-IN-3" (ON:
1, OFF: 0).

Disconnection in wiring 2) Disconnect connector PRE5 and terminal PRE16, then carry out
harness (Disconnection or troubleshooting.
1
defective contact in
Between connector PRE5 (5) – terminal Resis-
connector) Max. 1 z
PRE16 tance
2) Disconnect connector PRE5 and terminal PRE16.
Hot short circuit in wiring
3) Connect T-branch to connector PRE5 (female).
4) Turn starting switch ON and carry out troubleshooting.
power supply circuit)
Voltage Max. 1 V
Possible causes ground
value in normal 2) Disconnect terminal PRE16.
state 3) Start the engine and carry out troubleshooting.
Engine starting.
Resis-
Between terminal PRE16 (oil pressure switch Min. 1 Mz
Defective engine oil tance
3 side) and chassis ground
pressure switch
2) Disconnect terminal PRE16 and carry out troubleshooting.
While engine is starting
Resis-
Between terminal PRE16 (oil pressure switch Max. 1 z
tance
side) and chassis ground
controller
ried out.)
98 HD785-7
HD785-7 99
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1

Action code Failure code Service brake pressure switch trouble (Rear)
Trouble
E03 DDP6L4 (Retarder controller system)
Contents of
• When brake pedal is pressed, signal is not sent from service brake pressure switch.
trouble
Action of
controller
Problem that
appears on • When brake pedal is pressed, brake lamp (rear center lamp) does not light up.
machine
Related
information

1) Remove relay cover.
Defective stop lamp relay 2) Turn starting switch ON (Do not start engine).
1 3) Turn foot brake ON and OFF to check relay.
(R08)
R08 Turning ON/OFF sound is heard.
diode check mode).
Forward direction:
Between D09 (male) There is continuity
Continuity
(1) (-) and (2) (+) Backward direction:
2 Defective diode
diode check mode).
Forward direction:
Possible causes Between D10 (male) There is continuity
Continuity
and standard (1) (-) and (2) (+) Backward direction:
value in normal There is not continuity
state a Connect wires to T-adapter for DT-T-3.
2) Disconnect S01 and connect T-adapter (male).
Defective service brake 3) Turn starting switch ON.
3
switch When brake pressed:
Between S01 (male) There is continuity
Continuity
(A) and (B) When brake is released:
a Turn starting switch OFF and disconnect BRC1, S01 and
D10,then carry out troubleshooting without turning starting
switch ON.
Disconnection in wiring har- Between S01 (female) (A) and D10 (female) Resis-
ness (Disconnection in wiring (1) Max. 1 z
4 tance
or defective contact in con-
Between BRC1 (female) (17) and D10 Resis-
nector) Max. 1 z
(female) (2) tance
Resis-
Between S01 (female) (B) and ground Max. 1 z
tance
100 HD785-7

a Turn starting switch OFF and disconnect BRC1, S01, D09 and
D10, then carry out troubleshooting without turning starting
Grounding fault in wiring har- switch ON.
5 ness (Contact with ground Resis-
Between D10 (female) (1) and ground Min. 1 Mz
Possible causes circuit) tance
and standard Resis-
value in normal Between D10 (female) (2) and ground Min. 1 Mz
tance
state
Trouble in hydraulic system
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
normal)
If causes 1 – 5 are not detected, retarder controller may be defec-
out.)
HD785-7 101
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1

Action code Failure code Hi clutch fill switch: Disconnection
(Command is Holding pressure, fill switch is OFF, and slip is not
Trouble
E03 DDTHKA sensed)
Contents of • When the output to the Hi clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
trouble from the fill switch is not turned ON.
Action of • The controller keeps the current gear speed.
controller • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
• The gear cannot be shifted.
appears on
machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
• The signal from the fill switch can be checked in the monitoring function (Code: 38919) (0: OFF, 1:
ON).
• Method of reproducing failure code: Start the engine and travel at F3 (2nd: Hi).
k Lift the body to the maximum position, set the dump lever to HOLD and install a body lock
pin on the both sides of the body.
k Insertion and removal of the body lock pins must be carried out by at least two workers.
(Drop down of the body during the operation can cause serious personal injury or death.)
• Installation of body lock pin
Related 1. Start the engine.
information 2. Lift the body to the maximum position and set the dump lever to HOLD.
3. Be sure to insert the body lock pin into both sides of the body.
4. Set the dump lever to FLOAT and lock the lock knob.
5. Turn the starting switch to OFF position and stop the engine.
• Removal of body lock pin
1. Start the engine.
2. Set the dump lever to HOLD.
3. Pull out the body lock pins, store them inside the body and lock them with the fixing pin.
4. Set the dump lever to LOWER to seat the body.

a Make sure beforehand that failure code [DDTJKA] does not
appear when you set shift lever to D and gear speed to F2 (Lo:
2nd) while depressing brake pedal.
2) Lift the body to the maximum position and install body lock pins
(see the above "Related information").
4) Swap connectors of Hi clutch and Lo clutch.
Possible causes
q L.PS (CN17) < – – –> H.PS (CN19)
and standard
q L.SW (CN18) < – – –> H.SW (CN20)
value in normal 1 Defective Hi clutch fill switch 5) Start the engine.
state
6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTJKA] appears, Hi clutch fill switch remains OFF.
a Check the oil pressure. If oil pressure is normal, Hi clutch fill
switch is defective.
a If failure code [DDTJKA] does not appear, disconnection in wir-
ing harness or defective transmission controller.
a After completing the above check, lift the body again and return
connectors to their original positions.
102 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and H.SW (CN20).
Possible causes ness 3) Connect T-adapters (female).
2
Between ATC3 (female) (30) and H.SW Resis-
state (CN20) (female) (1) tance
If no abnormality is found in the above troubleshooting, the trans-
3 mission controller is defective. (Since this is an internal defect,
troller
HD785-7 103
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 1

Action code Failure code Lo clutch fill switch: Disconnection
Trouble
E03 DDTJKA sensed)
Contents of • When the output to the Lo clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F1 (1st: Lo).
a Make sure that the body is seated (the condition for F1 travel).

4) Swap connectors of Lo clutch and Hi clutch.
q L.PS (CN17) < – – –> H.PS (CN19)
q L.SW (CN18) < – – –> H.SW (CN20)
Possible causes
and standard
6) Set shift lever to D, gear speed to F2 (Lo: 2nd) while depressing
value in normal 1 Defective Lo clutch fill switch brake pedal.
state
If failure code [DDTJKA] does not appear, Lo clutch fill switch
remains OFF.
a Check the oil pressure. If oil pressure is normal, Lo clutch fill
a If failure code [DDTJKA] does appear, disconnection in wiring
harness or defective transmission controller.
104 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and L.SW (CN18).
2
Between ATC3 (female) (10) and L.SW Resis-
troller
HD785-7 105
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1

Action code Failure code 1st clutch fill switch: Disconnection
Trouble
E03 DDTKKA sensed)
Contents of • When the output to the 1st clutch ECMV soleniod is turned ON, the clutch is engaged but the signal
controller • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F1 (1st: Lo).

a Make sure beforehand that failure code [DDTLKA] does not
4) Swap connectors of 1st clutch and 2nd clutch.
Possible causes q 1.PS (CN6) < – – –> 2.PS (CN8)
and standard q 1.SW (CN7) < – – –> 2.SW (CN9)
value in normal 1 Defective 1st clutch fill switch 5) Start the engine.
state 6) Set shift lever to D, gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, 1st clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 1st clutch fill
a If failure code [DDTKKA] does appear, disconnection in wiring
106 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and 1.SW (CN7).
2
state and 1.SW (CN7) (female) (1) tance
troller
HD785-7 107
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 1

Action code Failure code 2nd clutch fill switch: Disconnection (KA)
Trouble
E03 DDTLKA sensed)
Contents of • When the output to the 2nd clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F3 (2nd: Hi).

a Make sure beforehand that failure code [DDTKKA] does not
appear when you set shift lever to L and gear speed to F1 (Lo:
1st) while depressing brake pedal.
4) Swap connectors of 2nd clutch and 1st clutch.
q 2.PS (CN8) < – – –> 1.PS (CN6)
Possible causes
q 2.SW (CN9) < – – –> 1.SW (CN7)
and standard
Defective 2nd clutch fill 5) Start the engine.
value in normal 1
switch 6) Set the dump lever to LOWER to seat the body.
state
7) Set shift lever to L, gear speed to F1 (Lo: 1st) while depressing
brake pedal.
If failure code [DDTKKA] appears, 2nd clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 2nd clutch fill
a If failure code [DDTKKA] does appear, disconnection in wiring
108 HD785-7

Possible causes ness 3) Connect T-adapter.
2
Between ATC3 (female) (9) and 2.SW Resis-
troller
HD785-7 109
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 1

Action code Failure code 3rd clutch fill switch: Disconnection
Trouble
E03 DDTMKA sensed)
Contents of • When the output to the 3rd clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F4 (3rd: Lo).

4) Swap connectors of 3rd clutch and 2nd clutch.
Possible causes q 3.PS (CN10) < – – –> 2.PS (CN8)
and standard q 3.SW (CN11) < – – –> 2.SW (CN9)
value in normal Defective 3rd clutch fill 5) Start the engine.
1
state switch 6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, 3rd clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 3rd clutch fill
a If failure code [DDTLKA] does not appear, disconnection in wir-
110 HD785-7

2
troller
HD785-7 111
Failure code [DDTNKA] R clutch fill switch: Disconnection 1

Action code Failure code R clutch fill switch: Disconnection
Trouble
E03 DDTNKA sensed)
Contents of • When the output to the R clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at R.

4) Swap connectors of R clutch and 2nd clutch.
Possible causes
q R.PS (CN12) < – – –> 2.PS (CN8)
and standard
q R.SW (CN13) < – – –> 2.SW (CN9)
value in normal 1 Defective R clutch fill switch 5) Start the engine.
state
6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, R clutch fill switch remains OFF.
a Check the oil pressure. If oil pressure is normal, R clutch fill
a If failure code [DDTLKA] does not appear, disconnection in wir-
112 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and R.SW (CN13).
Possible causes ness 3) Connect T-adapter.
2
state and R.SW (CN13) (female) (1) tance
troller
HD785-7 113
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 1

Action code Failure code 4th clutch fill switch : Disconnection
Trouble
E03 DDTPKA sensed)
Contents of • When the output to the 4th clutch ECMV is solenoid turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F6 (4th: Lo).

a Make sure beforehand that failure code [DDTJKA] does not
4) Swap connectors of 4th clutch and Lo clutch.
Possible causes q L.PS (CN17) < – – –> 4.PS (CN14)
and standard q L.SW (CN18) < – – –> 4.SW (CN15)
value in normal 1 Defective 4th clutch fill switch 5) Start the engine.
state 6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTJKA] appears, 4th clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 4th clutch fill
a If failure code [DDTJKA] does not appear, disconnection in wir-
114 HD785-7

2
troller
HD785-7 115
Failure code [DF10KA] Gear shift lever: Disconnection 1

Action code Failure code Gear shift lever: Disconnection
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• Gear shift lever signal is not input at all.
trouble
Action of
• Controls according to previous gear shift lever information before abnormality occurs.
controller
Problem that • Gear speed is still in neutral and cannot start vehicle.
appears on • Cannot shift between forward and reverse positions.
machine • All gear shift lever position lamps go out.
Related infor-
mation

• Gear shift lever is being pushed even though it is not operated.
1 Operational error • Gear shift lever has been stopped at the midway point between
each of the gear positions.
2) Remove fuse BT3 No.14
3) Connect T-adapters to connector SF1, ATC1, ATC2 and ATC3
(female).
Resis-
Between BT3 (14) and SF1 (female) (1) Max. 1 z
tance
Between ATC2 (female) (35) and SF1 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (5) tance
Max. 1 z
Disconnection in wiring (female) (4) tance
harness Between ATC2 (female) (15) and SF1 Resis-
2 Max. 1 z
(Disconnection or defective (male) (6) tance
contact of connectors) Between ATC2 (female) (5) and SF1 Resis-
Max. 1 z
(female) (7) tance
Possible causes Between ATC2 (female) (36) and SF1 Resis-
(female) (8) tance
value in normal Between ATC2 (female) (26) and SF1 Resis-
state Max. 1 z
(female) (9) tance
Max. 1 z
(female) (10) tance
Max. 1 z
(female) (11) tance
Between ATC3 (female) (21) (31), (32), Resis-
Max. 1 z
(33) and SF1 (female) (2) tance
2) Connect T-adapters to connectors ATC1 (female), ATC2
(female), and SF1 (female).
Min. 1 Mz
SF1 (female) (3) tance
Ground fault in wiring har-
3 ness Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
116 HD785-7

Min. 1 Mz
Ground fault in wiring har- Min. 1 Mz
3 ness
Min. 1 Mz
Min. 1 Mz
2) Insert T-adapter in connector SF1.
4) Operate shift lever and troubleshoot.
In shift range "R" Voltage 20 – 30 V
Between SF1 (3) and
ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "N" Voltage 20 – 30 V
Between SF1 (4) and
Voltage Max. 1 V
than "N"
In shift range "D" Voltage 20 – 30 V
Between SF1 (5) and
Voltage Max. 1 V
than "D"
In shift range "6" Voltage 20 – 30 V
Between SF1 (6) and
Voltage Max. 1 V
than "6"
Possible causes In shift range "5" Voltage 20 – 30 V
and standard 4 Defective gear shift lever Between SF1 (7) and
value in normal ground In shift range other
Voltage Max. 1 V
state than "5"
Between SF1 (8) and
Voltage Max. 1 V
than "4"
Between SF1 (9) and
Voltage Max. 1 V
than "3"
Between SF1 (10)
and ground In shift range other
Voltage Max. 1 V
than "2"
In shift range "L" Voltage 20 – 30 V
Between SF1 (11)
Voltage Max. 1 V
than "L"
a If wiring harness is normal and all the voltages at any selected
range are less than the standard value, the power supply line or
ground circuit in shift lever is defective.
mission controller is defective.
a Reference
Defective transmission 2) Insert T-adapter in connectors ATC1 and ATC2.
controller
Between ATC2 (35)
Voltage Max. 1 V
than "R"
HD785-7 117

In shift range "D" Voltage 20 – 30 V
Between ATC2 (25)
Voltage Max. 1 V
than “D“
Between ATC1 (6)
Voltage Max. 1 V
than "N"
Between ATC2 (15)
Voltage Max. 1 V
than "6"
Possible causes Between ATC2 (5)
and standard Voltage Max. 1 V
Defective transmission than "5"
value in normal 5
state controller In shift range "4" Voltage 20 – 30 V
Between ATC2 (36)
Voltage Max. 1 V
than "4"
Between ATC2 (26)
Voltage Max. 1 V
than "3"
Between ATC2 (16)
Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"
118 HD785-7
HD785-7 119
Failure code [DF10KB] Gear shift lever: Short circuit 1

Action code Failure code Gear shift lever: Short circuit
Trouble (Input of multiple lever signach)
E03 DF10KB (Transmission controller system)
Contents of
• Gear shift lever signals have been inputted at the same time from 2 or more systems.
trouble
• Controls according to high priority signal.
(1): N > D > 6> 5 > 4 > 3 > 2 > L
Action of
(2): N > R
controller
• Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the
same time.
• There are cases where the gear speed is shifted to a higher gear speed than that which has been
Problem that
set by the gear shift lever.
appears on
• Gear speed is still in neutral and cannot start vehicle.
machine
• Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
information

2) Disconnect connector SF1.
3) Connect T-adapter to connector SF1 (female).
When not
Between ground and SF1 (female) (3) Voltage at R, Max.
1V
When not
Between ground and SF1 (female) (5) Voltage at D, Max.
1V
When not
Between ground and SF1 (female) (4) Voltage at N, Max.
1V
When not
Between ground and SF1 (female) (6) Voltage at 6, Max.
Hot short in wiring harness
1 1V
(Contact with 24 V circuit)
When not
Possible causes 1V
and standard
value in normal When not
state Between ground and SF1 (female) (8) Voltage at 4, Max.
1V
When not
1V
When not
1V
When not
Between ground and SF1 (female) (11) Voltage at L, Max.
1V
2) Disconnect connectors ATC1, ATC2 and SF1, and connect the T-
adapters to each female side.
Short circuit in wiring har- a Use the continuity range of the multimeter for the measure-
ness ment.
2
(Contact between har-
Between ATC1 (female) (6) and each pin No continuity
nesses)
other than pin (6). (No sound is heard)
120 HD785-7

Short circuit in wiring har- Between SF1 (female) (3) and each pin other No continuity
ness than (3) (No sound is heard)
2
(Contact between har- Between SF1 (female) (4) and each pin other No continuity
nesses) than (4) (No sound is heard)
Between SF1 (female) (5) and each pin other No continuity
than (5) (No sound is heard)
Possible causes than (8) (No sound is heard)
and standard Between SF1 (female) (9) and each pin other No continuity
value in normal than (9) (No sound is heard)
state
Between SF1 (female) (10) and each pin No continuity
other than (10) (No sound is heard)
Between SF1 (female) (11) and each pin No continuity
2) Insert T-adapter in connector SF1 (female).
Between SF1 (3) and
Voltage Max. 1 V
than "R"
Between SF1 (4) and
Voltage Max. 1 V
than "N"
In shift range"D" Voltage 20 – 30 V
3 Defective gear shift lever Between SF1 (5) and
Voltage Max. 1 V
than "D"
Between SF1 (6) and
Voltage Max. 1 V
than "6"
Between SF1 (7) and
Voltage Max. 1 V
than "5"
Between SF1 (8) and
Voltage Max. 1 V
than "4"
HD785-7 121

Between SF1 (9) and
Voltage Max. 1 V
than "3"
Between SF1 (10)
3 Defective gear shift lever In shift range other
and ground Voltage Max. 1 V
than "2"
Between SF1 (11)
Voltage Max. 1 V
than "L"
mission controller is defective.
a Reference
2) Insert T-adapter in connectors ATC1 and ATC2.
Between ATC2 (35)
Voltage Max. 1 V
than "R"
Possible causes In shift range "D" Voltage 20 – 30 V
Between ATC2 (25)
and standard and ground In shift range other
Voltage Max. 1 V
value in normal than "D"
state In shift range"N" Voltage 20 – 30 V
Between ATC1 (6)
Voltage Max. 1 V
than “N“
Defective transmission In shift range "6" Voltage 20 – 30 V
4 Between ATC2 (15)
controller and ground In shift range other
Voltage Max. 1 V
than "6"
Between ATC2 (5)
Voltage Max. 1 V
than "5"
Between ATC2 (36)
Voltage Max. 1 V
than "4"
Between ATC2 (26)
Voltage Max. 1 V
than "3"
Between ATC2 (16)
Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"
122 HD785-7
HD785-7 123
Failure code [DGE5KX] or VHMS_LED display: "n4" o "01" 1

Atmospheric temperature sensor: Out of input signal range
Action code Failure code Atmospheric temperature sensor: Out of input signal range
Trouble
– DGE5KX (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
trouble less.
Action of
machine monitor
Problem that
appears on • Monitoring function fails to monitor the atmospheric temperature.
machine
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays "n4" o "01".
information • The input state (temperature) from the atmospheric temperature sensor can be checked with the
monitoring function (Code: 37501 ATR TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Defective atmospheric tem- Atmospheric
FL06 (male) Resistance
perature sensor temperature
1
(Internal disconnection or 25°C (Normal temp) 3.6 – 4.7 kz
short circuit)
Between (A) and (B) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz
Atmospheric
HM-CN2A (male) Resistance
Disconnection or short circuit temperature
2
in wiring harness 25°C (Normal temp) 3.6 – 4.7 kz
Between (10) and
About 0°C 10.2 – 13.4 kz
Possible causes (12)
and standard About 40°C 2.1 – 2.6 kz
value in normal
a If no abnormality is found in check on cause 2, this check is not
state
required.
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
(Disconnection or defective Between HM-CN2A (female) (10) and FL06 Resis-
Max. 1 z
contact of connector) (female) (A) tance
Between FL06 (female) (B) and chassis Resis-
Max. 1 z
ground tance
4 ness
(Contact with ground circuit) Between HM-CN2A (female) (10) or FL06 Resis- Min. 1
(female) (A) and chassis ground tance Mz
1) Starting switch OFF
2) Insert T-adapter into connector HM-CN2A or FL06.
Hot short in wiring harness 3) Starting switch ON
5
Between HM-CN2A (10) or FL06 (A) and Max. 4.9
Voltage
chassis ground V
124 HD785-7

and standard If causes are not found by above checks, transmission controller is
value in normal Defective VHMS & PLM con-
state troller
be performed.)
HD785-7 125
Failure code [DGF1KX] Transmission oil temperature sensor: Out of

input signal range 1
Action code Failure code Transmission oil temperature sensor: Out of input signal range
Trouble
E03 DGF1KX (Transmission controller system)
• The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above
Contents of 150°C) or only transmission oil temperature is low (transmission oil temperature sensor signal cir-
trouble cuit voltage is above 4.56 V (below 15 °C) and torque converter and brake oil temperature sensor
voltage is below 3.7 V (above 55 °C).
Action of
• The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
controller
Problem that
appears on • Gear shift shocks become large.
machine
• This failure can be checked in the monitoring function (Code: 32500 (°C), 32501 (V)).
Related
information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

2) Disconnect connector T/M.T (CN23).
3) Connect T-adapter (male).
Defective transmission oil Between Resis-
1 Oil temperature: 25 °C 37 – 50 kz *
temperature sensor T/M.T tance
(CN23)
(male) (1) Oil temperature: 100 °C Resis-
3.5 – 4.0 kz *
and (2) tance

Disconnection or short cir- Between Resis-
2 Oil temperature: 25 °C 37 – 50 kz
cuit in wiring harness ATC1 tance
(female)
(3) and Resis-
Oil temperature: 100 °C 3.5 – 4.0 kz
(21) tance
Possible causes a If no abnormality is found in check on cause 2, this check is not
value in normal 1) Turn the starting switch OFF.
state Disconnection in wiring har- 2) Disconnect connectors ATC1 and T/M.T (CN23).
ness 3) Connect T-adapters (female).
3
Between ATC1 (female) (21) and T/M.T Resis-
contact) Max. 1 z
Between ATC1 (female) (3) and T/M.T Resis-
Max. 1 z
Grounding fault in wiring 2) Disconnect connector ATC1 or T/M.T (CN23).
4 harness (Contact with 3) Connect T-adapter (female).
ground) Between ground and ATC1 (female) (3) or Resis-
Min. 1 Mz
T/M.T (CN23) (female) (1) tance
2) Disconnect connector ATC1 or T/M.T (CN23).
Hot short in wiring harness 3) Insert T-adapter into it.
(Contact with 24V)
Between ground and ATC1 (3) or T/M.T
Voltage Max. 4.5 V
(CN23) (1)
126 HD785-7

value in normal Defective transmission con-
state troller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as
retarder oil temperature sensor).
HD785-7 127
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear

wheel) system (Disconnection and short circuit) 1
Action code Failure code Trouble in retarder oil temperature sensor (rear wheel) system
Trouble (Disconnection and short circuit)
E01 DGR2KB (Retarder controller system)
Contents of
• Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
appears on • Oil temperature gauge does not work because of failure mode of sensor.
machine
Related • Input signal from oil temperature sensor can be checked with monitoring function (codes: 30211
information (°C) and 30212 (V)).

a Prepare with starting switch OFF, disconnect connector RTR
and troubleshooting with starting switch still OFF.
Retarder oil tempera-
RTR (male) Resistance (kz)*
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) and (2) 80 6.556
90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
Possible causes Retarder oil tempera-
BRC1 (female) Resistance (kz)
and standard ture (°C)
value in normal Disconnection or short circuit 25 42.7
state 2
in wiring harness
30 35.13
Between (3) and (21) 80 6.556
90 4.925
100 3.75
Ground fault in wiring har- and troubleshooting with starting switch still OFF.
3 ness
(Contact with ground circuit) Resis- Min. 1
Between BRC1 (female) (3) and ground
tance Mz
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30203).
*: Shown are average resistance values of the sensor at each temperature level.
The values actually vary.
128 HD785-7
HD785-7 129
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear

wheel) system (Ground fault) 1
Action code Failure code Trouble in retarder oil temperature sensor (rear wheel) system
Trouble (Ground fault)
E01 DGR2KZ (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

and standard
value in normal Perform troubleshooting for failure code [DGR2KB].
state
130 HD785-7
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front

wheel) system (Disconnection and short circuit) 1
Action code Failure code Trouble in retarder oil temperature sensor (front wheel) system
Trouble (Disconnection and short circuit)
E01 DGR4KB (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

and standard
value in normal Perform troubleshooting for failure code [DGR4KZ].
state
HD785-7 131
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front

wheel) system (Ground fault) 1
Action code Failure code Trouble in retarder oil temperature sensor (front wheel) system
Trouble (Ground fault)
E01 DGR4KZ (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

a Prepare with starting switch OFF, disconnect connector RTF
Retarder oil tempera-
RTF (male) Resistance (kz)*
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) and (2) 80 6.556
90 4.925
100 3.75
Possible causes Retarder oil tempera-
BRC1 (female) Resistance (kz)
and standard ture (°C)
value in normal Disconnection or short circuit 25 42.7
state 2
in wiring harness
30 35.13
Between (9) and
80 6.556
(21)
90 4.925
100 3.75
Ground fault in wiring har- and troubleshooting with starting switch still OFF.
3 ness
(Contact with ground circuit) Resis- Min. 1
Between BRC1 (female) (9) and ground
tance Mz
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30201).
*: Shown are average resistance values of the sensor at each temperature level.
The values actually vary.
132 HD785-7
HD785-7 133
Failure code [DGR6KX] Steering oil temperature sensor: Input signal

out of range 1
Action code Failure code Steering oil temperature sensor: Input signal out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Signal circuit voltage of steering oil temperature sensor has become below 0.97 V (more than 150
°C) or only steering oil temperature is low (signal circuit voltage of steering oil temperature sensor is
Contents of
above 4.56 V (less than 15 °C)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55 °C )
and normal.
Action of
controller
Problem that
appears on • Steering oil temperature gauge does not indicate properly.
machine
• Input signal from oil temperature sensor can be checked with monitoring function.
Related 1) Steering oil temperature sensor (codes: 32701 (°C) and 32702) (V))
information 2) Torque converter oil temperature sensor (codes: 30100 (°C) and 30101 (V))
3) Retarder oil temperature sensor (codes: 30211 (°C) and 30212 (V))

2) Connect T-adapter to connector STR (male).
Defective steering oil Between Oil temperature: Resis-
1 37 – 50 kz *
temperature sensor STR 25 °C tance
(male) (1) Oil temperature: Resis-
and (2) 3.5 – 4.0 kz *
100 °C tance
Disconnection or short circuit Between Oil temperature: Resis-

37 – 50 kz
2 ATC1 25 °C tance
in wiring harness
(female)
(20) and Oil temperature: Resis-
3.5 – 4.0 kz
(21) 100 °C tance
a If no abnormality is found in check on cause 2, this check is not

Possible causes required.
value in normal Disconnection in wiring 2) Connect T-adapters to connectors ATC1 (female) and STR
state harness (female).
3
Between ATC1 (female) (20) and STR Resis-
contact) Max. 1 z
(female) (1) tance
Between ATC1 (female) (21) and STR Resis-
Max. 1 z
(female) (2) tance
Ground fault in wiring har- 2) Disconnect connector ATC1 or STR.
4 ness 3) Connect T-adapter to connector ATC1 or STR (female).
Min. 1 Mz
STR (female) (1) tance
2) Disconnect connector ATC1 or STR.
Hot short in wiring harness 3) Insert T-adapter into it.
Max. 4.5
Between ground and ATC1 (21) or STR (2) Voltage
V
134 HD785-7

value in normal Defective transmission
state controller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as retarder oil tem-
perature sensor).
HD785-7 135
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of

Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Transmission controller system)
• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V
Contents of (above 150°C) or when transmission valve oil temperature signal voltage is below 3.7 V (above
trouble 55C°) and there is no abnormality, torque converter oil temperature sensor signal circuit voltage is
above 4.56 V (below 15°C).
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge does not indicate normally.
machine
Related
• This failure can be checked in the monitoring function (Code: 30100 (°C), 30101 (V)).
information

2) Disconnect connector T/C.T (CN22).
Defective torque converter Between Resis-
oil temperature sensor T/C.T tance
(CN22)
(male) (1) Oil temperature: 100 Resis-
3.5 – 4.0 kz
and (2) °C tance

3) Insert T-adapter (female).
Disconnection or short circuit Between Resis-
in wiring harness AT1 tance
(female)
(9) and Resis-
Oil temperature: 100 °C 3.5 – 4.0 kz
(21) tance
Possible causes a If no abnormality is found in check on cause 2, this check is not
state Disconnection in wiring har- 2) Disconnect connectors ATC1 and T/C.T (CN22).
ness 3) Connect T-adapter.
3
Between ATC1 (female) (21) and T/C.T Resis-
contact) Max. 1 z
Between ATC1 (female) (9) and T/C.T Resis-
Max. 1 z
Grounding fault in wiring har- 2) Disconnect connectors ATC1 and T/C.T (CN22).
4 ness 3) Connect T-adapter.
Min. 1 Mz
T/C.T (CN22) (female) (1) tance
2) Disconnect connector ATC1 or T/C.T (CN22).
Defective hot short in wiring 3) Insert T-adapter into it.
5 harness 4) Turn the starting switch ON.
Between ground and ATC1 (21) or T/C.T Max. 4.5
Voltage
(CN22) (female) (2) V
136 HD785-7

state troller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as retarder oil tem-
perature sensor).
HD785-7 137
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
138 HD785-7
SEN01944-02
HD785-7

HD785-7 7001 and up
Left bank exhaust temperature sensor system (Front): Disconnection ................................................... 3
Left bank exhaust temperature sensor system (Rear): Disconnection .................................................... 6
Left bank exhaust temperature sensor system (Front): Short circuit ....................................................... 9
Left bank exhaust temperature sensor system (Rear): Short circuit...................................................... 12
Right bank exhaust temperature sensor system (Front): Disconnection ............................................... 15
Right bank exhaust temperature sensor system (Rear): Disconnection................................................ 18
Right bank exhaust temperature sensor system (Front): Short circuit................................................... 21
Right bank exhaust temperature sensor system (Rear): Short circuit ................................................... 24
HD785-7 1
Failure code [DHE5KB] or VHMS_LED display: "n3" o "32" Blow-by pressure sensor: Short circuit .......... 27
Failure code [DHE5KY] (or VHMS_LED display: "n3" o "31")
(Blow-by pressure sensor: Short circuit with power supply line)............................................................ 30
Suspension pressure sensor system: Short circuit (Right front) ............................................................ 32
Suspension pressure sensor system: Disconnection or ground fault (Right front) ................................ 34
Suspension pressure sensor system: Short circuit (Left front) .............................................................. 36
Suspension pressure sensor system: Disconnection or ground fault (Left front)................................... 38
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) .......................... 40
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble:
Out of input signal range (Right rear)..................................................................................................... 41
Suspension pressure sensor system: Short circuit (Right rear)............................................................. 44
Suspension pressure sensor system: Disconnection or ground fault (Right rear) ................................. 46
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)............................. 48
Failure code [DHP7KX] Failure in suspension pressure sensor system:
Out of input signal range (Left rear) ....................................................................................................... 49
Suspension pressure sensor system: Short circuit (Left rear) ............................................................... 52
Suspension pressure sensor system: Disconnection or ground fault (Left rear) ................................... 54
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range............................. 56
Disagreement of run and stop condition with signal .............................................................................. 58
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range .......................... 60
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range........................... 62
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................................... 64
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) ...................................... 66
Failure code [DJF1KA] Fuel level sensor: Disconnection ............................................................................. 72
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)........................................... 74
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent
with swich signal .................................................................................................................................... 75
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ............................. 78
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal..................... 80
Failure code [DK54KX] Body positioner sensor: Out of input signal range................................................... 82
Failure code [DKD0L6] Failure in steering speed sensor.............................................................................. 84
Failure code [DKH0KX] Clinometer sensor signal out of range .................................................................... 86
Failure code [DKH1KX] (or VHMS_LED display: "n4"o"33") Abnormality in clinometer sensor .................. 88
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection........................................... 90
Disagreement of revolution speed signal............................................................................................... 92
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............................... 94
2 HD785-7
Failure code [DGT5KA] (or VHMS_LED display: "n3" o "12") Left bank
exhaust temperature sensor system (Front): Disconnection
Action code Failure code Left bank exhaust temperature sensor system (Front): Disconnection
Trouble
E01 DGT5KA (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
appears on • The left bank exhaust temperature cannot be monitored with the monitoring function.
machine
• The machine monitor does not display the failure code. (If the data saved in the VHMS controller
are downloaded to a personal computer, however, the failure code can be checked.)
• The LED of the VHMS controller indicates "n3" o "12".
Related • The input state (temperature) from the exhaust gas temperature sensor (FL) can be checked with
information the monitoring function (Code: 42604 EXHAUST TEMP FL).
• If failure code [DBB6KP] (VHMS controller 24 V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.

tery ground cable.
Defective left bank sen- 2) Disconnect connector HM-23A and connect the T-adapter to
sor amplifier power sup- female side.
1 ply (defective wiring 3) Connect the battery ground cable and turn the starting switch to
harness or defective ON position.
VHMS & PLM controller) a Ignore the failure code displayed
Approx.
Between HM-23A (female) (A) and (C) Voltage
24 V
a Check that failure code [dGT5KA] is not displayed.
Defective exhaust gas 1) Turn the starting switch to OFF position.
temperature sensor on 2) Swap A and C of connector HM-21, A and C of HM-22 and A and
left bank engine front C of HM-23 sequentially one by one.
side, or defective exhaust 3) Turn the starting switch to ON position and perform troubleshoot-
2 gas temperature sensor ing.
amplifier on left bank 4) Return to step 1) and conduct the test three times to locate the
engine front side, or failed portion.
Possible causes defective intermediate If failure code [DGT5KA] changed to [dGT5KA], the defective portion
and standard wiring harness. must be ahead (on the right side of the replaced connectors in the
value in normal
related circuit diagram).
state
Disconnection in wiring Between HM-23A (female) (A) and HM-CN1 Resis-
Max. 1 z
harness (female) (2) tance
3
(Disconnection or defec- Between HM-23A (female) (B) and HM-CN2A Resis-
Max. 1 z
tive contact of connector) (female) (7) tance
Between HM-23A (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23A.
3) Start engine and carry out troubleshooting.
Defective exhaust gas Exhaust gas temper-
temperature sensor HM-23A Voltage
4 ature
amplifier on the left bank
50 - 100°C 1.0 - 1.6 V
engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
HD785-7 3

If no abnormality is found in the above troubleshooting, the VHMS &
PLM controller may be defective. (Since this is an internal defect,
a Reference
2) Insert T-adapter into connector HM-CN2A
Defective VHMS & PLM 3) Start engine and carry out troubleshooting.
5
controller Exhaust gas temper-
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
value in normal 300 - 400°C 2.1 - 2.7 V
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Since the sensor output voltage range is mV, actual measurement
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21A Voltage
ature
Ref ture in exhaust gas tem- 50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
4 HD785-7
HD785-7 5
Failure code [dGT5KA] (or VHMS_LED display: "n3" o "22") Left bank
exhaust temperature sensor system (Rear): Disconnection 1
Action code Failure code Left bank exhaust temperature sensor system (Rear): Disconnection
Trouble
E01 dGT5KA (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RL) can be checked with
information the monitoring function (Code: 42606 EXHAUST TEMP RL).

tery ground cable.
Defective left bank sen- 2) Disconnect connector HM-23A and connect the T-adapter to
Approx.
Between HM-23C (female) (A) and (C) Voltage
24 V
a Check that failure code [DGT5KA] is not displayed.
temperature sensor on 2) Swap A and C of connector HM-21, A and C of HM-22 and A and
left bank engine rear C of HM-23 sequentially one by one.
engine rear side, or failed portion.
Possible causes defective intermediate If failure code [dGT5KA] changed to [DGT5KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23C (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23C (female) (B) and HM- Resis-
Max. 1 z
tive contact of connector) CN2A (female) (16) tance
Between HM-23C (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23C.
temperature sensor HM-23C Voltage
4 ature
amplifier on the engine
50 - 100°C 1.0 - 1.6 V
rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
6 HD785-7

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
value in normal Between (16) and 300 - 400°C 2.1 - 2.7 V
state (12) 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21C Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 7
8 HD785-7
Failure code [DGT5KB] (or VHMS_LED display: "n3" o "11") Left bank
exhaust temperature sensor system (Front): Short circuit 1
Action code Failure code Left bank exhaust temperature sensor system (Front): Short circuit
Trouble
— DGT5KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

temperature sensor on 2) Disconnect connector HM-21A, HM-22A and HM-23A sequen-
left bank engine front tially one by one.
defective intermediate If failure code [DGT5KB] changed to [DGT5KA], the defective por-
wiring harness. tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connector HM-23A, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23A (female).
2
and standard ness
Resis-
value in normal HM-23A (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23A.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23A
3 ness (female).
(Contact with 24 V circuit) 4) Start engine and carry out troubleshooting.
Between HM-23A (female) (B) or HM-CN2A
Voltage Max. 1 V
(7) and chassis ground
2) Disconnect connectors HM-23A, HM-22A, HM-CN2A.
Grounding fault in wiring 3) Connect T-adapter to anyone (female).
harness
4 Between HM-23A(female) (B) or HM-CN2A Resis-
(Contact with ground cir- Min. 1 Mz
(female) (7) and chassis ground tance
cuit)
Between HM-22A (female) (1) or (2) and Resis-
Min. 1 Mz
HD785-7 9

2) Insert T-adapter into HM-23A
temperature sensor HM-23A Voltage
5 ature
Between (A) and (C) Always 20 - 30 V
engine front side
50 - 100°C 1.0 - 1.6 V
Between (B) and (C) 300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
a Reference
and standard 2) Insert T-adapter into connector HM-CN2A
value in normal Defective VHMS & PLM 3) Start engine and carry out troubleshooting.
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21A Voltage
ature
Ref ture in exhaust gas tem-
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
10 HD785-7
HD785-7 11
Failure code [dGT5KB] (or VHMS_LED display: "n3" o "21") Left bank
exhaust temperature sensor system (Rear): Short circuit 1
Action code Failure code Left bank exhaust temperature sensor system (Rear): Short circuit
Trouble
— dGT5KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

temperature sensor on 2) Disconnect connector HM-21C, HM-22C and HM-23C sequen-
left bank engine rear tially one by one.
defective intermediate If failure code [dGT5KB] changed to [dGT5KA], the defective portion
wiring harness. must be ahead (on the right side of the disconnected connector in
the related circuit diagram).
2) Disconnect connector HM-23C, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23C (female).
2
and standard ness
Resis-
value in normal HM-23C (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23C.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23C
3 ness (female).
Between HM-23C (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23C, HM-22C, HM-CN2A.
harness
4 Between HM-23C(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22C (female) (1) or (2) and Resis-
Min. 1 Mz
12 HD785-7

2) Insert T-adapter into HM-23C
temperature sensor HM-23C Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
Between (16) and 300 - 400°C 2.1 - 2.7 V
(12) 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21C Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 13
14 HD785-7
Failure code [DGT6KA] (or VHMS_LED display: "n3" o "24") Right bank
exhaust temperature sensor system (Front): Disconnection 1
Action code Failure code Right bank exhaust temperature sensor system (Front): Disconnec-
Trouble
— DGT6KA tion (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
appears on • The right bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (FR) can be checked with
information the monitoring function (Code: 42602 EXHAUST TEMP FR).

tery ground cable.
Defective right bank sen- 2) Disconnect connector HM-23B and connect the T-adapter to
Approx.
Between HM-23B (female) (A) and (C) Voltage
24 V
temperature sensor on 2) Swap B and D of connector HM-21, B and D of HM-22 and B and
right bank engine front D of HM-23 sequentially one by one.
amplifier on right bank 4) Return to step 1) and conduct the test three times to locate the
Possible causes defective intermediate If failure code [DGT6KA] changed to [dGT6KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23B (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23B (female) (B) and HM-CN2A Resis-
Max. 1 z
tive contact of connector) (female) (5) tance
Between HM-23B (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23B.
temperature sensor HM-23B Voltage
4 ature
amplifier on the right
50 - 100°C 1.0 - 1.6 V
bank engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
HD785-7 15

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21B Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
16 HD785-7
HD785-7 17
Failure code [dGT6KA] (or VHMS_LED display: "n3" o "26") Right bank
exhaust temperature sensor system (Rear): Disconnection 1
Action code Failure code Right bank exhaust temperature sensor system (Rear): Disconnec-
Trouble
— dGT6KA tion (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RR) can be checked with
information the monitoring function (Code: 42601 EXHAUST TEMP RR).

tery ground cable.
Defective right bank sen- 2) Disconnect connector HM-23D and connect the T-adapter to
Approx.
Between HM-23D (female) (A) and (C) Voltage
24 V
temperature sensor on 2) Swap B and D of connector HM-21, B and D of HM-22 and B and
right bank engine rear D of HM-23 sequentially one by one.
Possible causes defective intermediate If failure code [dGT6KA] changed to [DGT6KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23D (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23D (female) (B) and HM- Resis-
Max. 1 z
tive contact of connector) CN2A (female) (6) tance
Between HM-23D (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23D.
temperature sensor HM-23D Voltage
4 ature
50 - 100°C 1.0 - 1.6 V
bank engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
18 HD785-7

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21D Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 19
20 HD785-7
Failure code [DGT6KB] (or VHMS_LED display: "n3" o "23") Right bank
exhaust temperature sensor system (Front): Short circuit 1
Action code Failure code Right bank exhaust temperature sensor system (Front): Short circuit
Trouble
— DGT6KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (FR) can be checked with
information the monitoring function (Code: 42602 EXHAUST TEMP FR).

temperature sensor on 2) Disconnect connector HM-21B, HM-22B and HM-23B sequen-
right bank engine front tially one by one.
defective intermediate If failure code [DGT6KB] changed to [DGT6KA], the defective por-
wiring harness. tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connector HM-23B, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23B (female).
2
and standard ness
Resis-
value in normal HM-23B (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23B.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23B
3 ness (female).
Between HM-23B (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23B, HM-22B, HM-CN2A.
harness
4 Between HM-23B(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22B (female) (1) or (2) and Resis-
Min. 1 Mz
HD785-7 21

2) Insert T-adapter into HM-23B
temperature sensor HM-23B Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
bank engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21B Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
22 HD785-7
HD785-7 23
Failure code [dGT6KB] (or VHMS_LED display: "n3" o "25") Right bank
exhaust temperature sensor system (Rear): Short circuit 1
Action code Failure code Right bank exhaust temperature sensor system (Rear): Short circuit
Trouble
— dGT6KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RR) can be checked with
information the monitoring function (Code: 42601 EXHAUST TEMP RR).

temperature sensor on 2) Disconnect connector HM-21D, HM-22D and HM-23D sequen-
right bank engine rear tially one by one.
defective intermediate If failure code [dGT6KB] changed to [dGT6KA], the defective portion
wiring harness. must be ahead (on the right side of the disconnected connector in
the related circuit diagram).
2) Disconnect connector HM-23D, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23D (female).
2
and standard ness
Resis-
value in normal HM-23D (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23D.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23D
3 ness (female).
Between HM-23D (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23D, HM-22D, HM-CN2A.
harness
4 Between HM-23D(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22D (female) (1) or (2) and Resis-
Min. 1 Mz
24 HD785-7

2) Insert T-adapter into HM-23D
temperature sensor HM-23D Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
bank engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21D Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 25
26 HD785-7
Failure code [DHE5KB] or VHMS_LED display: "n3" o "32" Blow-by

pressure sensor: Short circuit 1
Action code Failure code Blow-by pressure sensor: Short circuit
Trouble
– DHE5KB (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 0.1 V or less.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
• The LED of the VHMS controller displays "n3" o "32".
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-
• Method of reproducing failure code: Start engine and performs troubleshooting

2) Disconnect connectors HM-CN1, HM12, and HM-CN2A, and
Ground fault in wiring har- connect T-adapters to either female side.
1 ness Between ground and HM-CN1 (female) (4), Resis-
Min. 1 Mz
(Contact with ground circuit) (5), or HM12 (female) (B) tance
Between ground and HM-CN2A (female) Resis-
Min. 1 Mz
(18), or HM12 (female) (C) tance
2) Disconnect connector HM12 and connect the T-adapter to
female side.
Defective sensor power sup- 3) Turn the starting switch to ON position.
Possible causes 2
ply system a If the power supply voltage is abnormal, go to cause 4.
and standard
value in normal 4.85 -
Between HM 12 (female) (B) and (A) Voltage
state 5.15 V
2) Insert the T-adapter into connector HM12.
3) Turn the starting switch to ON position, start the engine and then
perform troubleshooting.
Defective blowby pressure Between HM 12 (C) Sensor output Voltage 0.5 - 4.5 V
3 sensor and (A) At high idle Voltage 0.5 - 0.9 V
(Internal short circuit) 1) Turn the starting switch to OFF position.
2) Disconnect connector HM12 and connect the T-adapter to male
side.
Between ground and HM 12 (male) (A), (B), Resis-
Min. 1 Mz
(C) tance
HD785-7 27

2) Disconnect connectors HM-CN1, HM12, and HM-CN2A, and
connect T-adapters to each female side.
a If the power supply voltage in cause 2 is
normal, this check is not required. Resis-
Between HM-CN2A (female) (12) and HM12 tance
ness (female) (A)
4
contact of connector) a If the power supply voltage in cause 2 is
normal, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (4), (5) and tance
HM12 (female) (B)
Possible causes
and standard Between HM-CN2A (female) (18) and Resis-
Max. 1 z
value in normal HM12(female) (C) tance
state If no abnormality is found in the above troubleshooting, the VHMS
& PLM controller may be defective. (Since this is an internal defect,
a Reference
Defective VHMS & PLM con- 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2A.
5 3) Turn the starting switch to ON position, start the engine and then
troller
4.85 -
Between HM-CN1 (4) and HM-CN2A (12) Voltage
5.15 V
Between HM-CN2A Anytime Voltage 0.5 - 4.5 V
(18) and (12) At high idle Voltage 0.5 - 0.9 V
28 HD785-7
HD785-7 29
Failure code [DHE5KY] or VHMS_LED display: "n3" o "31" Blow-by

pressure sensor: Short circuit with power supply line 1
Action code Failure code Blow-by pressure sensor: Short circuit with power supply line
Trouble
― DHE5KY (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 4.7 V and above.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-
• Method of reproducing failure code: Start engine and performs troubleshooting

2) Disconnect connector HM12 and connect the T-adapter to
female side.
Hot short in wiring harness 3) Turn the starting switch to ON position.
1
Between HM 12 (female) (C) and (A) Voltage Max. 1 V
4.85 -
Between HM 12 (female) (B) and (A) Voltage
5.15 V
2) Disconnect connector HM12.
Defective blowby pressure 3) Turn the starting switch to ON position.
2 sensor
Possible causes (Internal short circuit) If the failure code changes from [DHE5KY] to [DHE5KB] (if LED
and standard display of VHMS controller changes from "31" to "32"), blowby
value in normal pressure sensor is defective.
state If no abnormality is found in the above troubleshooting, the VHMS
a Reference
Defective VHMS & PLM con- 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2A.
3 3) Turn the starting switch to ON position, start the engine and then
troller
4.85 -
Between HM-CN1 (4) and HM-CN2A (12) Voltage
5.15 V
Between HM-CN2A Anytime Voltage 0.5 - 4.5 V
(18) and (12) At high idle Voltage 0.5 - 0.9 V
30 HD785-7
HD785-7 31
Failure code [DHP4KY] or VHMS_LED display: "n5" o "44" Short circuit

in suspension pressure sensor system (Front right) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front right)
Trouble
E01 DHP4KY (VHMS controller system) (Display: PLM)
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front right).
trouble
Action of
controller
Problem that
appears on • PLM may not be displayed normally.
machine
Related
information • Suspension pressure can be checked with the monitoring function (Code: 32804 (MPa) and 32810
(V)).

2) Disconnect connector SUFR.
3) Connect T-adapter to SUFR (female) or insert T-adapter into
HM-CN2B.
Hot short in wiring harness 4) Turn the starting switch ON.
1
(Contact with 24 V circuit) a Ignore the failure code displayed
Between wiring harness HM-
CN2B (1) or SUFR (female) (C) Voltage Max. 1 V
and ground
Defective sensor power sup- 4) Turn the starting switch ON.
2 a Ignore the failure code displayed
ply
Possible causes Power
and standard Between SUFR (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
Defective suspension pres- 3) Turn the starting switch to ON position.
3
sure sensor (FR)
If failure code changes from [DHP4KY] to[DHP4KZ], suspension
pressure sensor(FR) is defective.
If no abnormality is found in the above troubleshooting, the VHMS
a Reference
Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
4 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2B.
troller
Approx.
Between HM-CN1 (2) and HM-CN2B (9) Voltage
24 V
Between HM-CN2B (1) and (9) Voltage 1.0 - 5 V
32 HD785-7
HD785-7 33
Failure code [DHP4KZ] or VHMS_LED display: "n5" o "43" Disconnec-

tion or ground fault in suspension pressure sensor system(Front right)1
Action code Failure code Disconnection or ground fault in suspension pressure sensor sys-
Trouble tem (Front right)
E01 DHP4KZ (VHMS controller system) (Display: PLM)
Contents of • No signal received from the suspension pressure sensor (front right) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Ground fault in wiring har- 3) Connect T-adapter to HM-CN1 and HM-CN2B (female).
1 ness Between HM-CN2B (female) (1) or SUFR Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (C) and ground tance
Between HM-CN1 (female) (2) or SUFR Resis-
Min. 1 Mz
(female) (B) and ground tance
ply
Power
Between SUFR (female) (B) and
supply Approx. 24 V
Possible causes (A)
Voltage
and standard
value in normal 1) Turn the starting switch to OFF.
state Defective suspension pres- 2) Insert T-adapter into connector SUFR.
3 3) Turn the starting switch to ON position.
sure sensor (FR)
Between SUFR (C) and (A) Voltage 1.0 - 5 V
2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Between HM-CN2B (female) (1) and SUFR Resis-
Max. 1 z
(female) (C) tance
Disconnection in wiring har-
ness a If no abnormality is found in checks on
4 cause 2, this check is not required. Resis-
contact of connector) Between HM-CN2B (female) (9) and SUFR tance
(female) (A)
a If no abnormality is found in checks on
cause 2, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (2) and SUFR tance
(female) (B)
34 HD785-7

Possible causes
a Reference
and standard
value in normal Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
state trollers
Between HM-CN1 (2) and HM-
Voltage Approx. 24 V
CN2B (9)
HD785-7 35
Failure code [DHP5KY] or VHMS_LED display: "n5" o "54" Short circuit

in suspension pressure sensor system (Front left) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front left)
Trouble
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front left).
trouble
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFL.
3) Connect T-adapter to SUFL (female) or insert T-adapter into
Hot short in wiring harness HM-CN2B.
a Ignore the failure code displayed
Between wiring harness HM-CN2B (2) or
Voltage Max. 1 V
SUFL (female) (C) and ground
ply
Between SUFL (female) (B) and
and standard supply Approx. 24 V
(A)
value in normal Voltage
state 1) Turn the starting switch to OFF position.
3
sure sensor (FL)
pressure sensor(FL) is defective.
a Reference
Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
troller
CN2B (9)
36 HD785-7
HD785-7 37
Failure code [DHP5KZ] or VHMS_LED display: "n5" o "53" Disconnec-

tion or ground fault in suspension pressure sensor system(Front left) 1
Action code Failure code Disconnection or ground fault in suspension pressure sensor sys-
Trouble tem (Front left)
Contents of • No signal received from the suspension pressure sensor (front left) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Ground fault in wiring har- 3) Connect T-adapter to HM-CN1 and HM-CN2B (female).
1 ness Between HM-CN2B (female) (2) or SUFL Resis-
Min. 1 Mz
Between HM-CN1 (female) (2) or SUFL Resis-
Min. 1 Mz
3) Connect T-adapter.(female)
ply
Power
Between SUFL (female) (B) and
supply Approx. 24 V
Possible causes (A)
Voltage
and standard
value in normal 1) Turn the starting switch to OFF.
state Defective suspension pres- 2) Insert T-adapter into connector SUFL.
3 3) Turn the starting switch to ON position.
sure sensor (FL)
Between SUFL (C) and (A) Voltage 1.0 - 5 V
2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Between HM-CN2B (female) (1) and SUFL Resis-
Max. 1 z
(female) (C) tance
ness a If no abnormality is found in checks on
4 cause 2, this check is not required. Resis-
contact of connector) Between HM-CN2B (female) (9) and SUFL tance
(female) (A)
a If no abnormality is found in checks on
cause 2, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (2) and SUFL tance
(female) (B)
38 HD785-7

Possible causes
a Reference
and standard
value in normal Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
state trollers
CN2B (9)
HD785-7 39
Failure code [DHP6KA] Suspension pressure sensor system:

Disconnection (Right rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection rear right
Trouble
E01 DHP6KA (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
appears on • There is no great influence of machine.
machine
• The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32816 (MPa), 32817 (V)).
information
• This failure occurs only when the built-in PLM function is installed.

and standard
value in normal Carry out troubleshooting for failure code [DH6KX].
state
40 HD785-7
Failure code [DHP6KX] Failure in suspension pressure sensor system

trouble: Out of input signal range (Right rear) 1
Action code Failure code Failure in suspension pressure sensor system trouble: Out of input
Trouble signal range (Right rear)
E03 DHP6KX (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
machine
Related • The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
information tion (Code: 32816 (MPa), 32817 (V)).

2) Disconnect connectors BRC1, SURR, PM6.
Grounding fault in wiring 3) Connect T-adapter to BRC1 or SURR (female).
1 harness Between BRC1 (female) (7) or SURR Resis-
Min. 1 Mz
Between ground and BRC1 (female) (21) or Resis-
Min. 1 Mz
SURR (female) (A) tance
2) Disconnect connector SURR.
3) Connect T-adapter to SURR (female) or insert T-adapter into
Hot short in wiring harness BRC1.
2
Possible causes (Contact with 24V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and BRC1 (female) (7) or
Voltage Max. 1 V
state SURR (female) (C)
2) Disconnect connector SURR and connect T-adapter to it
(female)
Defective sensor power sup- 3) Turn starting switch ON.
3
plly
Power
Between SURR (female) (B) and
supply 18 ± 3 V
(A)
Voltage
Defective suspension 3) Insert T-adapter.
4
pressure sensor (Right rear) 4) Turn starting switch ON.
Between SURR (C) and (A) Voltage 1.0 – 5 V
HD785-7 41

2) Disconnect connectors BRC1, SURR, and PM6.
3) Connect T-adapter.(female)
Between BRC1 (female) (7) and SURR Resis-
Max. 1 z
(female) (C) tance
Disconnection in wiring
harness a If the power supply voltage is normal,
5 this check is not required. Resis-
contact) Between BRC1 (female) (21) and SURR tance
(female) (A)
a If the power supply voltage is normal,
this check is not required. Resis-
Between PM6 (female) (2) and SURR tance
and standard (female) (B)
value in normal
2) Disconnect connector PM6 and connect the T-adapter to male
6 Defective PLM controller side.
Between PM 6 (2) and (3) Voltage 18 ± 3 V
If no abnormality is found in the above troubleshooting, the retarder
controller may be defective. (Since this is an internal defect, trou-
a Reference
2) Insert the T-adapter into connector BRC1.
Between BRC1 (7) and (21) Voltage 1.0 – 5 V
42 HD785-7
HD785-7 43
Failure code [DHP6KY] or VHMS_LED display: "n5" o "64" Suspension

pressure sensor system: Short circuit (Right rear) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Right rear)
Trouble
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor (right rear).
trouble
Action of
• Stops auto-suspension function.
controller
Problem that
appears on • Auto-suspension function does not operate.
machine
information • Suspension pressure can be checked with monitoring function (Code: 32806 (MPa), 32812 (V)).

3) Connect T-adapter to SURR (female) or insert HM-CN2B.
Hot short in wiring harness 4) Turn starting switch ON.
1
(Contact with 24V circuit) a Ignore the failure code displayed
Between ground and HM-CN2B (7) or
Voltage Max. 1 V
SURR (female) (C)
3) Connect T-adapter to it (female)
plly
and standard Between SURR (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
3
sure sensor (RR)
pressure sensor(RR) is defective.
Defective VHMS & PLM con- a Reference
4
troller 1) Turn the starting switch to OFF position.
2) Insert the T-adapter into connector HM-CN2B.
Between HM-CN2B (7) and (9) Voltage 1.0 – 5 V
44 HD785-7
HD785-7 45
Failure code [DHP6KZ] or VHMS_LED display: "n5" o "63" Suspension

pressure sensor system: Disconnection or ground fault (Right rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Right rear)
Contents of
• Signal is not sent from suspension pressure sensor (right rear) or it is grounded.
trouble
Action of
controller
Problem that
machine

2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
3) Connect T-adapter to HM-CN1(female), HM-2B (female) or
Grounding fault in wiring har- SURR (female).
1 ness
Between HM-CN2B (female) (7) or SURR Resis-
(Contact with ground circuit) Min. 1 Mz
(female) (C) and ground tance
Between ground and HM-CN1 (female) (2) Resis-
Min. 1 Mz
or SURR (female) (B) tance
3) Connect T-adapter to it (female).
Defective sensor power sup- 4) Turn starting switch ON
2
plly
Power
Between SURR (female) (B)
supply Approx. 24 V
and (A)
Voltage
Possible causes 2) Disconnect connector SURR.
and standard 3
value in normal
state Between SURR (C) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
3) Connect T-adapters to them (female).
Disconnection in wiring har- Between HM-CN2B(female) (7) and SURR Resis-
ness Max. 1 z
4 (female) (C) tance
contact of connector) Between HM-CN2B (female) (9) and SURR Resis-
Max. 1 z
(female) (A) tance
Between HM-CN1 (female) (2) and SURR Resis-
Max. 1 z
(female) (B) tance
5
trollers 1) Turn the starting switch to OFF position.
46 HD785-7
HD785-7 47
Failure code [DHP7KA] Suspension pressure sensor system:

Disconnection (Left rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection (Left rear)
Trouble
E01 DHP7KA (Retarder controller system)
Contents of
• The voltage of the signal circuit of the suspension pressure sensor (Left rear) is below 0.3 V.
trouble
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [DHP7KX].
state
48 HD785-7
Failure code [DHP7KX] Failure in suspension pressure sensor system

trouble: Out of input signal range (Left rear) 1
Action code Failure code Failure in suspension pressure sensor system trouble (Left rear):
Out of input signal range
Trouble
E03 DHP7KX (When ARSC is not set or ARSC system switch is "ON")
Contents of • The voltage of the signal circuit of the suspension pressure sensor (left) is below1.0 V or above 4.6
trouble V.
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

2) Disconnect connectors BRC1, SURL, and PM6.
Grounding fault in wiring 3) Connect T-adapter.
1 harness Between ground and BRC1 (female) (1) or Resis-
Min. 1 Mz
(Contact with ground circuit) SURL (female) (C) tance
Between ground and PM6 (female) (2) or Resis-
Min. 1 Mz
SURL (female) (B) tance
2) Disconnect connector SURL.
3) Connect T-adapter to connector SURL (female) or insert T-
Hot short in wiring harness adapter into BRC1
2
Possible causes (Contact with 24V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and BRC1 (1) or SURL
Voltage Max. 1 V
state (female) (C)
2) Disconnect connector SURL and connect T-adapter to it
(female)
3
ply
Power
Between SURL(female) (B) and
supply 18 ± 3 V
(A)
Voltage
4
pressure sensor (Left rear) 4) Turn starting switch ON.
Between SURL (C) and (A) Voltage 1.0 – 5 V
HD785-7 49

2) Disconnect connectors BRC1, SURL, and PM6.
3) Connect T-adapters (female).
Between BRC1 (female) (1) and SURL Resis-
Max. 1 z
(female) (C) tance
harness a If the power supply voltage is normal,
5 this check is not required. Resis-
contact) Between BRC1 (female) (21) and SURL tance
(female) (A)
Between PM6 (female) (2) and SURL tance
and standard (female) (B)
value in normal
2) Disconnect connector PM6 and connect the T-adapter to male
6 Defective PLM controller side.
Between PM 6 (male) (2) and (3) Voltage 18 ± 3 V
If no abnormality is found in the above troubleshooting, the retarder
a Reference
2) Insert the T-adapter into connector BRC1.
Between BRC1 (1) and (3) Voltage 1.0 – 5 V
50 HD785-7
HD785-7 51
Failure code [DHP7KY] or VHMS_LED display: "n5" o "74" Suspension

pressure sensor system: Short circuit (Left rear) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Left rear)
Trouble
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor.
trouble
Action of
controller
Problem that
machine

3) Connect T-adapter to SURL (female) or insert HM-CN2B.
1
Between ground and HM-CN2B (8) or
Voltage Max. 1 V
SURL (female) (C)
3) Connect T-adapter to it (female)
plly
and standard Between SURL (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
3
sure sensor (RL)
pressure sensor(RL) is defective.
4
troller 1) Turn the starting switch to OFF position.
Between HM-CN2B (8) and (9) Voltage 1.0 – 5 V
52 HD785-7
HD785-7 53
Failure code [DHP7KZ] or VHMS_LED display: "n5" o "73" Suspension

pressure sensor system: Disconnection or ground fault (Left rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Left rear)
Contents of
• Signal is not sent from suspension pressure sensor or it is grounded (Abnormal).
trouble
Action of
controller
Problem that
machine

2) Disconnect connectors BRC1, SURL, HM-CN1 and HM-CN2B.
3) Connect T-adapter to HM-CN1(female), HM-2B (female) or
Grounding fault in wiring har- SURL (female).
1 ness
Between HM-CN2B (female) (8) or SURL Resis-
Between ground and HM-CN1 (female) (2) or Resis-
Min. 1 Mz
SURL (female) (B) tance
Defective sensor power sup- 3) Connect T-adapter to it (female).
plly
Between SURL (female) (B) and Power sup-
Approx. 24 V
(A) ply Voltage
Possible causes
value in normal 2) Disconnect connector SURL.
state 3
Between SURL (C) and (A) Voltage 1.0 – 4.6 V

2) Disconnect connectors BRC1, SURL, HM-CN1 and HM-CN2B.
3) Connect T-adapters to them (female)
Wiring harness between HM-CN2B(female) Resis-
Max. 1 z
(8) and SURL (female) (C) tance
ness a If the power supply voltage is normal, this
4 check is not required. Resis-
contact of connector) Wiring harness between HM-CN2B (female) tance
(9) and SURL (female) (A)
a If the power supply voltage is normal, this
check is not required. Resis-
Max. 1 z
Wiring harness between HM-CN1 (female) tance
(2) and SURL (female) (B)
54 HD785-7

5
trollers 1) Turn the starting switch to OFF position.
HD785-7 55
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of

Action code Failure code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX (Transmission controller system)
Contents of • The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in
controller itself.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32600 (MPa), 32605 (V)).
information

2) Disconnect connectors ATC1, ATC3 and T/C.P(CN21).
Ground fault in wiring 3) Connect T-adapter.
1 harness Between ground and ATC3A (female) (8) or T/ Resis-
Min. 1 Mz
(Contact with ground circuit) C.P(CN21) (female) (B) tance
Between ground and ATC1 (female) (1) or T/ Resis-
Min. 1 Mz
C.P(CN21) (female) (C) tance
2) Disconnect connector T/C.P(CN21).
3) Insert T-adapter into ATC1 or connect T-adapter to T/C.P(CN21)
Defective hot short in wiring (female)
Possible causes (Contact with 24V circuit)
and standard Between ground and ATC1 (1) or
value in normal between T/C.P(CN21) (female) Voltage Min. 1 V
state (C) and ground
2) Disconnect connector T/C.P(CN21) and connect T-adapter
(female).
3 a If the power supply voltage is abnormal, go to cause 5.
ply
Power
Between T/C.P(CN21) (female)
supply 20 – 30 V
(B) and (A)
Voltage
Defective torque converter 3) Insert T-adapter.
4
oil pressure sensor 4) Turn the starting switch ON.
Between T/C.P(CN21) (C) and (A) Voltage 0.8 – 2.0 V
56 HD785-7

2) Disconnect connectors ATC1, ATC3, and CN21.
3) Connect T-adapters (female)
a If no failure is found by check on cause 3,
Between ATC3(female) (8) and T/C.P(CN21) tance
harness (female) (B)
5
contact) a If no failure is found by check on cause 3,
Between ATC1(female) (21) and T/C.P(CN21) tance
and standard (female) (A)
value in normal
Between ATC1 (female) (1) and T/C.P(CN21) Resis-
state Max. 1 z
(female) (C) tance
mission controller may be defective. (Since this is an internal
a Reference
Defective transmission con- 1) Turn the starting switch to OFF position.
6
troller 2) Insert the T-adapter into connectors ATC1 and ATC3.
Between ATC1 (1) and (21) Voltage 20 – 30 V
Between ATC3 (8) and ATC1 (21) Voltage 0.8 – 2.0 V
HD785-7 57

Disagreement of run and stop condition with signal 1
Action code Failure code Torque converter oil pressure sensor: Disagreement of run and
Trouble stop condition with signal
E01 DHT5L6 (Transmission controller system)
• While the engine is stopped, the transmission controller detects oil pressure via output voltage from
Contents of
torque converter oil pressure sensor. (Output voltage of torque converter oil pressure sensor does
trouble
not decrease after engine is stopped.)
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure init-
controller self.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32601 (MPa), 32602 (V)).
information

3) Insert T-adapter into connector ATC1 or connect T/C.P(CN21)
Defective hot short in wiring (female).
Between ATC1 (1) or T/C.P(CN21) (female)
Voltage Max. 1.2 V
(C) and ground
2) Disconnect connector T/C.P (CN21).
Possible causes Defective torque converter a Ignore failure code [DHT5KX]
and standard 2
oil pressure sensor If failure code [DHT5L6] disappears, torque converter oil pressure
value in normal
sensor is defective.
state
a If failure code [DHT5L6] is displayed, the wiring harness or the
transmission controller is defective.
a Reference
3 2) Insert the T-adapter into connectors ATC1 and ATC3.
troller
Between ATC3 (8) and ATC1
Voltage 20 – 30 V
(21)
Between ATC1 (1) and (21) Voltage 0.8 – 2.0 V
58 HD785-7
HD785-7 59
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of

Action code Failure code Front accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU2KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35500 (MPa), and
Related 35504 (V)).
information • When only rear accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Disconnect connector ACCF and ATC1.
3) Connect T-adapter to connectors ATC1 (female) and ACCF
Ground fault in wiring har- (female).
1 ness
ACCF (female) (C) tance
Min. 1 Mz
ACCF (female) (B) tance
2) Disconnect connector ACCF.
3) Connect to connector ACCF (female) or insert T-adapter into
Hot short in wiring harness ATC1.
Possible causes 2
(Contact with 24 V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and ATC1 (13) or ACCF
state Voltage Max. 1 V
(C) (female)
2) Disconnect connector ACCF.
3) Connect T-adapter to connector ACCF (female).
Defective sensor power sup- 4) Carry out troubleshooting while starting switch is ON.
3 a If the power supply voltage is abnormal, to to cause 5.
ply
Power
Between ACCF (female) (B) and (A) supply 4.6 – 5.4 V
Voltage
Defective front accumulator 2) Insert T-adapter into connector ACCF.
4 3) Carry out troubleshooting while starting switch is ON.
oil pressure sensor
Between ACCF (C) and (A) Voltage 0.3 – 4.7 V
60 HD785-7

2) Connect T-adapter to connectors ATC1 (female) and ACCF
(female).
Between ATC1 (female) (13) and ACCF Resis-
Max. 1 z
(female) (C) tance
harness a If no failure is found by check on cause
5 3, this check is not required. Resis-
(Disconnection or Max. 1 z
defective contact) Between ATC1 (female) (21) and ACCF tance
(female) (A)
Possible causes a If no failure is found by check on cause
and standard
3, this check is not required. Resis-
Between ATC1 (female) (22) and ACCF tance
state
(female) (B)
a Reference
6
troller 2) Insert the T-adapter into connector ATC1.
HD785-7 61
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of

Action code Failure code Rear accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU3KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35501 (MPa),
Related and 35505 (V)).
information • When only front accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Connect T-adapter to connectors ATC1 (female) and ACCR
Ground fault in wring har- (female).
1 ness Between ground and ATC1 (female) (7) or Resis-
Min. 1 Mz
(Contact with ground circuit) ACCR (female) (C) tance
Min. 1 Mz
ACCR (female) (B) tance
2) Connect T-adapter to connector ACCR (female) or insert T-
Hot short in wiring harness adapter into ATC1.
(a contact with 24V circuit)
Between ground and ATC1 (7) or ACCR
Voltage Max. 1 V
(C) (female)
2) Connect T-adapter to connector ACCR (female).
3) Carry out troubleshooting while starting switch is ON.
Defective sensor power sup- a If the power supply voltage is abnormal, go to cause 5.
Possible causes 3
ply
and standard Power
value in normal Between ACCR (female) (B) and (A) supply 4.6 – 5.4 V
state Voltage
Defective rear accumulator 2) Insert T-adapter into ACCR.
4 3) Carry out troubleshooting while starting switch is ON.
oil pressure sensor
Between ACCR (C) and (A) Voltage 0.3 – 4.7 V
2) Connect T-adapter to connectors ATC1 (female) and ACCR
(female).
Between ATC1 (female) (7) and ACCR Resis-
Max. 1 z
(female) (C) tance
harness a If no failure is found by check on cause
5 3, this check is not required. Resis-
(Disconnection or Max. 1 z
defective contact) Between ATC1 (female) (21) and ACCR tance
(female) (A)
a If no failure is found by check on cause
3, this check is not required. Resis-
Max. 1 z
Between ATC1 (female) (22) and ACCR tance
(female) (B)
62 HD785-7

Possible causes defect, troubleshooting cannot be performed.).
and standard a Reference
value in normal Defective transmission con- 1) Turn the starting switch to OFF position.
6
state troller 2) Insert the T-adapter into connector ATC1.
HD785-7 63
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front right)
Trouble
E01 DHU6KX (ABS controller system)
Contents of • Input voltage from ABS control valve pressure sensor (front right: FR) became 0.3 V or less or 4.7 V
trouble and over.
Action of
controller • Stop ABS control.
Problem that
• ABS does not work.
appears on
machine • Ordinary brake operation can be carried out.
Related • ABS control valve pressure sensor output can be checked with the monitoring function (Code:
information 43314 (MPa) and 43315 (V)).

2) Disconnect connector ABS1 and BPFR.
3) Connect T-adapter to ABS1 and BPFR (female).
Disconnection in wiring Between ABS1 (female) (19) and BPFR Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFR Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (22) and BPFR Resis-
Max. 1 z
(female) (B) tance
2) Disconnect connector ABS1 and BPFR.
3) Connect T-adapter to ABS1 (female) or BPFR (female).
Ground fault in wiringhar-
2 Between ABS1 (female) (19) or BPFR Resis-
ness Max. 1 z
Between ABS1 (female) (22) or BPFR Resis-
Max. 1 z
Possible causes 1) Turn the starting switch OFF.

and standard 2) Disconnect connector BPFR.
value in normal 3) Connect T-adapter to BPFR (female) or insert T-adapter into
state 3 Hot short in wiring harness ABS1.
Between ABS1 (19) or BPFR (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFR.
Defective ABS control valve 3) Replace with the front left pressure sensor. (See [DHU7KX].)
pressure sensor (FR)
If failure code [DHU6KX] does not appear, ABS control valve
pressure sensor (FR) is defective.
If no abnormality is found in the above troubleshooting, the ABS
a Reference
5 Defective ABS controller 1) Turn the starting switch to OFF position.
2) Insert the T-adapter into connector ABS1.
Between ABS1 (22) and (21) Voltage 4.6 – 5.4V
Between ABS1 (19) + and (21) Voltage 0.3 – 4.7 V
64 HD785-7
HD785-7 65

(Front left) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (front left: FL) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

2) Disconnect connector ABS1 and BPFL.
3) Connect T-adapter to ABS1 and BPFL (female).
Disconnection in wiring Between ABS1 (female) (13) and BPFL Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFL Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (22) and BPFL Resis-
Max. 1 z
(female) (B) tance
3) Connect T-adapter to ABS1 (female) or BPFL (female).
2 Between ABS1 (female) (13) or BPFL Resis-
ness Max. 1 z
Between ABS1 (female) (22) or BPFL Resis-
Max. 1 z

and standard 2) Disconnect connector BPFL.
value in normal 3) Connect T-adapter to BPFL (female) or insert T-adapter into
Between ABS1 (13) or BPFL (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the front right pressure sensor. (See [DHU6KX].)
pressure sensor (FL)
pressure sensor (FL) is defective.
a Reference
Between ABS1 (22) and (21) Voltage 4.6 – 5.4V
66 HD785-7
HD785-7 67

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear right)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear right: RR) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

2) Disconnect connector ABS1 and BPRR.
3) Connect T-adapter to ABS1 and BPRR (female).
Disconnection in wiring Between ABS1 (female) (7) and BPRR Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPRR Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (16) and BPRR Resis-
Max. 1 z
(female) (B) tance
2) Disconnect connector ABS1 and BPRR.
3) Connect T-adapter to ABS1 (female) or BPRR (female).
2 Between ABS1 (female) (7) or BPRR Resis-
ness Max. 1 z
Between ABS1 (female) (16) or BPRR Resis-
Max. 1 z

and standard 2) Disconnect connector BPRR.
value in normal 3) Connect T-adapter to BPRR (female) or insert T-adapter into
Between ABS1 (7) or BPRR (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPRR.
Defective ABS control valve 3) Replace with the rear left pressure sensor. (See [DHU9KX].)
pressure sensor (RR)
pressure sensor (RR) is defective.
a Reference
Between ABS1 (16) and (21) Voltage Approx. 24 V
68 HD785-7
HD785-7 69

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear left: RL) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

3) Connect T-adapter to ABS1 and BPFL (female).
Disconnection in wiring Between ABS1 (female) (1) and BPFL Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFL Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (16) and BPFL Resis-
Max. 1 z
(female) (B) tance
3) Connect T-adapter to ABS1 (female) or BPFL (female).
2 Between ABS1 (female) (1) or BPFL Resis-
ness Max. 1 z
Between ABS1 (female) (16) or BPFL Resis-
Max. 1 z

and standard 2) Disconnect connector BPFL.
value in normal 3) Connect T-adapter to BPFL (female) or insert T-adapter into
Between ABS1 (1) or BPFL (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the rear right pressure sensor. (See [DHU8KX].)
pressure sensor (RL)
pressure sensor (RL) is defective.
a Reference
Between ABS1 (16) and (21) Voltage Approx. 24 V
70 HD785-7
HD785-7 71
Failure code [DJF1KA] Fuel level sensor: Disconnection 1

Action code Failure code Fuel level sensor: Disconnection
Trouble
E01 DJF1KA (Transmission controller system)
Contents of
trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Action of
controller • None in particular.
Problem that
appears on • The fuel level gauge does not indicate normally.
machine
Related
information • This failure can be checked in the monitoring function (Code: 04200 (V), 04201 (z)).

2) Disconnect connector FUEL.
3) Connect T-adapter to male side.
1 Defective fuel level sensor Fuel level: Resis-
Max. 12 z
Between FUEL When FULL tance
(male) (1) and (2) Fuel level: Resis-
74 – 100 z
When EMPTY tance
2) Disconnect connector ATC1 and connect T-adapter (female).
2 Fuel level: Resis-
in wiring harness Max. 12 z
Between ATC1 When FULL tance
(female) (8) and (21) Fuel level: Resis-
Possible causes 74 – 100 z
When EMPTY tance
and standard
value in normal a If no abnormality is found in checks on cause 2, this check is not
state required.
Disconnection in wiring 2) Disconnect connectors ATC1and FUEL.
3
contact) Between ATC1 (female) (8) and FUEL Resis-
Max. 1 z
(female) (1) tance
Between ATC1 (female) (21) and FUEL Resis-
Max. 1 z
(female) (2) tance
Defective hot short in wiring 2) Insert T-adapter connector ATC1.
Between ATC1 (female) (8) and (21). Voltage Max. 4 V
troller
be performed.)
72 HD785-7
HD785-7 73
Failure code [DK30KX] Steering angle potentiometer: Trouble

(Disconnection) 1
Action code Failure code Steering angle potentiometer: Trouble (Disconnection)
Trouble
E01 DK30KX (Retarder controller system)
Contents of
trouble • There is no voltage in signal coming from steering angle potentiometer.
Action of
Problem that
appears on • Since steering angle signal is not input to retarder controller, ASR may not operate normally and
machine tires may slip consequently.
Related • Input state from steering angle sensor can be checked with monitoring function (Code: 35400 (V),
information 35402(°))

Turn starting switch OFF and disconnect ASR1, then carry out
troubleshooting without turning starting switch ON.
ASR1 (Male: Sensor side) Resistance
Defective steering angle Between (A) and (C) 5 kz ± 20%
1
sensor
Between (A) and (B) 0 – 5 kz *1
Between (B) and (C) 0 – 5 kz *1
*1 Between (A) and (B) + between (B) and (C) = 5 kz ± 20%
a Turn starting switch OFF and disconnect ASR1, then carry out
Possible causes Between ASR1 (female) (B) and BRC1 Resis-
Max. 1 z
and standard Disconnection in wiring har- (female) (2) tance
value in normal ness (Disconnection in wiring
2
state or defective contact in con- 1) Turn starting switch OFF and disconnect ASR1.
nector) 2) Turn starting switch ON and carry out troubleshooting.
ASR1 (Female: Wiring harness
Voltage
side)
Between (C: +) and (A: -) 5V
a Turn starting switch OFF and disconnect connector ASR1 and
Grounding fault in wiring har- BRC1, then carry out troubleshooting without turning starting
3 ness (Contact with ground switch ON.
circuit) Resis-
Between ASR1 (female) (B) and ground Min. 1 Mz
tance
out.)
74 HD785-7
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer

signal is inconsistent with swich signal 1
Action code Failure code Retarder lever potentiometer: Potentiometer signal is inconsistent
Trouble with swich signal
E03 DK51L5 (Retarder controller system)
Contents of • The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
trouble the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
Action of • Controls with the potentiometer signal.
controller • Limits the output for the solenoid to 70%.
• Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that
• This failure does not have a serious effect on the machine.
appears on
• The retarder cannot control finely.
machine
• The retarder does not operate (The foot brake operates, however).
Related
• This failure can be checked in the monitoring function (Code: 33900 (V)).
information

2) Disconnect connectors BRC1, BRC3, RE1, and RTL.
3) Connect T-adapter to them (female).
Between BRC1 (female) (22) and RE1 Resis-
Max. 1 z
(female) (1) tance
Between RE1 (female) (2) and RTL Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring Between BRC1 (female) (21) and RTL Resis-
harness Max. 1 z
1 (female) (3) tance
contact) Between BRC1 (female) (14) and RTL Resis-
Max. 1 z
(female) (2) tance
Possible causes
Between BRC1 (female) (24) and RTL Resis-
(female) (4) tance
value in normal
state Between BRC1 (female) (18) and RTL Resis-
Max. 1 z
(female) (5) tance
Between RTL (female) (6) and BRC3 Resis-
Max. 1 z
(female) (21), (31), (32), (33) tance
2) Disconnect connectors BRC1, RE1, and RTL.
3) Connect T-adapter to BRC1 (female).
Grounding fault in wiring Between ground and BRC1 (female) (22) or Resis-
Min. 1 Mz
2 harness RE1 (female) (1) tance
(Contact with ground circuit) Between ground and RE1 (female) (2) or Resis-
Min. 1 Mz
RTL (female) (1) tance
Between ground and BRC1 (female) (14) Resis-
Min. 1 Mz
or RTL (female) (2) tance
HD785-7 75

2) Disconnect connector RTL.
3) Connect T-adapter to RTL (female) or insert T-adapter into
BRC1.
Hot short in wiring
3 harness
(Contact with 24V circuit) Between ground and BRC1 (22) or RTL
Voltage Approx. 5 V
(female) (1)
Between ground and BRC1 (14) or RTL
Voltage Max. 1 V
(female) (2)
2) Disconnect connector RE1.
4 Defective resistor (RE1) 3) Connect T-adapter.
Resis-
Between RE1 (male) (1) and (2) 250 ± 5 z
tance
2) Disconnect connector RTL
5) Check the potentiometer.
Between RTL (1) and (3) Voltage 4.1 – 4.8 V
Between RTL (2) and (3) Voltage 0.3 – 4.7 V
2) Disconnect connector RTL
5 Defective retarder lever 3) Connect T-adapter.
4) Check the switch.
Possible causes
and standard Lever at OFF posi- Resis-
Max. 1 z
value in normal Between RTL (male) tion tance
state (4) – (6) Resis-
Lever at ON position Min. 1 Mz
tance
Lever at OFF posi- Resis-
Min. 1 Mz
Between RTL (male) tion tance
(5) – (6) Resis-
Lever at ON position Max. 1 z
tance
2) Disconnect connectors BRC1, and BRC3.
Between BRC1 (22) and BRC3,
(21), (31), (32), (33)
Between BRC1 (14) and BRC3,
(21), (31), (32), (33)
2) Disconnect connector RTL.
6 Defective retarder controller 3) Connect T-adapter.
4) Check the switch.
Between BRC1 Max. 1 z
tion tance
(female) (24) and
ground Resis-
Lever at ON position Min. 1 Mz
tance
Between BRC1 Min. 1 Mz
tion tance
(female) (18) and
ground Resis-
Lever at ON position Max. 1 z
tance
76 HD785-7
HD785-7 77
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of

Action code Failure code Failure in hoist lever potentiometer 1: Out of input signal range
Trouble (Out of input signal range of lever potentiometer 1 or 2)
Contents of • The signal voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 0.3 V or above 4.7
trouble V.
Action of
• Operates body by using normal one of 2 potentiometers.
controller
Problem that
appears on • Machine is not affected in particular.
machine
Related
information

2) Disconnect connectors BRC1, BRC3, and HSL.
3) Connect T-adapter to them (female).
Between BRC3 (female) (34) and HSL Resis-
(female) (4) tance
harness
1 Between BRC1 (female) (20) and HSL Resis-
(female) (2) tance
contact)
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (1) tance
and standard 2) Disconnect connectors BRC1, BRC3, and HSL.
value in normal 3) Connect T-adapter.
state Grounding fault in wiring Between ground and BRC3 (female) (34) Resis-
Min. 1 Mz
2 harness or HSL (female) (4) tance
(Contact with ground circuit) Between ground and BRC1 (female) (20) Resis-
Min. 1 Mz
or HSL (female) (2) tance
Between ground and BRC1 (female) (19) Resis-
Min. 1 Mz
or HSL (female) (3) tance
Hot short in wiring harness 4) Turn the starting switch ON.
3
(Contact with 24V circuit) Between ground and HSL (female) (4) Voltage Approx. 5 V
Between ground and HSL (female) (2) Voltage Max. 1 V
Between ground and HSL (female) (3) Voltage Max. 1 V
78 HD785-7

2) Disconnect connector HSL.
4 Defective hoist lever
Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Possible causes If no abnormality is found in the above troubleshooting, the retarder
and standard controller may be defective. (Since this is an internal defect, trou-
value in normal bleshooting cannot be performed.)
state
a Reference
5 Defective retarder controller 3) Insert T-adapter.
4)Turn the starting switch ON.
Between BRC3 (34) – BRC1
(21)
Between BRC1 (20) – (21) Voltage 0.3 – 4.7 V
HD785-7 79
Failure code [DK53L8] Failure in hoist lever potentiometer 2:

Disagreement of analog signal 1
Action code Failure code Failure in hoist lever potentiometer 2: Disagreement of analog
Trouble signal
E03 DK53L8 (Retarder controller system)
Contents of
• The total voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
trouble
Action of
• The controller recognizes the hoist lever position as "NEUTRAL".
controller
Problem that
appears on • Body does not operate.
machine
Related • This failure can be checked in the monitoring function (Code: 34305 (V)).
information • If the failure code "DK52KX" is displayed, perform troubleshooting for it.

Short circuit in wiring har- 3) Connect the T-adapter to the female side of HSL.
1
ness
Resis-
Between HSL (female) (2) and (3) Max. 1 z
tance
2) Disconnect connector HSL and connect the T-adapter to male
side.
Possible causes
Resis-
and standard Between HSL (male) (2) and (3) Max. 1 z
tance
value in normal
state 1) Turn the starting switch OFF.
2 Defective hoist leverx 2) Insert T-adapter into connector HSL.
Sum of voltages 2 and 3 Voltage 4.5 – 5.5 V
• If the failure is not repaired by performing the troubleshooting in
1 above, the retarder controller is defective.
80 HD785-7
HD785-7 81
Failure code [DK54KX] Body positioner sensor: Out of input signal

range 1
Action code Failure code Body positioner sensor: Out of input signal range
Trouble
Contents of
• The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
trouble
Action of • The controller controls dumping according to the hoist lever signal.
controller • The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that
• The hoist lever positioner does not function.
appears on
machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the hoist lever is not at "FLOAT".
Related
information

2) Disconnect connector B07.
1 Defective body positioner
Resis-
Between B07 (male) (C) and (A) 4 – 6 kz
tance
Resis-
Between B07 (male) (B) and (A) 0 – 6 kz
tance
2) Disconnect connectors BRC1, BRC3, and B07.
Disconnection in wiring Between BRC1 (female) (8) and B07 Resis-
harness Max. 1 z
2 (female) (B) tance
contact) Between BRC3 (female) (34) and B07 Resis-
Max. 1 z
Possible causes (female) (C) tance
and standard Between BRC1 (female) (21) and B07 Resis-
(female) (A) tance
state
2) Disconnect connectors BRC1, BRC3, and B07.
Grounding fault in wiring 3) Connect T-adapters to them (female).
3 harness Between BRC1 (female) (8) or B07 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (B) and ground tance
Between BRC3 (female) (34) or B07 Resis-
Min. 1 Mz
2) Disconnect connector B07.
3) Connect T-adapter B07 (female) or insert T-adapter into conec-
Hot short in wiring tor BRC1, BRC3.
(Contact with 24V circuit) Between ground and BRC1 (8) or B07
Voltage Max. 1 V
(female) (B)
Between ground and BRC3 (34) or B07
Voltage Max. 1 V
(female) (C)
82 HD785-7

If no abnormality is found in the above troubleshooting, the
retarder controller may be defective. (Since this is an internal
Possible causes a Reference
value in normal 5 Defective retarder controller 2) Disconnect connectors BRC1, BRC3, and B07.
state 3) Insert T-adapter.
Between BRC3 (34) – BRC1
(21)
HD785-7 83
Failure code [DKD0L6] Failure in steering speed sensor 1

Action code Failure code Failure in steering speed sensor
Trouble
E01 DKD0L6 (Retarder controller system)
Contents of • Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sen-
trouble sor and no signals are input.
Action of
controller • Fix the auto-suspension in the M mode.
Problem that
machine
Related
information • This failure can be checked in the monitoring function (Code: 35403 (rad/s)).

2) Disconnect connector SR3.
1
ply
Power
Between SR3 (female) (1) and (3) supply 10 – 13 V
Voltage
2) Disconnect connectors BRC1, BRC2, and SR3.
Between BRC2 (female) (29) and SR3 tance
harness (female) (3)
2
contact) Between BRC2 (female) (37) and SR3 Resis-
Max. 1 z
(female) (2) tance
Possible causes a If the power supply voltage is normal,
and standard this check is not required. Resis-
Between BRC1 (female) (16) and SR3 tance
state (female) (1)
2) Disconnect connectors BRC1, BRC2, and SR3.
Grounding fault in wiring Between ground and BRC2 (female) (37) Resis-
Min. 1 Mz
3 harness or SR3 (female) (2) tance
(Contact with ground circuit) a If the power supply voltage is normal,
Min. 1 Mz
Between ground and BRC1 (female) (16) tance
or SR3 (female) (1)
a The measurement is impoosible with the multimeter because of
pulse voltage.
Steering speed sensor 2) Disconnect connector SR3.
4 3) Insert T-adapter.
defective
5) Turn the steering wheel slowly.
Between SR3 (2) and (3) Voltage See Fig-1.
84 HD785-7

If no abnormality is found in the above troubleshooting, the
retarder controller may be defective. (Since this is an internal
a Reference
2) Disconnect connectors BRC1, BRC2.
Possible causes 3) Insert T-adapter.
and standard 4) Turn the starting switch ON.
value in normal
state 5 Retarder controller defective Between BRC1 (16) and Voltage 10 – 13 V
BRC2 (29)
a The measurement is impoosible with the multimeter because of
pulse voltage.
5) Turn the steering wheel slowly.
Between BRC2 (37) and (29) Voltage See Fig-1.
HD785-7 85
Failure code [DKH0KX] Clinometer sensor signal out of range 1

Action code Failure code Clinometer sensor signal out of range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of Inclination sensor has become below 0.5 V or above 4.5 V.
Action of
Problem that
appears on • Machine roll angle abnormality [989D00] cannot be detected.
machine
• Signal from Inclination sensor can be checked with monitoring function (Code: 32900 (°) and 32903
Related
(V)).
information
• Cannot detect tipping over.

2) Disconnect connector AS3.
3) Connect T-adapter to connector AS3 (female).
Defective sensor power
supply
Power
Between AS3 (female) (C) and (A) supply 20 – 30 V
Voltage
2) Disconnect connectors ATC1 and AS3.
3) Connect T-adapter to connectors ATC1 (female) and AS3
(female).
Between ATC1 (female) (19) and AS3 Resis-
Max. 1 z
Disconnection in wiring (female) (B) tance
harness a If the power supply voltage is normal, this
2
(Disconnection or defective check is not required. Resis-
contact) Max. 1 z
Between ATC1 (female) (16) and AS3 tance
Possible causes (female) (C)
and standard a If the power supply voltage is normal, this
value in normal check is not required. Resis-
Max. 1 z
state Between ATC1 (female) (21) and AS3 tance
(female) (A)
2) Disconnect connectors ATC1 and AS3.
3) Connect T-adapter to ATC1 or AS3 (female).
Ground fault in wring har- Between ground and ATC1 (female) (19) or Resis-
Min. 1 Mz
3 ness AS3 (female) (B) tance
(Contact with ground circuit) a If the power supply voltage is normal, this
Min. 1 Mz
Between ground and ATC1 (female) (16) or tance
AS3 (female) (C)
2) Disconnect connector AS3.
Defective hot short in wiring 3) Connect T-adapter to AS3 (female) or insert T-adapter into
4 harness ATC1.
Between ground and ATC1 (female) (19) or
Voltage Max. 1 V
AS3 (female) (B)
86 HD785-7

2) Insert T-adapter into AS3.
5 Defective pitch angle sensor 3) Turn starting switch ON.
Between AS3 (B) and (A)
a Approximately 2.6 V in horizontal
Possible causes mission controller may be defective. (Since this is an internal defect,
and standard troubleshooting cannot be performed.)
value in normal
state a Reference
Defective transmission 1) Turn starting switch OFF.
6 2) Insert T-adapter into connector ATC1.
controller
Between ATC1 (16) – (21) Voltage 20 – 30 V
Between ATC1 (19) – (21)
HD785-7 87
Failure code [DKH1KX] (or VHMS_LED display: "n4"o"33") Abnormality

in clinometer sensor 1
Action code Failure code Pitch angle sensor: Abnormality (Disconnection or short circuit)
Trouble
E01 DKH1KX (VHMS & PLM controller system)
Contents of
• Abnormality (Disconnection or short circuit) was detected in signal from pitch angle sensor.
trouble
controller • Cannot detect tipping over.
Problem that
appears on • Load weight is not displayed or recorded correctly.
machine
Related
information • Input signal from pitch angle sensor can be checked with monitoring function (Code: 32901 (°),
32902 (V)).

2) Disconnect connector PM3.
3) Connect T-adapter to PM3 (female).
1
ply
Power
Between PM3 (female) (C) and (A) supply 20 - 30 V
Voltage
2) Disconnect connectors HM-CN1, HM-CN2B and PM3.
3) Connect T-adapter to HM-CN1 (female) or HM-CN2B (female)
and PM3 (female).
Between HM-CN2B (female) (3) and PM3 Resis-
Max. 1 z
ness a If the power supply voltage is normal, this
2
(Disconnection or defective check is not required. Resis-
contact) Max. 1 z
Between HM-CN1 (female) (2) and PM3 tance
Possible causes (female) (C)
and standard a If the power supply voltage is normal, this
value in normal check is not required. Resis-
state Max. 1 z
Between HM-CN2B (female) (9) and PM3 tance
(female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B and PM3.
3) Connect T-adapter to HM-CN1 (female) or HM-CN2B (female).
Between ground and HM-CN2B (female) Resis-
Ground fault in wring har- Min. 1 z
3 (3) or PM3(female) (B) tance
ness
(Contact with ground circuit) a If the power supply voltage is normal, this
Min. 1 z
Between ground and HM-CN1 (female) (2) tance
or PM3(female) (C)
2) Disconnect connector PM3.
Defective hot short in wiring 3) Connect T-adapter to PM3 (female) or insert T-adapter into
4 harness HM-CN2B.
Between ground and HM-CN2B (female)
Voltage Max. 1 V
(3) or PM3 (female) (B)
88 HD785-7

2) Insert T-adapter into connector PM3.
5 Defective clinometer sensor 3) Turn starting switch ON.
Between PM3 (B) and (A)
Voltage 0.5 - 4.5 V
Possible causes & PLM controller may be defective. (Since this is an internal defect,
and standard troubleshooting cannot be performed.)
value in normal
state a Reference
Defective VHMS & PLM con- 1) Turn starting switch OFF.
6 2) Insert T-adapter into HM-CN1, HM-CN2B.
troller
Between HM-CN1 (2) and HM-CN2B (9) Voltage 20 - 30 V
Between HM-CN2B (3) and HM-CN2B (9)
Voltage 0.5 - 4.5 V
HD785-7 89
Failure code [DLF1KA] Transmission input shaft speed sensor:

Disconnection 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E03 DLF1KA (Transmission controller system)
Contents of • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not
trouble input.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
• The lockup system is reset and the gear cannot be shifted.
appears on
Related
• This failure can be checked in the monitoring function (Code: 31200 (rpm)).
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission input shaft
a For details, see Testing and adjusting, "Adjustment of transmis-
speed sensor
sion speed sensor".
2) Disconnect connector N1 (CN3).
Defective transmission input
2 Resis-
shaft speed sensor Between N1 (CN3) (male) (1) and (2) 500 – 1,000 z
tance
Between N1 (CN3) (male) (1), (2) and Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Disconnection or short circuit 3) Connect T-adapter (female).
value in normal 3
in wiring harness
state Resis-
Between ATC2 (female) (40) and (29) 500 – 1,000 z
tance
required.
Disconnection in wiring 2) Disconnect connectors ATC2 and N1 (CN3).
4
Between ATC2 (female) (40) and N1 Resis-
contact) Max. 1 z
Between ATC2 (female) (29) and N1 Resis-
Max. 1 z
troller
be performed. )
90 HD785-7
HD785-7 91

Disagreement of revolution speed signal 1
Action code Failure code Transmission input shaft speed sensor: Disagreement of revolution
Trouble speed signal
E03 DLF1LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed
Contents of
sensor signal, and transmission output shaft speed sensor signal is different from the signal speed
trouble
of the transmission input shaft speed sensor.
Problem that
appears on
Related
information

Defective transmission input
1 Resis-
shaft speed sensor Between N1 (CN3) (male) (1) and (2) 500 – 1,000 z
tance
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect connectors ATC2 and N1 (CN3).
2 harness 3) Connect T-adapter (female).
(Contact with ground circuit) Between ground and ATC2 (female) Resis-
Min. 1 Mz
Possible causes (40) or N1 (CN3) (female) (1) tance
value in normal 2) Disconnect connectors N1 (CN3).
state 3) Connect T-adapter to N1 (CN3) (female) or insert T-adapter into
Defective hot short in wiring
3 harness ATC2.
(Contact with 24V circuit) 4) Turn the starting switch ON.
Between ground and ATC2 (40) or N1
Voltage Max. 1 V
(CN3) (female) (1)
2) Disconnect connector ATC2 and N1 (CN3).
Short circuit in wiring har- 3) Connect T-adapter to ATC2 (female).
4
ness
Between ATC2 (female) (40) and each Resis-
Min. 1 Mz
pin other than (40) tance
troller
be performed. )
92 HD785-7
HD785-7 93
Failure code [DLF2KA] Transmission intermediate shaft speed sensor:

Disconnection 1
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA (Transmission controller system)
Contents of • The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals
trouble are not input.
Problem that
appears on
Related
information

Wrong adjustment of
1 transmission intermediate
shaft speed sensor
sion speed sensor".
Defective transmission inter-
2 Resis- 500 –
mediate shaft speed sensor Between N2 (CN4) (male) (1) and (2)
tance 1,000 z
Min. 1 Mz
ground tance
Possible causes
and standard Disconnection or short circuit 3) Connect T-adapter (female).
value in normal 3
in wiring harness
state Resis- 500 –
tance 1,000 z
required.
Disconnection in wiring 2) Disconnect connectors ATC2, N2 (CN4).
4
Between ATC2 (female) (20) and N2 (CN4) Resis-
contact) Max. 1 z
(female) (1) tance
Between ATC2 (female) (39) and N2 (CN4) Resis-
Max. 1 z
(female) (2) tance
troller
be performed. )
94 HD785-7
HD785-7 95

Action code Failure code Transmission intermediate shaft speed sensor: Disagreement of
Trouble revolution speed signal
E03 DLF2LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from the signal speed of the
trouble
transmission intermediate shaft speed sensor.
Problem that
appears on
Related
information

Transmission intermediate
1 Resis-
shaft speed sensor defective Between N2 (CN4) (male) (1) and (2) 500 – 1,000 z
tance
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect connectors ATC2 and N2 (CN4).
2 harness 3) Connect T-adapter (female).
(Contact with ground circuit) Between ground and ATC2 (female) Resis-
Possible causes Min. 1 Mz
(20) or N2 (CN4) (female) (1) tance
and standard
state 2) Disconnect connector N2 (CN4).
Defective hot short in wiring 3) Connect T-adapter to N2 (CN4) or insert T-adapter into ATC2.
Between ground and ATC2 (20) or N2
Voltage Max. 1 V
(CN4) (female) (1)
2) Disconnect connector ATC2 and N2 (CN4).
Short circuit in wiring har- 3) Connect T-adapter to ATC2 (female).
4
ness
Between ATC2 (female) (20) and each Resis-
Min. 1 Mz
pin other than (20) tance
troller
be performed. )
96 HD785-7
HD785-7 97
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
98 HD785-7
SEN01945-02
HD785-7

HD785-7 7001 and up
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right) ................................................... 4
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right)............................................................... 6
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)...................................................... 8
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) ............................................................... 10
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear right) .................................................... 12
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)..................................................... 14
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right)............................................................... 16
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right) ................................................... 16
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) ...................................................... 18
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left).................................................................. 20
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) ................................................................. 22
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left)...................................................... 22
Failure code [DLT3KA] Transmission output shaft speed sensor: Disconnection......................................... 24
Failure code [DLT4KA] Transmission output shaft speed sensor: Disconnection......................................... 28
HD785-7 1
Failure code [DLT4MA] Transmission output shaft speed sensor: Disconnection ........................................ 30
Failure code [DUM7KY] Pre-lubrication operation lamp output abnormality: Hot short circuit...................... 32
Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality:
Disconnection or grounding fault ........................................................................................................... 34
Failure code [DV00KB] Buzzer output: Short circuit ..................................................................................... 36
Failure code [DW2AKA] Main pressure variable valve output: Disconnection.............................................. 38
Failure code [DW2AKB] Main pressure variable valve output circuit: Ground fault ...................................... 40
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot short ........................................... 42
Failure code [DW2AL1] Main pressure variable valve: Defective reset ........................................................ 44
Failure code [DW2ALH] Main pressure variable valve: Malfunction ............................................................. 46
Failure code [DW2BKA] Main oil level selector valve output: Disconnection................................................ 47
Failure code [DW2BKB] Main oil level selector valve output circuit: Ground fault ........................................ 48
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot short ............................................. 50
Failure code [DW2BL1] Main oil level selector valve: Defective reset .......................................................... 52
Failure code [DW2BLH] Main oil level selector valve: Malfunction ............................................................... 54
Failure code [DW2CKA] Transmission lubrication variable valve output: Disconnection.............................. 55
Failure code [DW2CKB] Transmission lubrication variable valve output circuit: Ground fault ...................... 56
Failure code [DW2CKY] Transmission lubrication variable valve output circuit: Hot short ........................... 58
Failure code [DW2CL1] Transmission lubrication variable valve: Defective reset ........................................ 60
Failure code [DW2CLH] Transmission lubrication variable valve: Malfunction ............................................. 62
Disconnection or short circuit................................................................................................................. 64
Failure code [DW71KZ] Exhaust brake output system trouble (Disconection/Ground fault/Hot short) ......... 68
Failure code [DW72KZ] Kick-out solenoid output system trouble: Disconnection or short circuit................. 70
Failure code [DW73KZ] Failure in hoist select valve output system: Disconnection or short circuit ............. 72
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output system trouble:
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps operating)............................................. 76
Failure code [DWNBKA] ASR shut-off valve output circuit: Disconnection ................................................... 78
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault...................................................... 80
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit ...................................................... 82
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not operate) .......................................... 82
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system .......................................................... 84
Failure code [DWNDMA] Defective ABS cut-off valve (Front) ...................................................................... 86
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system........................................................... 88
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) ....................................................................... 90
2 HD785-7
HD785-7 3
Failure code [DLF6KA] Disconnection in wheel speed sensor (Front

right) 1
Action code Failure code Disconnection in wheel speed sensor (Front right)
Trouble
E03 DLF6KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front right: FR).
Action of
Problem that
appears on
Related
information • Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
Defective wheel speed
1
sensor (FR) WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
2) Disconnect WSFR and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 (Disconnection in wiring or Between WSFR (female) (1) – ABS2 Resis-
Max. 1 z
defective contact in connec- (female) (40) tance
tor)
Between WSFR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFR and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFR (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Hot short in wiring harness 3) Connect T-branch to ABS2.
(Contact 24 V circuit)
Between ABS2 (40) – WSFR (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (40) – Resis-
1,150 – 1,450 z
(29) tance
4 HD785-7
HD785-7 5
Failure code [DLF6L3] Trouble in wheel speed sensor (Front right) 1

Action code Failure code Trouble in wheel speed sensor (Front right)
Trouble
E03 DLF6L3 (ABS controller system)
Contents of • Input signal (pulse signal) from the wheel speed sensor (front right: FR) to ABS controller is abnor-
trouble mal.
Action of
• Stop ABS control.
controller
Problem that
appears on
Related
• Wheel speed sensor (FR) signal can be checked with monitoring (Code: 39707 (rpm)).
information

and standard
value in normal Carry out troubleshooting for failure code [DLF6KA].
state
6 HD785-7
HD785-7 7
Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)1

Action code Failure code Disconnection in wheel speed sensor (Front left)
Trouble
E03 DLF7KA (ABS controller system)
Contents of • Defective harness wiring, defective speed sensor and the defective installation, etc. occurred and
trouble the pulse signal is not input to the signal circuit of wheel speed sensor (front left: FL).
Action of
Problem that
appears on
Related
information • Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).

a Turn the starting switch OFF, disconnect WSFR and carry out
troubleshooting in this state.
1 Defective sensor
WSFR (male: sensor side) Resistance
Between (1) – (2) 1,150 – 1,450 z
2) Disconnect WSFL and ABS2.
Disconnection in wiring 3) Connect the T-branch and carry out troubleshooting in this state.
harness
2 (Disconnection in wiring or Between WSFR (female) (1) – ABS2 Resis-
Max. 1 z
defective contact in connec- (female) (30) tance
tor)
Between WSFL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (29) tance
Possible causes
and standard a Turn the starting switch OFF, disconnect WSFL and carry out
value in normal Ground fault in wiring troubleshooting in this state.
state 3 harness
(Contact with ground circuit) Between WSFL (female) (1) and ground Resis-
Min. 1 Mz
tance
2) Disconnect connector ABS2 and WSFR.
Hot short in wiring harness 3) Connect T-branch to ABS2.
(Contact 24 V circuit)
Between ABS2 (30) – WSFL (female) (1)
Voltage Max. 1 V
and ground
2) Disconnect ABS2.
5 Defective ABS controller 3) Connect the T-branch and carry out troubleshooting in this state.
Between ABS2 (female) (30) – Resis-
1,150 – 1,450 z
(29) tance
8 HD785-7
HD785-7 9
Failure code [DLF7L3] Trouble in wheel speed sensor (Front left) 1

Action code Failure code Trouble in wheel speed sensor (Front left)
Trouble
Contents of • Input signal (pulse signal) from the wheel speed sensor (front left: FL) to ABS controller is abnor-
trouble mal.
Action of
• Stop ABS control.
controller
Problem that
appears on
Related
• Wheel speed sensor (FL) signal can be checked with monitoring (Code: 39706 (rpm)).
information

and standard
state
10 HD785-7
HD785-7 11
Failure code [DLF8KA] Wheel speed sensor: Disconnection (Rear

right) 1
Action code Failure code Wheel speed sensor: Disconnection (Rear right)
Trouble
E01 DLF8KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
• Does not control ASR.
controller
Problem that
appears on • ASR is not controlled normally.
machine
• ABS controller inspects same trouble by failure code [DLF8MA].
a If ABS is installed and [DLF8MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF8MA] is displayed, perform following operations.
Related
2) Disconnect ABS7 connector.
information
Check that failure code [DLF8KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.
• Input state from wheel speed sensor (right rear) can be checked with monitoring function (Code:
39709 (rpm)).

a Turn starting switch OFF and disconnect WSRR, then carry out
Defective wheel speed sen- troubleshooting without turning starting switch ON.
1
sor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Possible causes harness
Between WSRR (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring Max. 1 z
(female) (10) tance
value in normal or defective contact in
state connector) Between WSRR (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
If causes 1 – 3 are not detected, retarder controller may be
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
12 HD785-7
HD785-7 13
Failure code [DLF8L3] Wheel speed sensor: Disconnection (Rear right)1

Trouble
Contents of
• Wheel speed signal (pulse) input to ABS controller is abnormal.
trouble
Action of
• Does not control ABS.
controller
Problem that
appears on • ABS is not controlled normally.
machine
• Retarder controller inspects same trouble by failure code [DLF8LC].
a If [DLF8L3] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF8LC] is displayed, disconnect BRC2 connector and check that [DLF8L3] is displayed
information again and then carry out following troubleshooting.
39709 (rpm)).

1
sor WSRR (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRR, ABS2
conector, then carry out troubleshooting without turning starting
harness switch ON.
Possible causes
and standard 2 (Disconnection in wiring Between WSRR (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (20) tance
state connector) Between WSRR (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRR (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
14 HD785-7
HD785-7 15
Failure code [DLF8LC] Wheel speed sensor: Trouble (Rear right) 1

Action code Failure code Wheel speed sensor: Trouble (Rear right)
Trouble
E01 DLF8LC (Retarder controller system)
Contents of
• Wheel speed signal (pulse) input to retarder controller is abnormal.
trouble
Action of
• Does not control retarder.
controller
Problem that
machine
• ABS controller inspects same trouble by failure code [DLF8L3].
a If ABS is installed and [DLF8L3] is not displayed, sensor and wiring harness out of cab are
judged normal.
Related
a If ABS is installed and [DLF8L3] is displayed, turn starting switch OFF and disconnect ABS7
information
connector. Check that failure code [DLF8LC] is displayed again.
39709 (rpm)).

and standard
state
Failure code [DLF8MA] Wheel speed sensor: Disconnection (Rear right)1

Trouble
E03 DLF8MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
machine
• Retarder controller inspects same trouble by failure code [DLF8KA].
a If [DLF8KA] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF8KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
information BRC2 connector. Check that failure code [DLF8MA] is displayed again.
39709 (rpm)).

and standard
value in normal Carry out troubleshooting for failure code [DLF8L3].
state
16 HD785-7
HD785-7 17
Failure code [DLF9KA] Wheel speed sensor: Disconnection (Rear left) 1

Action code Failure code Wheel speed sensor: Disconnection (Rear left)
Trouble
E01 DLF9KA (Retarder controller system)
Contents of
• Wheel speed signal (pulse) is not input to retarder controller.
trouble
Action of
controller
Problem that
• ASR is not controlled normally.
appears on
• (ABS is not controlled normally.)
machine
• ABS controller inspects same trouble by failure code [DLF9MA].
a If ABS is installed and [DLF9MA] is not displayed, sensor and wiring harness out of cab are
judged normal.
a If ABS is installed and [DLF9MA] is displayed, perform following operations.
Related
2) Disconnect ABS7 connector.
information
Check that failure code [DLF9KA] is displayed again (factors of ABS controller are eliminated)
and then carry out following troubleshooting.
• Input state from wheel speed sensor (left rear) can be checked with monitoring function (Code:
39708 (rpm)).

a Turn starting switch OFF and disconnect WSRL, then carry out
Defective wheel speed sen-
1
sor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
Disconnection in wiring troubleshooting without turning starting switch ON.
Possible causes harness
Between WSRL (female) (1) – BRC2 Resis-
and standard 2 (Disconnection in wiring or Max. 1 z
(female) (20) tance
value in normal defective contact
state in connector) Between WSRL (female) (2) – BRC2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
4 Defective retarder controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
18 HD785-7
HD785-7 19
Failure code [DLF9L3] Wheel speed sensor: Trouble (Rear left) 1

Action code Failure code Wheel speed sensor: Trouble (Rear left)
Trouble
Contents of
trouble
Action of
controller
Problem that
machine
• Retarder controller inspects same trouble by failure code [DLF9LC].
a If [DLF9LC] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF9LC] is displayed, disconnect BRC2 connector and check that [DLF9L3] is displayed
information again and then carry out following troubleshooting.
39708 (rpm)).

1
sor WSRL (Male: Sensor side) Resistance
Between (1) – (2) 1,750 z ± 10 %
a Turn starting switch OFF and disconnect BRC2, WSRL and
ABS2 connectors, then carry out troubleshooting without turn-
harness ing starting switch ON.
Possible causes
and standard 2 (Disconnection in wiring Between WSRL (female) (1) – ABS2 Resis-
Max. 1 z
value in normal or defective contact in (female) (11) tance
state connector) Between WSRL (female) (2) – ABS2 Resis-
Max. 1 z
(female) (39) tance
3 harness
(Contact with ground circuit) Between WSRL (female) (1) – ground Resis-
Min. 1 Mz
tance
carried out.)
20 HD785-7
HD785-7 21
Failure code [DLF9LC] Wheel speed sensor: Trouble (Rear left) 1

Action code Failure code Wheel speed sensor: Trouble (Rear left)
Trouble
E01 DLF9LC (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine
• ABS controller inspects same trouble by failure code [DLF9L3].
a If ABS is installed and [DLF9L3] is not displayed, sensor and wiring harness out of cab are
judged normal.
Related
a If ABS is installed and [DLF9L3] is displayed, turn starting switch OFF and disconnect ABS7
information
connector. Check that failure code [DLF9LC] is displayed again.
39708 (rpm)).

and standard
state
Failure code [DLF9MA] Wheel speed sensor: Disconnection (Rear left) 1

Action code Failure code Wheel speed sensor: Disconnection (Rear left)
Trouble
E03 DLF9MA (ABS controller system)
Contents of
• Wheel speed signal (pulse) is not input to ABS controller.
trouble
Action of
controller
Problem that
• ABS is not controlled normally.
appears on
• (Retarder is not controlled normally.)
machine
• Retarder controller inspects same trouble by failure code [DLF9KA].
a If [DLF9KA] is not displayed, sensor and wiring harness out of cab are judged normal.
Related a If [DLF9KA] is displayed, turn starting switch OFF and disconnect retarder controller connector
information BRC2 connector. Check that failure code [DLF9MA] is displayed again.
39708 (rpm)).

and standard
value in normal Carry out troubleshooting for failure code [DLF9L3].
state
22 HD785-7
HD785-7 23
Failure code [DLT3KA] Transmission output shaft speed sensor:

Disconnection 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • The signal circuit of the transmission output shaft speed sensor is disconnected and signals are not
trouble input.
• Keeps gear speed when trouble occurs.
Action of
• If gearshift lever is set in "N", gear is kept in neutral.
controller
• Turns lockup system OFF.
1) Stop travel and set gearshift lever in "N" position.
2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
Problem that
other to set machine in emergency escape mode.
appears on
machine
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – L or from N to R.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
Related
information

Wrong adjustment of
1 transmission output shaft
speed sensor
sion speed sensor".
2) Disconnect connector CN5.
2 Resis- 500 –
output shaft speed sensor Between CN5 (male) (1) – (2)
tance 1,000 z
Possible causes Resis-
Between CN5 (male) (1), (2) – ground Min. 1 Mz
and standard tance
state 2) Disconnect connectors BRC2, ATC2, CN5.
harness 3) Connect T-adapter to ATC2 (female) and CN5 (female).
3 (Disconnection in wiring or Wiring harness between ATC2 (female) (30) Resis-
Max. 1 z
defective contact in connec- – CN5 (female) (1) tance
tor) Wiring harness between ATC2 (female) (29) Resis-
Max. 1 z
– CN5 (female) (2) tance
2) Disconnect connectors BRC2, ATC2.
Defective transmission 3) Connect T-adapter to ATC2 (female).
4
controller
Resis- 500 –
Between ATC2 (female) (30) – (29)
tance 1,000 z
24 HD785-7
HD785-7 25

Action code Failure code Transmission output shaft speed sensor: Disagreement of revolu-
Trouble tion speed signal
E01 DLT3LC (Retarder controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission intermediate shaft speed sensor signal is different from the signal speed of
trouble
the transmission output shaft speed sensor.
Problem that
appears on
machine • If the shift lever is set in the "N" position, the gear is set in neutral.
Related
information

1 Resis- 500 –
tance 1,000 z
Between CN5 (male) (1), (2) – chassis Resis-
Min. 1 Mz
ground tance
2) Disconnect connectors ATC2, BRC2, and CN5.
Grounding fault in wiring 3) Connect T-adapter.
2 harness
Possible causes
(Contact with ground circuit) Between ground and wiring harness Resis-
and standard between ATC2 (female) (30) – BRC2 Min. 1 Mz
(female) (30) – CN5 (female) (1)
state
2) Disconnect connectors ATC2, BRC2, CN5.
Defective hot short in wiring 3) Connect T-adapter.
(a contact with 24 V circuit) Wiring harness between ATC2 (female) (30)
– BRC2 (female) (30) – CN5 (female) (1) Voltage Max. 1 V
and chassis ground
Defective transmission 3) Connect T-adapter.
4
controller
Resis- 500 –
Between ATC2 (female) (30) – (29)
tance 1,000 z
26 HD785-7
HD785-7 27
Failure code [DLT4KA] Transmission output shaft speed sensor:

Disconnection 1
Trouble
E01 DLT4KA (Retarder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• Turns output to ASR proportional solenoid OFF.
Action of • Turns output to auto-suspension solenoid OFF.
controller • When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
• ARSC control cannot be continued. (Even if ARSC switch ON with ARSC selection.)
• ASR control cannot be continued.
Problem that 1) Stop travel and set gearshift lever in "N" position.
appears on 2) Disconnect emergency escape connectors A1 (female) and A1 (male) and connect them to each
machine other to set machine in emergency escape mode.
a When operating gearshift lever, release accelerator pedal.
a Operate gearshift lever from N to D – L or from N to R.
a Machine is kept in emergency escape mode until starting switch is turned OFF.
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (rpm)).
Related
Wheel speed can be also checked with monitoring function (Code: 39704 (rpm), 39705 (rpm)).
information
• Controller does not defect ground fault and hot short.

Wrong adjustment of
then return it by 1/2 - 1 turn.
1 transmission output shaft
speed sensor
sion speed sensor".
2) Connect T-adapter to connector CN5 (male).
Defective transmission Resis- 500 –
2 Between CN5 (male) (1) – (2)
output shaft speed sensor tance 1,000 z
Resis-
Possible causes Between CN5 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
value in normal 1) Turn starting switch OFF.
state Disconnection in wiring 2) Disconnect connectors ATC2, BRC2, and CN5.
harness 3) Connect T-adapter to BRC2 (female) and CN5 (female).
3 (Disconnection in wiring or Wiring harness between BRC2 (female) (30) Resis-
Max. 1 z
defective contact in connec- – CN5 (female) (1) tance
tor) Wiring harness between BRC2 (female) (29) Resis-
Max. 1 z
2) Disconnect connectors BRC2 and ATC2.
4 Defective reterder controller 3) Connect T-adapter to BRC2 (female).
Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
28 HD785-7
HD785-7 29
Failure code [DLT4MA] Transmission output shaft speed sensor:

Disconnection 1
Trouble
E03 DLT4MA (Reterder controller system)
Contents of • When ARSC, ASR, and auto-suspension are set, signal circuit of transmission output shaft speed
trouble sensor has disconnection and no signals are input.
• ASR control released.
• Turns output to ASR proportional solenoid OFF.
Action of
controller • Turns output to auto-suspension solenoid OFF.
• When ARSC operates, brake is released gradually, then control is stopped until power is turned
OFF.
Problem that
• ARSC control cannot be continued.
appears on
• Transmission output shaft speed can be checked with monitoring function (Code: 31400 (rpm),
31403 (rpm)). Wheel speed can be also checked with monitoring function (Code: 39704 (rpm),
Related
39705 (rpm)).
information
• Controller does not defect ground fault and hot short.
• "Method for emergency escape procedure" refers to [DLT4KA]

2) Disconnect connectors ATC2, BRC2, CN5.
Disconnection in wiring 3) Connect T-adapter to connectors BRC2 (female) and CN5
harness (female).
Wiring harness between BRC2 (female) (30) Resis-
defective contact in connec- Max. 1 z
tor)
Wiring harness between BRC2 (female) (29) Resis-
Max. 1 z
2 Resis- 500 –
tance 1,000 z
Resis-
Between CN5 (male) (1), (2) – ground Min. 1 Mz
and standard Press the sensor lightly against the revolution pickup gear, and
value in normal Wrong adjustment of
state 3 transmission output shaft
speed sensor
sion speed sensor".
2) Disconnect connectors ATC2, BRC2, PM5, and CN5.
Grounding fault in wiring 3) Connect T-adapter to connector BRC2 (female).
4 harness Between ground and wiring harness
(Contact with ground circuit) between BRC2 (female) (30) – ATC2 Resis-
Min. 1 Mz
(female) (30) – PM5 (female) (7) – CN5 tance
(female) (1)
2) Disconnect connectors BRC2, ATC2, PM5, and CN5.
Defective hot short in wiring 4) Turn the starting switch ON.
5 harness
(a contact with 24 V circuit) Between ground and wiring harness
between ATC2 (female) (30) – BRC2
Voltage Max. 1 V
(female) (30) – PM5 (female) (7) – CN5
(female) (1)
30 HD785-7

and standard 2) Disconnect connector BRC2 and ATC2.
value in normal 6 Defective reterder controller 3) Connect T-adapter.
state Resis- 500 –
Between BRC2 (female) (30) – (29)
tance 1,000 z
HD785-7 31
Failure code [DUM7KY] Pre-lubrication operation lamp output

abnormality: Hot short circuit 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Hot short circuit
Trouble
E01 DUM7KY (Pre-lubrication controller system)
Contents of • Pre-lubrication controller shows abnormality at operation lamp output: Hot short circuit is detected.
trouble (PRE5 (17) pin voltage: Min. 5.7 V)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

2) Disconnect PRE9 and PRE10, then carry out troubleshooting.
a Measure in diode range.
1 Between connectors PRE10 (male) and
lamp Continuity Yes
PRE9 (female)
Between connectors PRE9 (female) and
Continuity None
PRE10 (male)
Possible causes
and standard
value in normal Between connectors PRE5 (female) (17) – Resis-
Min. 1 Mz
state (30) tance
Hot short circuit of wiring
2 harness (Contact with 1) Turn starting switch OFF.
power supply circuit) 2) Disconnect connector PRE10.
3) Connect T-branch to connector PRE5 (female).
Voltage Max. 1 V
ground
controller
ried out.)
32 HD785-7
HD785-7 33
Failure code [DUM7KZ] Pre-lubrication operation lamp output

abnormality: Disconnection or grounding fault 1
Action code Failure code Pre-lubrication operation lamp output abnormality: Disconnection or
Trouble grounding fault)
E01 DUM7KZ
(Pre-lubrication controller system)
• Pre-lubrication controller shows abnormality when the operation lamp does not output: Disconnec-
Contents of
tion and/or grounding fault is detected.
trouble
(PRE5 (17) pin voltage: Max. 5.7 V for 3 seconds)
Action of
• Pre-lubrication controller stops output to operation lamp.
controller
Problem that
appears on • Pre-lubrication operation lamp does not light up or remains lit.
machine
Related • The output state of the pre-lubrication operation lamp can be checked with the monitoring code
information 40975, "D-00T-15" (1: ON, 0: OFF).

a Measure in diode range.
1 Between connectors PRE10 (male) and
lamp Continuity Yes
PRE9 (female)
Between connectors PRE9 (male) and
Continuity None
PRE10 (male)
Disconnection in wiring 1) Turn starting switch OFF.
Possible causes harness (Disconnection or 2) Disconnect PRE5 and PRE9, then carry out troubleshooting.
2
and standard defective contact in Between connectors PRE5 (female) (17) – Resis-
Max. 1 z
value in normal connector) PRE9 (male) tance
2) Disconnect PRE5, PRE9 and PRE10, then carry out troubleshoot-
Grounding fault in wiring ing.
3 harness (Contact with Between PRE5 (female) (17) and chassis Resis-
Min. 1 Mz
ground circuit) ground tance
Resis-
Between PRE9 (female) and chassis ground Min. 1 Mz
tance
controller
ried out.)
34 HD785-7
HD785-7 35
Failure code [DV00KB] Buzzer output: Short circuit 1

Action code Failure code Buzzer output: Short circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• When signal is output to buzzer circuit, abnormal current flows.
trouble
Action of • Keeps abnormality until starting switch is turned OFF.
machine monitor • Turns alarm buzzer output OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
Related • If buzzer sounds, BZ2 (2) is Sink output (Normal).
information • Controller cannot detect disconnection and ground fault of wiring harness.

1) Turn starting switch OFF, disconnect connector BZ2, and
remove buzzer.
1 Defective buzzer 2) Connect +24 V to BZ2 (male) (1) and connect GND to BZ2
(male) (2).
a If buzzer does not sound, buzzer is defective. (Replace)
Grounding fault in wiring a Turn starting switch OFF and disconnect BZ2, then carry out
harness troubleshooting without turning starting switch ON.
2
(Contact with ground circuit) Resis-
(Reference) Between DPC1 (male) (13) – ground Min. 1 Mz
tance
Possible causes 1) Turn starting switch OFF, disconnect DPC1 and BZ2, and insert
Hot short T-adapter in DPC1 (female).
and standard
3 (Contact with 24V circuit) in 2) Turn starting switch ON and carry out troubleshooting.
value in normal
wiring harness
state Between DPC1 (male) (13) – ground Voltage Max. 1 V
Disconnection in wiring without turning starting switch ON. (When voltage in Cause 1 is
harness abnormal)
4 (Disconnection in wiring or Resis-
Between DPC1 (female) (13) – BZ2 (2) Max. 1 z
defective contact in tance
connector) (Reference) Resis-
Between BT2 (16) – BZ2 (1) Max. 1 z
tance
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
36 HD785-7
HD785-7 37
Failure code [DW2AKA] Main pressure variable valve output:

Disconnection 1
Action code Failure code Main pressure variable valve output: Disconnection
Trouble
E01 DW2AKA (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to main pressure variable valve solenoid circuit.
controller
Problem that
appears on • If the machine keeps traveling as it is, fuel consumption increases.
machine
• Output state to main pressure variable valve solenoid can be checked with monitoring function
Related (Code: 31643 (mA)).
information • Signal is not output to main pressure variable valve solenoid circuit until starting switch is turned
OFF once.

Defective main pressure without turning starting switch ON.
1 variable valve solenoid
CN27 (male) Resistance
(Internal disconnection)
Between (1) – (2) 5 – 15 z
Possible causes
and standard Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON. (When check result of Cause
state 2 (Disconnection in wiring 1 is normal)
or defective contact in Resis-
connector) Between ATC3 (female) (13) – (37) 5 – 15 z
tance
If causes 1 and 2 are not detected, transmission controller may be
controller
carried out.)
38 HD785-7
HD785-7 39
Failure code [DW2AKB] Main pressure variable valve output circuit:

Ground fault 1
Action code Failure code Main pressure variable valve output circuit: Ground fault
Trouble
E01 DW2AKB (Transmission controller system)
Contents of
• When signal is output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
OFF once.

1 variable valve solenoid
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect CN27, then carry out
2 harness
(Contact with ground circuit) Between ATC3 (female) (37) – ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect CN27, then carry out
Short circuit in wiring troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between ATC3 (female) (37) Resis-
Min. 1 Mz
– ATC3 (female) (pin other than 37) tance
a Turn starting switch OFF and insert T-adapter in ATC3, then turn
Hot short (Contact with 24 V starting switch ON and carry out troubleshooting.
4
circuit) in wiring harness
Between ATC3 (female) (37) – ground Voltage Max. 1 V
If causes 1 – 4 are not detected, transmission controller may be
controller
carried out.)
40 HD785-7
HD785-7 41
Failure code [DW2AKY] Main pressure variable valve output circuit: Hot
short 1
Action code Failure code Main pressure variable valve output circuit: Hot short
Trouble
E01 DW2AKY (Transmission controller system)
Contents of
• While signal is not output to main pressure variable valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
• Error [15*OMW] may be detected because of oil pressure reduction.
appears on
machine • The transmission clutch may be damaged during travel in F1, F2 or F3.
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AKB].
state
42 HD785-7
HD785-7 43
Failure code [DW2AL1] Main pressure variable valve: Defective reset 1

Action code Failure code Main pressure variable valve: Defective reset
Trouble
E01 DW2AL1 (Transmission controller system)
Contents of • When outputting signal to main pressure variable valve solenoid circuit is stopped, response of
trouble main pressure switch is abnormal.
Action of
controller
Problem that
appears on
OFF once.

1 switch
Between (1) – (2) Max. 10 z
Defective main pressure Main pressure variable valve may have mechanical trouble.
2
variable valve Check it directly.
3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
Possible causes Grounding fault in wiring troubleshooting without turning starting switch ON.
and standard 4 harness
tance
state
5 harness
Min. 1 Mz
– ATC (female) (pin other than 7) tance
6
controller
carried out.)
44 HD785-7
HD785-7 45
Failure code [DW2ALH] Main pressure variable valve: Malfunction 1

Action code Failure code Main pressure variable valve: Malfunction
Trouble
E01 DW2ALH (Transmission controller system)
Contents of • When signal is output to main pressure variable valve solenoid circuit, main pressure switch does
trouble not respond.
Action of
controller
Problem that
machine
OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2AL1].
state
46 HD785-7
Failure code [DW2BKA] Main oil level selector valve output:

Disconnection 1
Action code Failure code Main oil level selector valve output: Disconnection
Trouble
E01 DW2BKA (Transmission controller system)
Contents of
• When signal is output to main oil level selector valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to main oil level selector valve solenoid circuit.
controller
Problem that
machine
• Output state to main oil level selector valve solenoid can be checked with monitoring function
information • Signal is not output to main oil level selector valve solenoid circuit until starting switch is turned OFF
once.

Defective main oil level without turning starting switch ON.
1 selector valve solenoid
Possible causes Between (1) – (2) 5 – 15 z
value in normal harness without turning starting switch ON.
state 2 (Disconnection in wiring
Between ATC3 (female) (3) – (28) 5 – 15 z
connector) tance

controller
carried out.)
HD785-7 47
Failure code [DW2BKB] Main oil level selector valve output circuit:
Ground fault 1
Action code Failure code Main oil level selector valve output circuit: Ground fault
Trouble
E01 DW2BKB (Transmission controller system)
Contents of
• When signal is output to main oil level selector valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
once.

1 selector valve solenoid
Between (1) – (2) 5 – 15 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
controller
carried out.)
48 HD785-7
HD785-7 49
Failure code [DW2BKY] Main oil level selector valve output circuit: Hot
short 1
Action code Failure code Main oil level selector valve output circuit: Hot short
Trouble
E01 DW2BKY (Transmission controller system)
Contents of
• While signal is not output to main oil level selector valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
appears on
once.

and standard
value in normal Carry out troubleshooting for failure code [DW2BKB].
state
50 HD785-7
HD785-7 51
Failure code [DW2BL1] Main oil level selector valve: Defective reset 1
Action code Failure code Main oil level selector valve: Defective reset
Trouble
E01 DW2BL1 (Transmission controller system)
Contents of • When outputting signal to main oil level selector valve solenoid circuit is stopped, response of main
trouble oil level selector switch is abnormal.
Action of
controller
Problem that
appears on
once.

1 selector switch
Defective main oil level Main oil level selector valve may have mechanical trouble.
2
selector valve Check it directly.
tance
state
5 harness
Min. 1 Mz
6
controller
carried out.)
52 HD785-7
HD785-7 53
Failure code [DW2BLH] Main oil level selector valve: Malfunction 1

Action code Failure code Main oil level selector valve: Malfunction
Trouble
E01 DW2BLH (Transmission controller system)
Contents of • When signal is output to main oil level selector valve solenoid circuit, main oil level selector switch
trouble does not respond.
Action of
controller
Problem that
machine
once.

and standard
value in normal Carry out troubleshooting for failure code [DW2BL1].
state
54 HD785-7
Failure code [DW2CKA] Transmission lubrication variable valve output:

Disconnection 1
Action code Failure code Transmission lubrication variable valve output: Disconnection
Trouble
E01 DW2CKA (Transmission controller system)
Contents of
• When signal is output to transmission lubrication variable valve solenoid circuit, no current flows.
trouble
Action of
• Stops outputting signal to transmission lubrication variable valve solenoid circuit.
controller
Problem that
machine
• Output state to transmission lubrication variable valve solenoid can be checked with monitoring
Related function (Code: 38001 (mA)).
information • Signal is not output to transmission lubrication variable valve solenoid circuit until starting switch is
turned OFF once.

Defective transmission lubri- without turning starting switch ON.
1 cation variable valve sole-
noid (Internal disconnection)
Between (1) – (2) 5 – 15 z
Possible causes
value in normal harness without turning starting switch ON. (When check result of Cause
state 2 (Disconnection in wiring 1 is normal)
connector) Between ATC3 (female) (23) – (38) 5 – 15 z
tance
controller
carried out.)
HD785-7 55
Failure code [DW2CKB] Transmission lubrication variable valve output

circuit: Ground fault 1
Action code Failure code Transmission lubrication variable valve output circuit: Ground fault
Trouble
E01 DW2CKB (Transmission controller system)
Contents of • When signal is output to transmission lubrication variable valve solenoid circuit, abnormal current
trouble flows.
Action of
controller
Problem that
machine
turned OFF once.

Defective transmission lubri- without turning starting switch ON.
1 cation variable valve sole-
noid (Internal disconnection)
Between (1) – (2) 5 – 15 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
controller
carried out.)
56 HD785-7
HD785-7 57
Failure code [DW2CKY] Transmission lubrication variable valve output

circuit: Hot short 1
Action code Failure code Transmission lubrication variable valve output circuit: Hot short
Trouble
E01 DW2CKY (Transmission controller system)
Contents of • While signal is not output to transmission lubrication variable valve solenoid circuit, abnormal cur-
trouble rent flows.
Action of
controller
Problem that
appears on
turned OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2CKB].
state
58 HD785-7
HD785-7 59
Failure code [DW2CL1] Transmission lubrication variable valve:

Defective reset 1
Action code Failure code Transmission lubrication variable valve: Defective reset
Trouble
E01 DW2CL1 (Transmission controller system)
Contents of • When outputting signal to transmission lubrication variable valve solenoid circuit is stopped,
trouble response of transmission lubrication variable valve pressure switch is abnormal.
Action of
controller
Problem that
appears on
turned OFF once.
Defective transmission lubri- a Prepare with starting switch OFF, then carry out troubleshooting
cation variable valve pres- without turning starting switch ON.
1
sure switch CN24 (male) Resistance
(Internal disconnection) Between (1) – (2) Max. 10 z
Defective transmission lubri- Transmission lubrication variable valve may have mechanical trou-
2
cation variable valve ble. Check it directly.
tance
state
5 harness
Min. 1 Mz
6
controller
carried out.)
60 HD785-7
HD785-7 61
Failure code [DW2CLH] Transmission lubrication variable valve:

Malfunction 1
Action code Failure code Transmission lubrication variable valve: Malfunction
Trouble
E01 DW2CLH (Transmission controller system)
Contents of • When signal is output to transmission lubrication variable valve solenoid circuit, transmission lubri-
trouble cation variable valve pressure switch does not respond.
Action of
controller
Problem that
machine
turned OFF once.

and standard
value in normal Carry out troubleshooting for failure code [DW2CL1].
state
62 HD785-7
HD785-7 63
Failure code [DW35KZ] Failure in output system of auto suspension

solenoid 1: Disconnection or short circuit 1
Action code Failure code Failure in output system of auto suspension solenoid 1: Disconnec-
Trouble tion or short circuit
E01 DW35KZ (Retarder controller system)
Contents of • When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S04.
Defective auto suspension
1 Resis-
solenoid 1 Between S04 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S04 (female) (1), (2) – ground Min. 1 Mz
tance
Disconnection in wiring 2) Disconnect connectors BRC3 and S04.
Possible causes 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (7) Resis-
Max. 1 z
and standard defective contact in connec- – S04 (female) (1) tance
value in normal tor) Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S04 (female) (2) tance
2) Disconnect BRC3 and S04.
Hot short in wiring harness 3) Connect T-adapter to BRC3 (female).
Wiring harness between BRC3 (female) (7)
Voltage Max. 1 V
– S04 (female) (1) and chassis ground
Resis-
Between BRC3 (female) (7) – ground 15 – 35 z
tance
64 HD785-7
HD785-7 65
Failure code [DW36KZ] Failure in output system of auto suspension

solenoid 2: Disconnection or short circuit 1
Action code Failure code Failure in output system of auto suspension solenoid 2: Disconnec-
Trouble tion or short circuit
Contents of • When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any
trouble current does not flow. Or, some current is flowing while the output is OFF.
Action of
• The controller turns the output to auto suspension solenoid 1 and 2 OFF.
controller
Problem that
appears on • The auto suspension system does not operate.
machine
Related
information

2) Disconnect connector S05.
Defective auto suspension
1 Resis-
solenoid 2 Between S05 (female) (1) – (2) 15 – 35 z
tance
Resis-
Between S05 (female) (1), (2) – ground Min. 1 Mz
tance
Disconnection in wiring 2) Disconnect connectors BRC3 and S05.
Possible causes 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (37) Resis-
Max. 1 z
and standard defective contact in connec- – S05 (female) (1) tance
value in normal tor) Wiring harness between BRC3 (female) (3) Resis-
state Max. 1 z
– S05 (female) (2) tance
2) Disconnect BRC3 and S05.
Voltage Max. 1 V
– S05 (female) (1) and chassis ground
Resis-
Between BRC3 (female) (37) – ground 15 – 20 z
tance
66 HD785-7
HD785-7 67
Failure code [DW71KZ] Exhaust brake output system trouble

(Disconection/Ground fault/Hot short) 1
Action code Failure code Exhaust brake output system trouble (Disconection/Ground fault/
Trouble Hot short)
Contents of
• Disconection/Ground fault/Hot short of Exhaust brake solenoid.
trouble
• Ground fault at the time of the detection,turn off exhaust brake and do not return normally unless
Action of
turn off a start switch once.
controller
• Disconection/Hot short fault at the time of the detection,continue control of exhaust brake.
Problem that
appears on • Exhaust brake do not operate normally.
machine
Related • Condition of exhaust brake can be checked with monitoring function.
information (Code:3 5900 exhaust brake OFF[0],ON[1])"

Defective exhaust brake without turning starting switch ON.
1
solenoid EXSOL(male) Resistance
Between (1) – (2) 15 – 30 z
harness
Between wiring harness BRC3 (female) (13) Resis-
2 (Disconnection in wiring Max. 1 z
– EXSOL(female) (2) tance
or defective contact in
connector) Between wiring harness BRC3 (female) (38) Resis-
Max. 1 z
– EXSOL(female) (1) tance
Possible causes Grounding fault in wiring without turning starting switch ON.
and standard 3 harness Between ground and wiring harness
value in normal (Contact with ground circuit) between BRC3 (female) (38) – EXSOL Resis-
Min. 1 Mz
state tance
(female) (1)
2) Disconnect connectors BRC3 and EXSOL.
4 (Contact with power source 4) Turn the starting switch ON.
wiring harness) Between ground and wiring harness
between BRC3 (female) (38) – EXSOL Voltage Max. 1 V
(female) (1)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective retarder controller Between BRC3 (38) – (13) Voltage
Exhaust brake not operating Max. 1 V
Exhaust brake operating 20 – 30 V
68 HD785-7
HD785-7 69
Failure code [DW72KZ] Kick-out solenoid output system trouble:

Disconnection or short circuit 1
Action code Failure code Kick-out solenoid output system trouble: Disconnection or short
Trouble circuit
Contents of • When signal is output to hoist lever kick-out solenoid circuit, large current flows or no current flows
trouble or when signal is not output, some current flows.
Action of
• Turns output to hoist lever kick-out solenoid OFF.
controller
Problem that
appears on • Hoist lever is not locked by detent.
machine
• This phenomenon also occurs when signals from body potentiometer and sensor are abnormal.
Related
(See failure code DK54KX.)
information
• When kick-out solenoid needs to be replaced, hoist lever must be replaced.

Disconnection in wiring 2) Disconnect connector BRC3 and LK0.
1 (Disconnection in wiring or Wiring harness between LK0 (female) (2) – Resis-
Max. 1 z
defective contact in connec- ground tance
Max. 1 z
– LK0 (female) (1) tance
2) Disconnect connector BRC3 and LK0.
Defective hot short in wiring 3) Connect T-adapter to BRC3 (female).
2 harness 4) Turn starting switch ON.
Possible causes (a contact with 24 V circuit)
and standard Wiring harness between BRC3 (female) (27)
Voltage Max. 1 V
value in normal – LK0 (female) (1) and chassis ground
state 1) Turn the starting switch OFF.
2) Disconnect connector LK0.
Defective hoist lever kick-out
3 Resis- 39 z ±
solenoid Between LK0 (male) (1) – (2)
tance 5%
Resis-
Between LK0 (male) (1) and (2) – ground Min. 1 Mz
tance
Resis- 39 z ±
Between BRC3 (female) (27) – ground
tance 5%
70 HD785-7
HD785-7 71
Failure code [DW73KZ] Failure in hoist select valve output system:

Disconnection or short circuit 1
Action code Failure code Failure in hoist select valve output system: Disconnection or short
Trouble circuit
Contents of • When the output to the hoist lever select valve solenoid circuit is ON, a too large current flows or
trouble any current does not flow. Or, some current is flowing while the output is OFF.
Action of • The controller turns the output to the hoist lever select valve solenoid OFF.
controller • The controller turns the output to the hoist lever EPC valve solenoid OFF.
Problem that
machine
Related
information

Disconnection in wiring 2) Disconnect connectors BRC3 and HSOL.
1 (Disconnection in wiring or Wiring harness between BRC3 (female) (3) Resis-
Max. 1 z
defective contact in connec- – HSOL (female) (2) tance
Max. 1 z
– HSOL (female) (1) tance
2) Disconnect connectors BRC3 and HSOL.
Defective hot short in wiring 3) Connect T-adapter to BRC3 (female).
Possible causes (a contact with 24 V circuit) Between ground and wiring harness
and standard
between BRC3 (female) (17) – HSOL Voltage Max. 1 V
value in normal
(female) (1)
state
2) Disconnect connector HSOL.
Defective hoist lever select
3 Resis-
valve solenoid Between HSOL (male) (1) – (2) 15 – 35 z
tance
Resis-
Between HSOL (male) (1), (2) – ground Min. 1 Mz
tance
2) Disconnect connector HSOL.
Resis-
Between BRC3 (female) (17) – (13) 15 – 35 z
tance
72 HD785-7
HD785-7 73
Failure code [DW78KZ] Brake cooling valve (BCV) (rear wheel) output
system trouble: Disconnection or short circuit 1
Action code Failure code Brake cooling valve (BCV) (rear wheel) output system trouble:
Trouble Disconnection or short circuit
Contents of • Since no current flows or overcurrent flows in BCV relay primary side, BCV relay cannot be turned
trouble ON/OFF. Accordingly, BCV solenoid cannot be driven.
Action of • Stops supplying current when BCV circuit is disconnected.
controller • Turns output to BCV relay (R14) primary side OFF.
Problem that
appears on • Since retarder is not cooled, it may overheat.
machine
Related
• For troubleshooting for BCV relay (R14) secondary side, see [B@C7NS].
information

a Turn starting switch OFF and disconnect R14 (BCV relay), then
carry out troubleshooting without turning starting switch ON.
1 Defective R14 (BCV relay) R14
Resistance
(female: Wiring harness side)
Between (1) – (2) 100 – 500 z
a Turn starting switch OFF and disconnect R14 (BCV relay), then
Grounding fault in wiring carry out troubleshooting without turning starting switch ON.
2 harness
(Contact with ground circuit) Between R14 (female) (1) – ground Min. 1 Mz
and standard tance
value in normal
a Turn starting switch OFF and disconnect R14 (BCV relay) and
state
Disconnection in wiring BRC3, then carry out troubleshooting without turning starting
harness switch ON.
3 (Disconnection in wiring Between BRC3 (female) (18) – R14 Resis-
Max. 1 z
or defective contact in (female) (1) tance
connector) Resis-
Between ER1 (ground) – R14 (female) (2) Max. 1 z
tance
out.)
74 HD785-7
HD785-7 75
Failure code [DWNBK4] ASR shut-off valve: Trouble (Valve keeps

operating) 1
Action code Failure code ASR shut-off valve: Trouble (Valve keeps operating)
Trouble
E01 DWNBK4 (Retarder controller system)
Contents of
• ASR pressure sensor does not respond to shut-off valve OFF command of retarder controller.
trouble
Action of
• Stops controlling ASR.
controller
Problem that
machine
• ASR pressure sensor is turned OFF when pressure is 0.3 MPa {3 kg/cm²} or less. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

a ASR shut-off valve may have mechanical trouble. Check it
directly.
1 Defective ASR shut-off valve 1) Turn starting switch ON.
2) Turn ASR switch ON/OFF.
Operating sound of ASR shut-off valve solenoid is heard.
2) Disconnect ASR7.
3) Prepare and turn starting switch ON.
Defective ASR pressure sen- 4) Turn ASR switch ON and OFF and carry out troubleshooting.
2
sor ASR7 (male) (1) – (2) Resistance
Possible causes Turn ASR switch OFF Min. 1 Mz

and standard Turn ASR switch ON Max. 1 z
value in normal a Turn starting switch OFF and disconnect ASR7 and BRC3, then
state Disconnection in wiring carry out troubleshooting without turning starting switch ON.
harness
Between ASR7 (female) (1) – BRC3 Resis-
3 (Disconnection in wiring or Max. 1 z
(female) (30) tance
defective contact in connec-
tor) Between ASR7 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
(Contact with ground circuit) Between ASR7 (female) (1) – ground Resis-
Min. 1 Mz
tance
out.)
76 HD785-7
HD785-7 77
Failure code [DWNBKA] ASR shut-off valve output circuit:

Disconnection 1
Action code Failure code ASR shut-off valve output circuit: Disconnection
Trouble
E01 DWNBKA (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, no current flows.
trouble
Action of
controller
Problem that
machine
Related
• Signal is not output to ASR shut-off valve solenoid circuit until starting switch is turned OFF once.
information

Defective ASR shut-off valve without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
Between (1) – (2) 5 – 15 z
and standard Disconnection in wiring without turning starting switch ON. (When check result of Cause
value in normal harness 1 is normal)
state 2 (Disconnection in wiring Resis-
Between J04 (male) (42) – (43) 5 – 15 z
or defective contact in tance
connector) Resis-
tance
If causes 1 and 2 are not detected, retarder controller may be
carried out.)
78 HD785-7
HD785-7 79
Failure code [DWNBKB] ASR shut-off valve output circuit: Ground fault1
Action code Failure code ASR shut-off valve output circuit: Ground fault
Trouble
E01 DWNBKB (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

Defective ASR shut-off valve troubleshooting without turning starting switch ON.
1 solenoid
ASR2 (male) Resistance
(Internal short circuit)
Between (1) – (2) 5 – 15 z
a Turn starting switch OFF and disconnect BRC3 and ASR2, then
2 harness
(Contact with ground circuit) Between BRC3 (female) (15) – ground Resis-
tance
and standard
value in normal a Turn starting switch OFF and disconnect BRC3 and ASR2, then
Short circuit in wiring carry out troubleshooting without turning starting switch ON.
state
3 harness
(with another wiring harness) Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
(15) – BRC3 (female) (pin other than (15)) tance
a Turn starting switch OFF and insert T-adapter in BRC3, then
Hot short (Contact with 24 V turn starting switch ON and carry out troubleshooting.
4
Between BRC3 (female) (15) – ground Voltage Max. 1 V
out.)
80 HD785-7
HD785-7 81
Failure code [DWNBKY] ASR shut-off valve output circuit: Short circuit1
Action code Failure code ASR shut-off valve output circuit: Short circuit
Trouble
E01 DWNBKY (Retarder controller system)
Contents of
• When signal is output to ASR shut-off valve solenoid circuit, abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting for failure code [DWNBKB].
state
Failure code [DWNBMA] ASR shut-off valve: Trouble (Valve does not
operate) 1
Action code Failure code ASR shut-off valve: Trouble (Valve does not operate)
Trouble
E01 DWNBMA (Retarder controller system)
Contents of
• Sensor does not respond to shut-off valve ON command of retarder controller.
trouble
Action of
controller
Problem that
• Retarder is not controlled normally.
appears on
machine • ASR is not controlled normally.
• ASR pressure sensor is turned ON when pressure is 0.7 MPa {7 kg/cm²} or above. (In range of 0.3
Related
MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information
• If ASR shut-off valve has electrical trouble, code [DWNBKA], [DWNBKB] or [DWNBKY] is output.

and standard
value in normal Carry out troubleshooting for failure code [DWNBK4].
state
82 HD785-7
HD785-7 83
Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system 1

Action code Failure code Trouble in ABS cut-off valve (Front) system
Trouble
E03 DWNDKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Front) (CUTF).
trouble
• The current flows when ABS cut-off valve relay (Front) (CUTF) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Front)(CUTF).
controller (Stop ABS control.)
Problem that
appears on
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF).

1) Turn the starting switch OFF and remove the relay cover.
2) Replace R11 (horn relay) and CUTF relay.
3) Turn the starting switch ON (without starting the engine).
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
The horn does not sound.
(Replace).
2) Disconnect ABS3 and CUTF relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTF (female) and
harness carry out troubleshooting in this state.
Resis-
defective contact in connec- Between ABS3 (female) (8) – CUTF (1) Max. 1 z
tance
tor)
Resis-
Between ABS3 (female) (21) – CUTF (2) Max. 1 z
value in normal 2) Disconnect ABS3 and CUTF relay.
state Ground fault in wiring 3) Connect T-branch to ABS3 (female) or CUTF (female) and
3 harness carry out troubleshooting in this state.
Between ABS3 (female) (8) – ABS3 Resis-
Min. 1 Mz
(female) (21) tance
2) Disconnect CVF.
Hot short in wiring harness 3) Connect T-branch.
4
(Contact 24 V circuit) 4) Turn the starting switch ON.
Between CVF (1) – CVF (2) Voltage Max. 1 V
2) Disconnect ABS3 and CUTF.
3) Connect T-branch to ABS3 (female) and CUTF (female).
5 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON and OFF.
Between ABS3 (female) (8) and ABS3 24 V/0 V
Voltage
(female) (21) change
84 HD785-7
HD785-7 85
Failure code [DWNDMA] Defective ABS cut-off valve (Front) 1

Action code Failure code Defective ABS cut-off valve (Front)
Trouble
E03 DWNDMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Front) does not match response from the ABS cut-off
trouble valve solenoid switch (Front)
Action of • Stop outputting to ABS cut-off valve relay (Front) (CUTF).
Problem that
appears on
• Ordinary brake operation can be carried out.
machine
• ABS cut-off valve solenoid (front) is turned ON and OFF by turning the ABS cut-off valve relay
(Front) (CUTF) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Front) (CUTF) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Front) (CUTF) with [DWNDKZ].

2) Replace R11 (horn relay) and CUTF relay.
1 Defective relay (CUTF) 4) Sound the horn.
The horn sounds. Relay (CUTF) is normal.
Abnormal relay (CUTF)
(Replace).
Defective solenoid (Internal 2) Disconnect connector CVF and carry out troubleshooting in this
2 disconnection) of ABS cut-off state.
valve (Front) CVF (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSF.
3) Connect T-branch to connector CVSF and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Front)
Resis-
value in normal OFF: between CVSF (1) – (2) Min. 1 Mz
tance
state
Resis-
ON: between CVSF (1) – (2) Max. 1 z
tance
2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female), CUTF
(female) and CVSF (female) and carry out troubleshooting in
this state.
Disconnection in wiring Resis-
Between ABS3 (female) (2) – CUTF (5) Max. 1 z
harness tance
defective contact in connec- Between CVF (female) (1) – CUTF (3) Max. 1 z
tance
tor)
Resis-
Between CVF (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (23) – CVSF (1) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSF (2) Max. 1 z
tance
86 HD785-7

2) Disconnect CUTF relay, connectors ABS1, ABS3, CVF and
CVSF.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTF
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (23) – CVSF (1) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVF (female) (1) – CUTF (3) and Resis-
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (F) to restore normal state.
(F)
2) Disconnect ABS1 and connect T-branch.
3) Connect T-branch to ABS1 (female).
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (23) – ground Voltage
change
HD785-7 87
Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system 1

Action code Failure code Trouble in ABS cut-off valve (Rear) system
Trouble
E03 DWNEKZ (ABS controller system)
• Large amount of current flows or the current does not flow when signal is output to the primary cir-
Contents of
cuit of ABS cut-off valve relay (Rear) (CUTR).
trouble
• The current flows when the ABS cut-off valve relay (Rear) (CUTR) is turned OFF.
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR)
controller (Interrupt ABS control)
Problem that
appears on
machine
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
Related
information • ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR).

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
2) Disconnect ABS3 and CUTR relay.
Disconnection in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
harness carry out troubleshooting in this state.
Resis-
Possible causes defective contact in connec- Between ABS3 (female) (18) – CUTR (1) Max. 1z
tor) tance
and standard
Between ABS3 (female) (21) – CUTR (2) Max. 1z
state tance
2) Disconnect ABS3 and CUTR relay.
Ground fault in wiring 3) Connect T-branch to ABS3 (female) and CUTR (female) and
3 harness carry out troubleshooting in this state.
Min. 1 Mz
(female) (21) tance
2) Disconnect ABS3 and CUTR.
3) Connect T-branch to ABS3 (female) and CUTR (female).
4 Defective ABS controller 4) Turn the starting switch ON (without starting the engine).
5) Turn ABS switch ON-OFF.
Between ABS3 (female) (18) and ABS3 24 V/0 V
Voltage
(female) (21) change
88 HD785-7
HD785-7 89
Failure code [DWNEMA] Defective ABS cut-off valve (Rear) 1

Action code Failure code Defective ABS cut-off valve (Rear)
Trouble
E03 DWNEMA (ABS controller system)
Contents of • Command to ABS cut-off valve solenoid (Rear) does not match response from the ABS cut-off valve
trouble solenoid switch (Rear)
Action of • Stop outputting to ABS cut-off valve relay (Rear) (CUTR).
Problem that
appears on
machine
• ABS cut-off valve solenoid (Rear) is turned ON and OFF by turning the ABS cut-off valve relay
(Rear) (CUTR) ON and OFF.
Related
• No signal is output to ABS cut-off valve relay (Rear) (CUTR) until starting switch is turned OFF.
information
• ABS controller is carrying out troubleshooting for the primary coil side of the ABS cut-off valve relay
(Rear) (CUTR) with [DWNEKZ].

2) Replace R11 (horn relay) and CUTR relay.
1 Defective relay (CUTR) 4) Sound the horn.
The horn sounds. Relay (CUTR) is normal.
Abnormal relay (CUTR)
(Replace).
Defective solenoid of ABS 2) Disconnect connector CVR and carry out troubleshooting in
2 cut-off valve (Rear) this state.
(Internal disconnection) CVR (male) Resistance
Between (1) – (2) 10 – 30 z
2) Disconnect connector CVSR
3) Connect T-branch to connector CVSR and extend the wiring.
4) Start engine.
Possible causes Defective ABS cut-off sole- 5) Turn ABS switch ON and OFF.
3
and standard noid switch (Rear)
Resis-
value in normal OFF: between CVSR (1) – (2) Min. 1 Mz
tance
state
Resis-
ON: between CVSR (1) – (2) Max. 1 z
tance
2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
(female) and CVSR (female), and carry out troubleshooting in
this state.
Disconnection in wiring Resis-
Between ABS3 (female) (2) – CUTR (5) Max. 1 z
harness tance
defective contact in connec- Between CVR (female) (1) – CUTR (3) Max. 1 z
tance
tor)
Resis-
Between CVR (female) (2) – chassis ground Max. 1 z
tance
Resis-
Between ABS1 (female) (17) – CVSR (1) Max. 1 z
tance
Resis-
Between ABS3 (female) (21) – CVSR (2) Max. 1 z
tance
90 HD785-7

2) Disconnect CUTR relay, connectors ABS1, ABS3, CVR and
CVSR.
3) Connect T-branch to ABS1 (female), ABS3 (female) and CUTR
5 harness (female), and carry out troubleshooting in this state.
(Contact with ground circuit) Between ABS1 (female) (17) – CVSR (1) Resis-
Max. 1 z
and ground tance
Possible causes
Between CVR (female) (1) – CUTR (3) and Resis-
ground tance
value in normal
state Defective ABS cut-off valve
6 Replace ABS cut-off valve (R) to restore normal state.
(R)
2) Disconnect ABS1.
3) Connect T-branch to ABS1 (female).
7 Defective ABS controller 4) Start engine.
8 V/0 V
Between ABS1 (female) (17) – ground Voltage
change
HD785-7 91
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
92 HD785-7
SEN01946-02
HD785-7

HD785-7 7001 and up
Failure code [DX11K4] Rear brake proportional pressure reducing solenoid valve: Out of control ................ 4
Failure code [DX11KA] Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection .......................................................................................................................................... 6
Failure code [DX11KB] Rear brake proportional pressure reducing solenoid valve: Short circuit .................. 7
Failure code [DX11KY] Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line............................................................................................................. 8
Failure code [DX11MA] Rear brake proportional pressure reducing solenoid valve: Malfunction ................ 10
Failure code [DX12K4] Front brake proportional pressure reducing solenoid valve: Out of control ............. 12
Failure code [DX12KA] Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection ........................................................................................................................................ 14
Failure code [DX12KB] Front brake proportional pressure reducing solenoid valve: Short circuit ............... 15
Failure code [DX12KY] Front brake proportional pressure reducing solenoid valve:
Short circuit to power source line........................................................................................................... 16
Failure code [DX12MA] Front brake proportional pressure reducing solenoid valve: Malfunction ............... 18
Failure code [DX13KA] Output circuit of hoist EPC valve: Disconnection .................................................... 20
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit........................................................ 22
HD785-7 1
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit with power source line ................... 24
Failure code [DX17K4] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve keeps operating) ............................................................................................................ 26
Failure code [DX17KA] ASR proportional pressure reducing solenoid valve (right) output circuit:
Disconnection ........................................................................................................................................ 28
Failure code [DX17KB] ASR proportional pressure reducing solenoid valve (right) output circuit:
Ground fault ........................................................................................................................................... 30
Failure code [DX17KY] ASR proportional pressure reducing solenoid valve (right) output circuit:
Short circuit ............................................................................................................................................ 32
Failure code [DX17MA] ASR proportional pressure reducing solenoid valve (right):
Trouble (Valve does not operate)........................................................................................................... 32
Failure code [DX18K4] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve keeps operating) ............................................................................................................ 34
Failure code [DX18KA] ASR proportional pressure reducing solenoid valve (left) output circuit:
Disconnection ........................................................................................................................................ 36
Failure code [DX18KB] ASR proportional pressure reducing solenoid valve (left) output circuit:
Ground fault ........................................................................................................................................... 38
Failure code [DX18KY] ASR proportional pressure reducing solenoid valve (left) output circuit:
Short circuit ............................................................................................................................................ 40
Failure code [DX18MA] ASR proportional pressure reducing solenoid valve (left):
Trouble (Valve does not operate)........................................................................................................... 40
Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right)................................ 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right) .................................. 42
Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right)........................................ 43
Failure code [DX21MA] Defective ABS control valve (Front right)................................................................ 44
Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left) .................................. 45
Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)..................................... 46
Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left) .......................................... 47
Failure code [DX22MA] Defective ABS control valve (Front left) .................................................................. 48
Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right) ................................ 49
Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right) ................................... 50
Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right) ........................................ 51
Failure code [DX23MA] Defective ABS control valve (Rear right) ................................................................ 52
Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left) .................................. 53
Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left) ..................................... 54
Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left) .......................................... 55
Failure code [DX24MA] Defective ABS control valve (Rear left)................................................................... 56
Failure code [DX25MA] Defective ABS front wheel system control valve..................................................... 57
Failure code [DX26MA] Defective ABS rear wheel system control valve ..................................................... 57
2 HD785-7
HD785-7 3
Failure code [DX11K4] Rear brake proportional pressure reducing

solenoid valve: Out of control 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX11K4 (Valve is stuck in operated condition)
• Rear brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
return or their condition cannot be judged normally because of defect in sensor switch after they
trouble
return.
Action of
• Continues control.
controller
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related • Retarder oil pressure switch state can be checked with monitoring function (Code: 40932)
information (bit [3], 0:OFF, 1:ON).

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
2) Connect T-adapter to connector REVR (male).
Oil
Defective rear brake Resis-
pressure Max. 1 z
2 proportional pressure tance
is ON.
reducing solenoid Between REVR (male) (1) – (2)
Oil
Resis-
pressure Min. 1 Mz
tance
is OFF.
2) Connect T-adapter to connector RESWR.
3) Start engine.
Possible causes Defective retarder pressure
3 RESWR Retarder Voltage
and standard switch
value in normal When not operated 20 – 30 V
state Between (1) – (2)
When operated Max. 1 V
2) Disconnect connectors BRC1 and RESWR.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
between BRC1 (female) (5) – RESWR Min. 1 Mz
tance
(female) (1)
Oil
pressure Voltage Max. 1 V
is ON.
Between BRC3 (16) – (13)
Oil
pressure Voltage 10 – 30 V
is OFF.
4 HD785-7
HD785-7 5
Failure code [DX11KA] Rear brake proportional pressure reducing

solenoid valve output circuit: Disconnection 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve output
Trouble circuit: Disconnection
E03 DX11KA (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (rear brake) does not operate.
machine
Related
information

Defective rear brake
Resis-
1 proportional pressure Between REVR (male) (1) – (2) 10 – 30 z
tance
reducing solenoid valve
Resis-
Between REVR (female) (1), (2) – ground Min. 1 Mz
tance
and standard Disconnection in wiring 2) Connect T-adapter to connectors BRC3 (female) and REVR
value in normal harness (female).
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) Resis-
Max. 1 z
defective contact in connec- (16) – REVR (female) (1) tance
tor) Wiring harness between BRC3 (female) Resis-
Max. 1 z
(13) – REVR (female) (2) tance
Resis-
tance
6 HD785-7
Failure code [DX11KB] Rear brake proportional pressure reducing

solenoid valve: Short circuit 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit
E03 DX11KB (Retarder controller system)
Contents of • When output to solenoid circuit of rear brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of rear brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and REVR.
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground between BRC3 (female) (16) – REVR Min. 1 Mz
2 tance
circuit or contact between (female) (1)
harnesses) Between wiring harness from BRC3
(female) (16) – REVR (female) (1) and wir- Resis-
Min. 1 Mz
ing harness from BRC3 (female) (13) – tance
REVR (female) (2)
Resis-
tance
HD785-7 7
Failure code [DX11KY] Rear brake proportional pressure reducing

solenoid valve: Short circuit to power source line 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
E03 DX11KY (Retarder controller system)
Contents of • When output to rear brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to rear brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
and standard 2) Disconnect connectors BRC3 and REVR.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
(a contact with 24 V circuit)
Between ground and wiring harness
between BRC3 (female) (16) – REVR Voltage Max. 1 V
(female) (1)
Resis-
tance
8 HD785-7
HD785-7 9
Failure code [DX11MA] Rear brake proportional pressure reducing

solenoid valve: Malfunction 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Malfunction
E03 DX11MA (Retarder controller system)
• Rear brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that
• If solenoid is defective, rear brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related • Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932)

Defective rear brake • Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure If there is an abnormality (mechanical failure), repair or replace
reducing solenoid valve it.
2) Connect T-adapter to connector REVR.
Resis-
tance
reducing solenoid
Resis-
Between REVR (female) (1), (2) and ground Min. 1 Mz
tance
2) Insert T-adapter in connector RESWR.
3) Start engine.
Defective retarder pressure
3 RESWR Retarder Voltage
switch
Possible causes
and standard When not operated 20 – 30 V
Between (1) – (2)
value in normal When operated Max. 1 V
state
2) Disconnect connectors BRC1 and RESWR.
Defective harness grounding 3) Connect T-adapter to BRC1.
4
Resis-
between BRC1 (female) (5) – RESWR Min. 1 Mz
tance
(female) (1)
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
10 HD785-7
HD785-7 11
Failure code [DX12K4] Front brake proportional pressure reducing

solenoid valve: Out of control 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX12K4 (Valve is stuck in operated condition)
• Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that • If solenoid is defective, front brake drags.
appears on • If switch is defective or switch input circuit has ground fault, gear shift-up operation becomes difficult
machine and gear shift-down operation becomes easy.
Related • Retarder oil pressure switch state can be checked with monitoring function (Code: 40932)

Defective front brake • Check front brake proportional pressure reducing solenoid
1 proportional pressure valve. If there is an abnormality (mechanical failure), repair or
reducing solenoid valve replace it.
2) Connect T-adapter to connector REVF (male).
Defective front brake
Resis-
2 proportional pressure Between REVF (male) (1) – (2) 10 – 30 z
tance
reducing solenoid
Resis-
Between REVF (female) (1), (2) and ground Min. 1 Mz
tance
2) Connect T-adapter to connector RESWF.
3) Start engine.
3 RESWF Retarder Voltage
Possible causes switch
value in normal Between (1) – (2)
state When operated Max. 1 V
2) Disconnect connectors BRC1 and RESWF.
Defective harness grounding 3) Connect T-adapter to BRC1 (female).
4
Resis-
between BRC1 (female) (11) – RESWF Min. 1 Mz
tance
(female) (1)
Oil
pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
12 HD785-7
HD785-7 13
Failure code [DX12KA] Front brake proportional pressure reducing

solenoid valve output circuit: Disconnection 1
Action code Failure code Front brake proportional pressure reducing solenoid valve output
Contents of • When output to front brake proportional pressure reducing valve solenoid circuit is ON, current does
trouble not flow.
Action of
• Turn output to front brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
appears on • Retarder (front brake) does not operate.
machine
Related
information

Resis-
tance
Resis-
Between REVF (female) (1), (2) – ground Min. 1 Mz
tance
and standard Disconnection in wiring 2) Connect T-adapter to connectors BRC3 (female) and REVF
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (6) Resis-
Max. 1 z
defective contact in connec- – REVF (female) (1) tance
Max. 1 z
(13) – REVF (female) (2) tance
Resis-
tance
14 HD785-7
Failure code [DX12KB] Front brake proportional pressure reducing

solenoid valve: Short circuit 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Short
Trouble circuit
Contents of • When output to solenoid circuit of front brake proportional pressure reducing valve is turned ON,
trouble much current flows.
Action of
• Turns output to solenoid circuit of front brake proportional pressure reducing valve OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and REVF.
Possible causes
and standard
value in normal Short circuit of harness Between ground and wiring harness
Resis-
state (Contact with ground between BRC3 (female) (6) – REVF Min. 1 Mz
2 tance
circuit or contact between (female) (1)
harnesses) Between wiring harness from BRC3
(female) (6) – REVF (female) (1) and wiring Resis-
Min. 1 Mz
harness from BRC3 (female) (13) – REVF tance
(female) (2)
Resis-
tance
HD785-7 15
Failure code [DX12KY] Front brake proportional pressure reducing

solenoid valve: Short circuit to power source line 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Short
Trouble circuit to power source line
Contents of • When output to front brake proportional pressure reducing valve solenoid circuit is OFF, electric cur-
trouble rent flows.
Action of
• Turn output to front brake proportional pressure reducing valve solenoid OFF.
controller
Problem that
machine
Related
information

Resis-
tance
Resis-
tance
and standard 2) Disconnect connectors BRC3 and REVF.
value in normal 3) Connect T-adapter to BRC3 (female).
state Hot short in wiring harness 4) Turn starting switch ON.
2
(a contact with 24 V circuit)
between BRC3 (female) (6) – REVF Voltage Max. 1 V
(female) (1)
Resis-
tance
16 HD785-7
HD785-7 17
Failure code [DX12MA] Front brake proportional pressure reducing

solenoid valve: Malfunction 1
Action code Failure code Front brake proportional pressure reducing solenoid valve:
Trouble Malfunction
• Front brake proportional pressure reducing solenoid valve and solenoid keep operating and do not
Contents of
trouble
return.
Action of
controller
Problem that
• If solenoid is defective, front brake drags.
appears on
machine • If switch is defective or switch input circuit has disconnection, condition does not change.
Related • Condition of retarder oil pressure switch can be checked with monitoring function (Code: 40932)

Defective front brake • Check front brake proportional pressure reducing solenoid
1 proportional pressure valve. If there is an abnormality (mechanical failure), repair or
reducing solenoid valve replace it.
2) Connect T-adapter to connector REVF.
Resis-
tance
reducing solenoid
Resis-
Between REVF (female) (1), (2) and ground Min. 1 Mz
tance
2) Insert T-adapter in connector RESWF.
3) Start engine.
3 RESWF Retarder Voltage
switch
Possible causes
Between (1) – (2)
value in normal When operated Max. 1 V
state
2) Disconnect connectors BRC1 and RESWF.
Defective harness grounding 3) Connect T-adapter to BRC1.
4
Resis-
between BRC1 (female) (11) – RESWF Min. 1 Mz
tance
(female) (1)
Oil
5 Defective retarder controller pressure Voltage Max. 1 V
is ON.
Oil
is OFF.
18 HD785-7
HD785-7 19
Failure code [DX13KA] Output circuit of hoist EPC valve:

Disconnection 1
Action code Failure code Output circuit of hoist EPC valve: Disconnection
Trouble
Contents of
• When the output to the hoist EPC solenoid circuit is ON, any current does not flow.
trouble
Action of • The controller turns the output to the hoist select valve solenoid OFF.
controller • The controller turns the output to the hoist EPC valve solenoid OFF.
Problem that
machine
Related
• This failure can be checked in the monitoring function (Code: 45600 (mA)).
information

2) Disconnect connector HEPC.
Defective hoist EPC valve
1 Resis-
solenoid Between HEPC (male) (1) – (2) 15 – 20 z
tance
Resis-
Between HEPC (female) (1), (2) – ground Min. 1 Mz
tance
and standard Disconnection in wiring 2) Disconnect connectors BRC3 and HEPC.
value in normal harness 3) Connect T-adapter.
state 2 (Disconnection in wiring or Wiring harness between BRC3 (female) (5) Resis-
Max. 1 z
defective contact in connec- – HEPC (female) (1) tance
Max. 1 z
(13) – HEPC (female) (2) tance
Resis-
tance
20 HD785-7
HD785-7 21
Failure code [DX13KB] Output circuit of hoist EPC valve: Short circuit 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit
Trouble
Contents of
• When the output to the hoist EPC valve solenoid circuit is ON, a too large current flows.
trouble
Problem that
machine
Related
information

1 Resis-
tance
Resis-
tance
Possible causes 2) Disconnect connectors BRC3 and HEPC.
and standard 3) Connect T-adapter to BRC3 (female).
value in normal Grounding fault or short
state circuit in wiring harness Resis-
2 between BRC3 (female) (5) – HEPC Min. 1 Mz
(Contact with ground circuit tance
(female) (1)
or another wiring harness)
Resis-
– HEPC (female) (1) and between BRC3 Min. 1 Mz
tance
(female) (13) – HEPC (female) (2)
Resis-
tance
22 HD785-7
HD785-7 23
Failure code [DX13KY] Output circuit of hoist EPC valve: Short circuit
with power source line 1
Action code Failure code Output circuit of hoist EPC valve: Short circuit with power source
Trouble line
Contents of
• While the output to the hoist EPC valve solenoid circuit is OFF, some large current is flowing.
trouble
Problem that
machine
Related
information

1 Resis-
tance
Resis-
tance
2) Disconnect connectors BRC3 and HEPC.
Possible causes
and standard
value in normal Hot short in wiring harness
state Between ground and wiring harness
2 (Contact with power source
between BRC3 (female) (5) – HEPC Voltage Max. 1 V
wiring harness)
(female) (1)
between BRC3 (female) (13) – HEPC Voltage Max. 1 V
(female) (2)
Resis-
tance
24 HD785-7
HD785-7 25
Failure code [DX17K4] ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve keeps operating) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve keeps operating)
E01 DX17K4 (Retarder controller system)
Contents of • ASR pressure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (right) OFF command of retarder controller.
Action of
controller
Problem that
machine
Related MPa {3 kg/cm²} – 0.7 MPa {7 kg/cm²}, operation of sensor is unstable because of hysteresis.)
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],
[DX17KB] or [DX17KY] is output.

a ASR proportional pressure reducing solenoid valve (right) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (right) If the failure is repaired by replacing the ASR valve (right), the ASR
valve (right) is defective.
2) Disconnect ASR6 and insert jig in ASR6 (male) (Keep ASR6
Defective ASR pressure (female) disconnected).
2 3) Turn starting switch OFF and ON (Keep ASR switch OFF).
sensor
Between ASR6 (male) (1) – ASR6 (male) Resis-
Min. 1 Mz
and standard a Turn starting switch OFF and disconnect ASR6 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
(female) (10) tance
connector) Between ASR6 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
26 HD785-7
HD785-7 27
Failure code [DX17KA] ASR proportional pressure reducing solenoid

valve (right) output circuit: Disconnection 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (right) solenoid circuit
information until starting switch is turned OFF once.
Defective ASR proportional a Turn starting switch OFF and disconnect ASR4, then carry out
pressure reducing solenoid troubleshooting without turning starting switch ON.
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal disconnection) Between (1) – (2) 20 z
Between J04 (male) (36) – (37) 20 z
connector) Resis-
Between BRC3 (female) (26) – (23) 20 z
tance
carried out.)
28 HD785-7
HD785-7 29
Failure code [DX17KB] ASR proportional pressure reducing solenoid

valve (right) output circuit: Ground fault 1
Trouble circuit: Ground fault
trouble abnormal current flows.
Action of
controller
Problem that
machine
1
valve (right) solenoid (Inter- ASR4 (male) Resistance
nal short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
30 HD785-7
HD785-7 31
Failure code [DX17KY] ASR proportional pressure reducing solenoid

valve (right) output circuit: Short circuit 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX17KB].
state
Failure code [DX17MA] ASR proportional pressure reducing solenoid

valve (right): Trouble (Valve does not operate) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (right): Trouble
Trouble (Valve does not operate)
Contents of • ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve
trouble (right) ON command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (right) has electrical trouble, code [DX17KA],

and standard
value in normal Carry out troubleshooting for failure code [DX17K4].
state
32 HD785-7
HD785-7 33
Failure code [DX18K4] ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve keeps operating) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve keeps operating)
Contents of • ASR pressure sensor does not respond normally to ASR proportional pressure reducing solenoid
trouble valve (left) OFF command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

a ASR proportional pressure reducing solenoid valve (left) may
Defective ASR proportional have mechanical trouble. Check it directly.
1 pressure reducing solenoid
valve (left) If the failure is repaired by replacing the ASR valve (left), the ASR
valve (left) is defective.
2) Disconnect ASR5 and insert jig in ASR5 (male) (Keep ASR5
Defective ASR pressure (female) disconnected).
2 3) Turn starting switch OFF and ON (Keep ASR switch OFF).
sensor
Between ASR5 (male) (1) – ASR5 (male) Resis-
Min. 1 Mz
and standard a Turn starting switch OFF and disconnect ASR5 and BRC3, then
value in normal Disconnection in wiring carry out troubleshooting without turning starting switch ON.
state harness
(female) (20) tance
connector) Between ASR5 (female) (2) – BRC3 Resis-
Max. 1 z
(female) (21) tance
4 harness
Min. 1 Mz
tance
out.)
34 HD785-7
HD785-7 35
Failure code [DX18KA] ASR proportional pressure reducing solenoid

valve (left) output circuit: Disconnection 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left) output
Contents of • When signal is output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit,
trouble no current flows.
Action of
controller
Problem that
machine
Related • Signal is not output to ASR proportional pressure reducing solenoid valve (left) solenoid circuit until
information starting switch is turned OFF once.
1
valve (left) solenoid (Internal ASR3 (male) Resistance
disconnection) Between (1) – (2) 20 z
Between J04 (male) (38) – (39) 20 z
connector) Resis-
Between BRC3 (female) (36) – (23) 20 z
tance
carried out.)
36 HD785-7
HD785-7 37
Failure code [DX18KB] ASR proportional pressure reducing solenoid

valve (left) output circuit: Ground fault 1
Trouble circuit: Ground fault
Action of
controller
Problem that
machine
1
valve (left) solenoid (Internal ASR3 (male) Resistance
short circuit) Between (1) – (2) 20 z
2 harness
tance
and standard
state
3 harness
Min. 1 Mz
4
out.)
38 HD785-7
HD785-7 39
Failure code [DX18KY] ASR proportional pressure reducing solenoid

valve (left) output circuit: Short circuit 1
Trouble circuit: Short circuit
Action of
controller
Problem that
machine

and standard
value in normal Carry out troubleshooting for failure code [DX18KB].
state
Failure code [DX18MA] ASR proportional pressure reducing solenoid

valve (left): Trouble (Valve does not operate) 1
Action code Failure code ASR proportional pressure reducing solenoid valve (left): Trouble
Trouble (Valve does not operate)
Contents of • ASR pressure sensor does not respond to ASR proportional pressure reducing solenoid valve (left)
trouble ON command of retarder controller.
Action of
controller
Problem that
machine
information • If ASR proportional pressure reducing solenoid valve (left) has electrical trouble, code [DX18KA],

and standard
value in normal Carry out troubleshooting for failure code [DX18K4].
state
40 HD785-7
Failure code [DX21KA] Disconnection in ABS control valve output

circuit (Front right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front right)
Trouble
E03 DX21KA (ABS controller system)
Contents of
• No current flows when the signal is output to the ABS control valve (Front right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
(Code: 43309, output current (0 – 1000 (mA))
information
• No signal is output to ABS control valve solenoid until starting switch is turned OFF.

2) Disconnect connector ABSFR.
Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSFR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFR and ABS3 and
value in normal harness carry out troubleshooting in this state.
state 2 (Disconnection in wiring or
Resis-
defective contact in connec- Between ABS3 (female) (3) and ABSFR (2) Max. 1 z
tance
tor)
Resis-
Between ABS3 (female) (6) and ABSFR (1) Max. 1 z
tance
2) Disconnect connector ABS3.
3 Defective ABS controller 3) Connect T-branch.
10 – 30 z
(female) (3) terminals tance
HD785-7 41
Failure code [DX21KB] Ground fault in ABS control valve output circuit
(Front right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front right)
Trouble
E03 DX21KB (ABS controller system)
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front right) solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (front right-hand) solenoid can be checked with the monitoring function.
Related
information

Defective solenoid (internal 3) Connect the T-branch to connector ABSFR and carry out trou-
1 disconnection) in ABS con- bleshooting in this state.
trol valve
ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSFR and ABS3.
value in normal Ground fault in wiring 3) Connect the T-branch to connector ABS3 and carry out trouble-
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSFR and ABS3 being disconnected).
Resis-
Between ABS3 (female) (6) and ground Max. 1 Mz
tance
10 – 30 z
42 HD785-7
Failure code [DX21KY] Hot short in ABS control valve output circuit
(Front right) 1
Action code Failure code Hot short in ABS control valve output circuit (Front right)
Trouble
E03 DX21KY (Transmission controller system)
Contents of
• Abnormal current flows when no signal is output to ABS control valve solenoid circuit.
trouble
Problem that
appears on
• Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.
Related
information

3) Connect the T-branch to connector ABSFR and carry out trou-
Defective solenoid (internal
bleshooting in this state.
1 hot short) in ABS control
valve ABSFR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSFR.
Hot short circuit in wiring 3) Connect the T-branch to ABS3.
state
2 harness (With connector ABSFR being disconnected).
(Contact with 24-V circuit) 4) Carry out troubleshooting with the starting switch ON.
Between ABS3 (female) (6) and ground Voltage Max. 1 V
10 – 30 z
HD785-7 43
Failure code [DX21MA] Defective ABS control valve (Front right) 1

Action code Failure code Defective ABS control valve (Front right)
Trouble
E03 DX21MA (ABS controller system)
Contents of • Command to ABS control valve (Front right) does not match response from ABS control valve pres-
trouble sure sensor.
Problem that
appears on
• Troubleshooting for ABS control valve (Front right) solenoid circuit is carried out with [DX21KA],
[DX21KB] and [DX21KY].
Related • Troubleshooting for ABS control valve (Front right) pressure sensor is carried out with [DHU6KX].
information • Output to ABS control valve (Front right) solenoid can be checked with the monitoring function.

If failure codes [DX21KA], [DX21KB], [DX21KY] and [DHU6KX] are displayed, carry out trouble-
1
Possible causes shooting for them.
and standard Defective ABS control valve Main pressure variable valve may be damaged mechanically.
2
value in normal (Front right) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be damaged. Check it directly.
If causes 1 – 3 are not detected, ABS controller may be defective.
4 Defective ABS controller
44 HD785-7

circuit (Front left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Front left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Front left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Front left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSFL.
Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
1 solenoid bleshooting with the starting switch OFF.
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSFL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSFL and ABS3, and
value in normal harness carry out troubleshooting with the starting switch OFF.
Wiring harness between ABS3 (female) (3) Resis-
– ABSFL (2) tance
tor)
Max. 1 z
– ABSFL (1) tance
10 – 30 z
– ABS3 (female) (3) tance
HD785-7 45
(Front left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Front left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Front left) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSFL and carry out trou-
ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSFL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSFL and ABS3 disconnected)
Resis-
tance
10 – 30 z
– ABS3 (female) (3) terminal tance
46 HD785-7
(Front left) 1
Action code Failure code Hot short in ABS control valve output circuit (Front left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSFL and carry out trou-
Defective ABS control valve
bleshooting with the starting switch OFF.
1 solenoid
(Internal hot short) ABSFL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSFL.
Hot short circuit in wiring 3) Connect T-branch to connector ABS3.
state
2 harness (With connector ABSFL being disconnected)
(Contact with 24V circuit) 4) Turn starting switch ON and carry out troubleshooting.
10 – 30 z
HD785-7 47
Failure code [DX22MA] Defective ABS control valve (Front left) 1

Action code Failure code Defective ABS control valve (Front left)
Trouble
Contents of • Command to ABS control valve (Front left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Front left) solenoid circuit is carried out with [DX22KA],
Related • Troubleshooting for ABS control valve (Front left) pressure sensor is carried out with [DHU7KX].
information • Output to ABS control valve (Front left) solenoid can be checked with the monitoring function.

1
2
value in normal (Front left) Check it directly.
state 3 Defective hydraulic piping Hydraulic piping may be defective. Check it directly.
(Since trouble is in system, troubleshooting is disabled.)
48 HD785-7

circuit (Rear right) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear right)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rear right) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear right) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRR.
Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connectors ABSRR and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRR and ABS3, and
– ABSRR (2) tance
tor)
Max. 1 z
– ABSRR (1) tance
10 – 30 z
HD785-7 49
(Rear right) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear right)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear right) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSRR and carry out trou-
1 solenoid bleshooting in this state.
ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connectors ABSRR and ABS3.
state 2 harness shooting in this state.
(Contact with ground circuit) (With connectors ABSRR and ABS3 being disconnected)
Resis-
tance
10 – 30 z
50 HD785-7
(Rear right) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear right)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSRR and carry out trou-
bleshooting in this state.
1 solenoid
(Internal hot short) ABSRR (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes
value in normal 2) Disconnect connectors ABS3 and ABSRR.
Hot short circuit in wiring 3) Connect T-branch to connector ABS3.
state
2 harness (With connector ABSRR being disconnected)
(Contact with 24-V circuit) 4) Carry out troubleshooting with the starting switch turned ON.
10 – 30 z
HD785-7 51
Failure code [DX23MA] Defective ABS control valve (Rear right) 1

Action code Failure code Defective ABS control valve (Rear right)
Trouble
Contents of • Command to ABS control valve (Rear right) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear right) solenoid circuit is carried out with [DX23KA],
Related • Troubleshooting for ABS control valve (Rear right) pressure sensor is carried out with [DHU8KX].
information • Output to ABS control valve (Rear right) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear right) Check it directly.
52 HD785-7

circuit (Rear left) 1
Action code Failure code Disconnection in ABS control valve output circuit (Rear left)
Trouble
Contents of
• No current flows when the signal is output to the ABS control valve (Rea left) solenoid circuit.
trouble
Action of • Stop outputting to ABS control valve (Rear left) solenoid circuit.
Problem that
appears on
• Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.
Related
information

2) Disconnect connector ABSRL.
Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z
Possible causes 2) Disconnect connector ABSRL and ABS3.
and standard Disconnection in wiring 3) Connect the T-branch to connectors ABSRL and ABS3, and
– ABSRL (2) tance
tor)
Max. 1 z
– ABSRL (1) tance
10 – 30 z
HD785-7 53
(Rear left) 1
Action code Failure code Ground fault in ABS control valve output circuit (Rear left)
Trouble
Contents of
• Abnormal current flows when signal is output to ABS control valve (Rear left) solenoid circuit.
trouble
Problem that
appears on
Related
information

Defective ABS control valve 3) Connect the T-branch to connector ABSRL and carry out trou-
ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z

and standard 2) Disconnect connector ABSRL and ABS3.
state 2 harness shooting with the starting switch OFF.
(Contact with ground circuit) (With connectors ABSRL and ABS3 being disconnected)
Resis-
tance
10 – 30 z
54 HD785-7
(Rear left) 1
Action code Failure code Hot short in ABS control valve output circuit (Rear left)
Trouble
Contents of
trouble
Problem that
appears on
Related
information

3) Connect the T-branch to connector ABSRL and carry out trou-
bleshooting with the starting switch OFF.
1 solenoid
(Internal hot short) ABSRL (male) Resistance
Between (1) – (2) 10 – 30 z
and standard 2) Disconnect connectors ABS3 and ABSRL.
value in normal 3) Connect T-branch to connector ABS3.
Hot short circuit in wiring
state (With connector ABSRL being disconnected)
2 harness
(Contact with 24-V circuit) 4) Turn starting switch ON and carry out troubleshooting.
Between ABS3 (female) (36) and chassis
Voltage Max. 1 V
ground
10 – 30 z
HD785-7 55
Failure code [DX24MA] Defective ABS control valve (Rear left) 1

Action code Failure code Defective ABS control valve (Rear left)
Trouble
Contents of • Command to ABS control valve (Rear left) does not match response from ABS control valve pres-
Problem that
appears on
• Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DX24KA],
Related • Troubleshooting for ABS control valve (Rear left) solenoid circuit is carried out with [DHU9KX].
information • Output to ABS control valve (Rear left) solenoid can be checked with the monitoring function.

1
2
value in normal (Rear left) Check it directly.
56 HD785-7
Failure code [DX25MA] Defective ABS front wheel system control valve 1
Action code Failure code Defective ABS front wheel system control valve
Trouble
• Command to ABS control valve (Front) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Front right or front left)
Action of • Stop outputting to ABS control valve (Front) solenoid circuit.
Problem that
appears on
• Check for front right or front left according to failure codes [DX21MA] (front right) and [DX22MA]
Related
(front left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX21MA] or [DX22MA].
state
Failure code [DX26MA] Defective ABS rear wheel system control valve 1
Action code Failure code Defective ABS rear wheel system control valve
Trouble
• Command to ABS control valve (Rear) does not match response from ABS control valve pressure
Contents of
sensor switch.
trouble
(Rear right or rear left)
Action of • Stop outputting to ABS control valve (Rear) solenoid circuit.
Problem that
appears on
• Check for rear right or rear left according to failure codes [DX23MA] (rear right) and [DX24MA] (rear
Related
left) output elsewhere.
information

and standard
value in normal 1 Carry out troubleshooting for [DX23MA] or [DX24MA].
state
HD785-7 57
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
58 HD785-7
SEN01947-02
HD785-7

HD785-7 7001 and up
Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection ............................................... 4
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit ................................................... 6
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuit to power supply line .................. 8
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection...................................................... 10
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit ......................................................... 12
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to power supply line ........................ 14
Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection ..................................................... 18
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit......................................................... 20
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line ........................ 22
Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection .................................................... 26
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit........................................................ 28
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line ....................... 30
Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection ................................................... 34
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit....................................................... 36
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line ...................... 38
Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection.................................................... 42
HD785-7 1
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit........................................................ 44
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line....................... 46
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection....................................................... 50
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit .......................................................... 52
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line ......................... 54
Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.................................................... 56
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit ....................................................... 58
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line ...................... 60
Failure code [F@BBZL] or VHMS_LED display: "n3"o"38" Blow-by pressure: High error........................... 63
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1):
Exhaust temperature abnormal rise....................................................................................................... 64
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1):
Failure code [F@BZNS] (or VHMS_LED display "n3" o "81") Right front exhaust temperature sensor (1):
Failure code [f@BZNS] (or VHMS_LED display "n3" o "91") Right rear exhaust temperature sensor (1):
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2):
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2):
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2):
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2):
2 HD785-7
HD785-7 3
Failure code [DXH1KA] Lockup clutch solenoid output circuit:

Disconnection 1
Action code Failure code Lockup clutch solenoid output circuit: Disconnection
Trouble
E03 DXH1KA (Transmission controller system)
Contents of
trouble • When signal is output to lockup clutch solenoid, no current flows.
• Keeps gear speed used for travel.

Action of
controller • Turns lockup operation OFF.
Problem that • Lockup system does not operate.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• As controller detects disconnection of solenoid while output is ON, be sure to turn output ON to
check operation after repair.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
Related infor- • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
mation ON, wait for 5 seconds without starting the engine.
• If trouble has not been repaired, error is detected again.

Defective lockup clutch
1 Resis-
solenoid Between L/U.PS (CN16) (male) (1) and (2) 5 – 15 z
tance
Min. 1 Mz
and ground tance
Disconnection or short circuit 3) Connect T-adapter to connector ATC3 (female).
2
in wiring harness
and standard Between ATC3 (female) (35) and (23) 5 – 15 z
tance
value in normal
a If no abnormality is found in check on cause 2, this check is
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L/U.PS (CN16).
harness 3) Connect T-adapters to connectors ATC3 (female) and L/U.PS
3 (CN16) (female).
(Disconnection or improper
contact) Between ATC3 (female) (35) and L/U.PS Resis-
Max. 1 z
Between ATC3 (female) (23) and L/U.PS Resis-
Max. 1 z
troller
be performed.)
4 HD785-7
HD785-7 5
Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short cir-
cuit 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit
Trouble
E03 DXH1KB (Transmission controller system)
Contents of • When signal is output to lockup clutch solenoid, much current flows, or while signal is OFF, some
trouble current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Lockup system is kept OFF.
appears on
machine • If gearshift lever is set in N, machine cannot restart until it stops.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA)).
Related infor-
mation

2) Disconnect connector L/U.PS (CN16)
1 Resis-
tance
Min. 1 Mz
and ground tance
2
in wiring harness
Resis-
tance
Possible causes
value in normal 2) Disconnect connectors ATC3 and L/U.PS (CN16).
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or L/U.PS (CN16) (female).
3
ness Between ground and ATC3 (female) (35)
Resis-
and (23) or between L/U.PS (CN16) (female) Min. 1 Mz
tance
(1) and (2)
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and L/U.PS (CN16).
4
ness 3) Connect T-adapter to ATC3 or L/U.PS (CN16) (female).
Between ATC3 (female) (35) and (23) or Resis-
Min. 1 Mz
between L/U.PS (CN16) (female) (1) and (2) tance
troller
be performed.)
6 HD785-7
HD785-7 7
Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short cir-
cuit to power supply line 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit to power supply
Trouble line
E03 DXH1KY (Transmission controller system)
Contents of
trouble • While output to lock-up clutch solenoid is OFF, electric current flows.
Action of • Keeps gear speed used for travel and turns lockup operation OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Cannot change gear speed.
appears on • Keeps lockup OFF
machine • When gear shift lever is operated to N, machine cannot move off.
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609 (mA))
Related infor-
mation

1 Resis-
tance
Min. 1 Mz
and ground tance
3) Connect T-adapter to connector L/U.PS (CN16) (female) or
insert T-adapter into connector ATC3.
2
(Contact with 24 V circuit) a If failure code [DXH1KA] for disconnection appears, hot short
circuit is not present. (Lockup clutch solenoid is defective.)
Between ground and ATC3 (35) or L/U.PS
Voltage Max. 1 V
(CN16) (female) (1)
and standard 2) Disconnect connectors ATC3 and L/U.PS (CN16).
value in normal 3) Connect the T-adapter to connector ATC3 (female).
state a Use the continuity range of the multimeter for the measure-
ment.
2) Disconnect connectors ATC3, J05, TM3, and L/U.PS (CN16).
3) Connect the T-adapter to either male or female side of connec-
Short circuit in wiring har- tors J05 or TM3.
3
ness a Use the continuity range of the multimeter for the measure-
ment.
Between TM3 (female) (12) and each pin No continuity
Between TM3 (male) (12) and each pin No continuity
Between J05 (female) (26) and each pin No continuity
Between J05 (male) (26) and each pin other No continuity
8 HD785-7

and standard If no abnormality was found in the above troubleshooting, the
4 transmission controller is defective. (Since this is an internal
state troller
HD785-7 9
Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection1

Action code Failure code Hi clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • No electric current flows when the output to Hi clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
appears on • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
• Electric current of output to ECMV can be checked with monitoring function (code: 31600 (mA)).
Related infor- • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
mation ON, wait for 5 seconds without starting the engine.

3) Connect T-adapter to connector H.PS (CN19) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and H.PS (CN19).
harness 3) Connect T-adapters to connectors ATC3 (female) and H.PS
3 (CN19) (female).
(Disconnection or
defective contact) Between ATC3 (female) (26) and H.PS Resis-
Max. 1 z
Max. 1 z
troller
be performed.)
10 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 11
Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit 1

Action code Failure code Hi clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to Hi clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
• Electric current of output to ECMV solenoid can be checked by monitoring function (code: 31600
Related infor- (mA)).
mation k Raise the body at the highest position, and set damp lever to "Hold", and install body lock

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and H.PS (CN19).
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or H.PS (CN19) (female).
3
ness
Min. 1 Mz
H.PS (CN19) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and H.PS (CN19).
4
ness 3) Connect T-adapter to ATC3 or H.PS (CN19) (female).
Min. 1 Mz
between H.PS (CN19) (female) (1) and (2) tance
troller
be performed.)
12 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 13
Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit to

power supply line 1
Action code Failure code Hi clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to Hi clutch ECMV solenoid is OFF, electric current flows.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector H.PS (CN19) (female) or insert
T-adapter into connector ATC3.
2
circuit is not present. (Hi clutch solenoid is defective.)
Between ground and ATC3 (26) or H.PS
Voltage Max. 1V
(CN19) (female) (1)
and standard 2) Disconnect connectors ATC3 and H.PS (CN19).
value in normal 3) Insert the T-adapter into connector ATC3.
ment.
2) Disconnect connectors ATC3, J05, TM3, and H.PS (CN19).
3
ment.
Between TM3 (male) (1) and each pin other No continuity
14 HD785-7

state troller
HD785-7 15
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
16 HD785-7
HD785-7 17
Failure code [DXH3KA] Lo clutch solenoid output circuit:

Disconnection 1
Action code Failure code Lo clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to Lo clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
• Electric current of output to ECMV solenoid can be checked with monitoring function (code: 31601
(mA)).
Related infor-
mation • Since output is turned ON and self-check is performed for 5 seconds after starting switch is turned
ON, wait for 5 seconds without starting the engine.

3) Connect T-adapter to connector ATC3 (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and L.PS (CN17).
harness 3) Connect T-adapters to connectors ATC3 (female) and L.PS
3 (CN17) (female).
contact) Between ATC3 (female) (6) and L.PS Resis-
Max. 1 z
Max. 1 z
troller
be performed.)
18 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 19
Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit 1

Action code Failure code Lo clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Excessive current flows while output to Lo clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

3) Connect T-adapter to connector L.PS (CN17) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and L.PS (CN17).
state Ground fault in wiring of har- 3) Connect T-adapters to ATC3 or L.PS (CN17) (female).
3
ness
Min. 1 Mz
L.PS (CN17) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and L.PS (CN17).
4
ness 3) Connect T-adapters to ATC3 or L.PS (CN17) (female).
Min. 1 Mz
between L.PS (CN17) (female) (1) and (2) tance
troller
be performed.)
20 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 21
Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit

in power supply line 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to Lo clutch ECMV solenoid is turned “OFF“, current flows to circuit.
Action of
ure.
controller
Problem that
machine

3) Connect T-adapter to connector L.PS (CN17) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector L.PS (CN17) (female) or insert
2
circuit is not present. (Lo clutch solenoid is defective.)
Between ground and ATC3 (6) or L.PS
Voltage Max. 1 V
(CN17) (female) (1)
and standard 2) Disconnect connectors ATC3 and L.PS (CN17).
ment.
2) Disconnect connectors ATC3, J05, TM3, and L.PS (CN17).
3
ment.
22 HD785-7

state troller
HD785-7 23
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
24 HD785-7
HD785-7 25
Failure code [DXH4KA] 1st clutch solenoid output circuit:

Disconnection 1
Action code Failure code 1st clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 1st clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

2) Disconnect connector 1.PS (CN6).
Defective 1st clutch ECMV
1 Resis-
solenoid Between 1.PS (CN6) (male) (1) and (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
Disconnection or short circuit 3) Connect T-adapter to ATC3 (female).
2
Possible causes in wiring harness
Resis-
state a If no abnormality is found in check on cause 2, this check is
not required.
Disconnection in wiring 2) Disconnect connector ATC3 and 1.PS (CN6).
harness 3) Connect T-adapters to ATC3 (female) and 1.PS (CN6) (female).
3
(Disconnection or improper
contact) Max. 1 z
Max. 1 z
(female) (2) tance
troller
be performed.)
26 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 27
Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit1
Action code Failure code 1st clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows when output to 1st clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
Related infor- • Electric current of output to ECMV solenoid can be checked by monitoring function (code: 31602
mation (mA)).

1 Defective 1st clutch ECMV Resis-
Between 1.PS (CN6) (male) (1) and (2) 5 – 15 z
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and 1.PS (CN6).
state Ground fault in wiring har- 3) Connect T-adapter to connector ATC3 or 1.PS (CN6) (female).
3
ness
Min. 1 Mz
1.PS (CN6) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and 1.PS (CN6).
4
ness 3) Connect T-adapter to connector ATC3 or 1.PS (CN6) (female).
Min. 1 Mz
between 1.PS (CN6) (female) (1) and (2) tance
troller
be performed.)
28 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 29
Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit
to power supply line 1
Action code Failure code 1st clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to 1st clutch ECMV solenoid is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine

Defective 1st clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 1.PS (CN6) (female) or insert T-
adapter into connector ATC3.
2
circuit is not present. (1st clutch solenoid is defective.)
Voltage Max. 1 V
1.PS (CN6) (female) (1)
and standard 2) Disconnect connectors ATC3 and 1.PS (CN6).
value in normal 3) Connect the T-adapter into connector ATC3 (female).
ment.
2) Disconnect connector ATC3, J05, TM3, and 1.PS (CN6).
3
ment.
30 HD785-7

state troller
HD785-7 31
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
32 HD785-7
HD785-7 33
Failure code [DXH5KA] 2nd clutch solenoid output circuit:

Disconnection 1
Action code Failure code 2nd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

Defective 2nd clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and 2.PS (CN8).
harness 3) Connect T-adapters to connectors ATC3 (female) and 2.PS
3 (CN8) (female).
contact) Between ATC3 (female) (5) and 2.PS (CN8) Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
troller
34 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 35
Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 2nd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

2) Disconnect connector 2.PS(CN8).
3) Connect T-adapter to connector 2.PS(CN8) (male).
1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
state Ground fault in wiring har- 3) Connect T-adapters to ATC3 (female) or 2.PS (CN8).
3
ness
Min. 1 Mz
not required.
4
ness 3) Connect T-adapters to ATC3 (female) or 2.PS (CN8).
Min. 1 Mz
troller
36 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 37
Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit
in power supply line 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit in power supply line
Trouble
Contents of
trouble • When output to 2nd clutch ECMV solenoid is "OFF", current flows to circuit.
Action of
ure.
controller
Problem that
machine

2) Disconnect connector 2.PS(CN8).
3) Connect T-adapter to connector 2.PS(CN8) (male).
1 Resis-
solenoid Between 2.PS(CN8) (male) (1) and (2) 5 – 15 z
tance
Between 2.PS(CN8) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 2.PS (CN8) (female) or insert T-
adapter into connector ATC3.
2
(Contact with 24V circuit) a If failure code [DXH5KA] for disconnection appears, hot short
circuit is not present. (2nd clutch solenoid is defective.)
Between ground and ATC3 (5) or 2.PS(CN8)
Voltage Max. 1 V
(female) (1)
ment.
2) Disconnect connectors ATC3, J05, TM3, and 2.PS (CN8).
3
ment.
38 HD785-7

state troller
HD785-7 39
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
40 HD785-7
HD785-7 41
Failure code [DXH6KA] 3rd clutch solenoid output circuit:

Disconnection 1
Action code Failure code 3rd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 3rd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine
(mA)).
Related infor-

Defective 3rd clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and 3.PS (CN10).
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and 3.PS (CN10).
harness 3) Connect T-adapters to connectors ATC3 (female) and 3.PS
3 (CN10) (female).
contact) Between ATC3 (female) (15) and 3.PS Resis-
Max. 1 z
Max. 1 z
troller
42 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 43
Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to 3rd clutch ECMV solenoid is ON.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or 3.PS (CN10) (female).
3
ness
Min. 1 Mz
not required.
4
ness 3) Connect T-adapter to ATC3 or 3.PS (CN10) (female).
Min. 1 Mz
troller
44 HD785-7
Table 1

Speed when trouble
was detected
F7
F6
Low Low 4H F7 OFF
3rd 3rd 4L F6 OFF
F5
High High 4L F6 OFF
3rd 3rd 4L F6 OFF
F4
Low Low 3H F5 OFF
2nd 2nd 3L F4 OFF
F3
High High 3L F4 OFF
2nd 2nd 3L F4 OFF
F2
Low Low 2H F3 OFF
1st 1st 2L F2 OFF
F1
Low Low 2H F3 OFF
RH
RL
Low Low RH RH OFF
HD785-7 45
Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit
Action code Failure code 3rd clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to 3rd clutch ECMV solenoid is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 3.PS (CN10) (female) or insert
2
circuit is not present. (3rd clutch solenoid is defective.)
Between ground and ATC3 (15) or 3.PS
Voltage Max. 1 V
(CN10) (female) (1)
state a Use the continuity range of the multimeter for the mea-
surement.
2) Disconnect connectors ATC3, J05, TM3, and 3.PS (CN10).
3
ness a Use the continuity range of the multimeter for the mea-
surement.
46 HD785-7

state troller
HD785-7 47
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
48 HD785-7
HD785-7 49
Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection1

Action code Failure code R clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to R clutch ECMV solenoid is ON.
Action of • The controller sets the gear in neutral.

Problem that
appears on • Machine can not move off in any gear speeds.
machine
(mA)).
Related infor-

3) Connect T-adapter to connector R.PS (CN12) (male).
1 Resis-
tance
Between R.PS (CN12) (male) (1) or (2) and Resis-
Min. 1 Mz
ground tance
2) Disconnect connector ATC3 .
2
in wiring harness
tance
value in normal
state
not required.
Disconnection in wiring 2) Disconnect connectors ATC3 and R.PS (CN12).
harness 3) Connect T-adapters to connectors ATC3 (female) and R.PS
3 (CN12) (female).
contact) Between ATC3 (female) (25) and R.PS Resis-
Max. 1 z
Max. 1 z
troller
50 HD785-7
HD785-7 51
Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit 1

Action code Failure code R clutch solenoid output circuit: Short circuit
Trouble
Contents of
trouble • Abnormally excessive current flows while output to R clutch ECMV solenoid is ON.

Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
value in normal 2) Disconnect connectors ATC3 and R.PS (CN12).
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or R.PS (CN12) (female).
3
ness
Min. 1 Mz
R.PS (CN12) (female) (1) tance
not required.
Short circuit in wiring har- 2) Disconnect connectors ATC3 and R.PS (CN12).
4
ness 3) Connect T-adapter to ATC3 or R.PS (CN12) (female).
Min. 1 Mz
between R.PS (CN12) (female) (1) and (2) tance
troller
52 HD785-7
HD785-7 53
Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to

power supply line 1
Action code Failure code R clutch solenoid output circuit: Short circuit to power supply line
Trouble
Contents of
trouble • When output to R clutch ECMV solenoid is OFF, current flows to circuit.

Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
2) Disconnect connectors ATC3 and R.PS (CN12).
3) Connect T-adapter to connector R.PS (CN12) (female) or insert
2
circuit is not present. (R clutch solenoid is defective.)
Between ground and ATC3 (25) or R.PS
Voltage Max. 1 V
(CN12) (female) (1)
and standard 2) Disconnect connectors ATC3 and R.PS (CN12).
value in normal 3) Connect the T-adapter to connector ATC3.
ment.
2) Disconnect connectors ATC3, J05, TM3, and R.PS (CN12).
3
ment.
54 HD785-7

state troller
HD785-7 55
Failure code [DXHHKA] 4th clutch solenoid output circuit:

Disconnection 1
Action code Failure code 4th clutch solenoid output circuit: Disconnection
Trouble
E03 DXHHKA (Transmission controller system)
Contents of
trouble • Current does not flow when output to 4th clutch ECMV solenoid is ON.

Problem that
machine
(mA)).
Related infor-

2) Disconnet connector 4.PS (CN14).
Defective 4th clutch ECMV
1 Resis-
tance
Min. 1 Mz
ground tance
2) Disconnet connector ATC3.
2
Possible causes in wiring harness
Resis-
state a If no abnormality is found in check on cause 2, this check is
not required.
Disconnection in wiring 2) Disconnet connectors ATC3 and 4.PS (CN14).
harness 3) Connect T-adapter to ATC3 (female) and 4.PS (CN14) (female).
3
contact) Max. 1 z
Max. 1 z
troller
56 HD785-7
HD785-7 57
Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit1
Action code Failure code 4th clutch solenoid output circuit: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of
trouble • Abnormally excessive current flows while output to 4th clutch ECMV solenoid is ON.

Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
2
in wiring harness
Resis-
state Ground fault in wiring har- 3) Connect T-adapter to ATC3 or 4.PS (CN14) (female).
3
ness
Min. 1 Mz
not required.
4
ness 3) Connect T-adapter to ATC3 or 4.PS (CN14) (female).
Min. 1 Mz
troller
58 HD785-7
HD785-7 59
Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit
Action code Failure code 4th clutch solenoid output circuit: Short circuit to power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of
trouble • When output to 4th clutch ECMV solenoid is OFF, current flows to circuit.
Action of
ure.
controller
Problem that
machine

1 Resis-
tance
Min. 1 Mz
ground tance
3) Connect T-adapter to connector 4.PS (CN14) (female) or insert
2
(Contact with 24 V circuit) a If failure code [DXHHKA] for disconnection appears, hot short
circuit is not present. (4th clutch solenoid is defective.)
Voltage Max. 1 V
4.PS (CN14) (female) (1)
value in normal 3) Connect the T-adapter into connector ATC3 (female).
ment.
2) Disconnect connector ATC3, J05, TM3, and 4.PS (CN14).
3
ment.
60 HD785-7

state troller
HD785-7 61
Table 2
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
High
Low OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
4th
Low
High 4H F7 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
High
Low 4L F6 OFF
4th 4L F6 OFF
2nd OFF NEUTRAL OFF
3rd
Low
High 3H F5 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
High
Low 3L F4 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
2nd
Low
High 2H F3 OFF
4th 4L F6 OFF
3rd 3L F4 OFF
1st
F1 2nd 2L F2 OFF
Low
High 2H F3 OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
High
1st OFF NEUTRAL OFF
Low OFF NEUTRAL OFF
4th OFF NEUTRAL OFF
3rd OFF NEUTRAL OFF
Reverse
Low
1st OFF NEUTRAL OFF
High RH RH OFF
62 HD785-7
Failure code [F@BBZL] or VHMS_LED display: "n3"o"38" Blow-by

pressure: High error 1
Action code Failure code Blow-by pressure: High error
Trouble
– F@BBZL (VHMS controller system) (Display: PLM)
Contents of
• Blow-by pressure exceeded 12.9 kPa {1,320 mmH2O}.
trouble
Action of
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The LED of the VHMS controller displays "n3"o"38"
• The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
Related infor-
mation function (Code: 42801 BLOWBY PRESS)
• If failure code: DHE5KB (Blow-by pressure sensor: Short circuit) or failure code: DHE5KY (Blow-by
pressure sensor: Short circuit with power supply line) is displayed, troubleshooting for it is per-
formed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Check the engine for abnormality. Correct, if any.
1 Blow-by pressure increases Check the breather hose for clogging, bend, or break. If any, repair
Possible causes it.
and standard
value in normal Defective blow-by pressure Check the blow-by pressure sensor for abnormality. Replace, if
2
state sensor any.
If the above items 1 and 2 is normal, the VHMS controller may be
Defective VHMS & PLM con-
3 defective. (Troubleshooting cannot be carried out since the defect
troller
is in the machine monitor.)
HD785-7 63
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Left front exhaust temperature sensor (1): Exhaust temperature
Trouble abnormal rise
— F@BYNS (VHMS controller system) (Display: PLM)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Contents of
perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C
trouble
in range above rated output speed and 750°C in range below maximum torque speed)
Action of
controller
Problem that
appears on • If machine is used as it is, engine may be broken.
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
Related
saved in VHMS controller into personal computer).
information
• "n3" on VHMS controller LED changes to "61".

Abnormal rise of left front
1 exhaust temperature Check engine and repair, if there is abnormality.
(When system is normal)
Possible causes Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou-
and standard 2
temperature sensor bleshooting for it.
value in normal
state
Defective VHMS & PLM HM-CN2A Exhaust temperature Voltage
3
controller
20°C Approx. 0.9 – 1.2 V
(7) – (12)
500°C Approx. 2.6 – 3.5 V
64 HD785-7
HD785-7 65
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear
Action code Failure code Left rear exhaust temperature sensor (1): Exhaust temperature
Trouble
— f@BYNS abnormal rise (VHMS controller system) (Display: PLM)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of left rear
Possible causes Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble-
and standard 2
temperature sensor shooting for it.
value in normal
state
3
controller
20°C Approx. 0.9 – 1.2 V
(16) – (12)
500°C Approx. 2.6 – 3.5 V
66 HD785-7
HD785-7 67
Failure code [F@BZNS] (or VHMS_LED display "n3" o "81") Right front
Action code Failure code Right front exhaust temperature sensor (1): Exhaust temperature
Trouble
— F@BZNS abnormal rise (VHMS controller system) (Display: PLM)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Contents of
temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
trouble
700°C in range above rated output speed and 750°C in range below maximum torque speed)
Action of
controller
Problem that
machine
• Failure code is not displayed on machine monitor (It can be checked, however, by downloading
Related
data saved in VHMS controller into personal computer).
information

Abnormal rise of right front
Possible causes Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou-
and standard 2 exhaust temperature sen-
bleshooting for it.
value in normal sor
state a Prepare with starting switch OFF, then turn starting switch ON or
Defective VHMS & PLM
3 HM-CN2A Exhaust temperature Voltage
controller
20°C Approx. 0.9 – 1.2 V
(5) – (12)
500°C Approx. 2.6 – 3.5 V
68 HD785-7
HD785-7 69
Failure code [f@BZNS] (or VHMS_LED display "n3" o "91") Right rear
Action code Failure code Right rear exhaust temperature sensor (1): Exhaust temperature
Trouble abnormal rise
— f@BZNS (VHMS controller system) (Display: PLM)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of right rear
Possible causes Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble-
shooting for it.
value in normal sor
controller
20°C Approx. 0.9 – 1.2 V
(6) – (12)
500°C Approx. 2.6 – 3.5 V
70 HD785-7
Circuit diagram related 1
HD785-7 71
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front
Action code Failure code Left front exhaust temperature sensor (2): Exhaust temperature
Trouble
— F@BYNR abnormal rise (VHMS controller system) (Display: PLM)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of left front
Possible causes Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou-
and standard 2
temperature sensor bleshooting for it.
value in normal
state
3
controller
20°C Approx. 0.9 – 1.2 V
(7) – (12)
500°C Approx. 2.6 – 3.5 V
72 HD785-7
HD785-7 73
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear
Action code Failure code Left rear exhaust temperature sensor (2): Exhaust temperature
Trouble
— f@BYNR abnormal rise (VHMS controller system) (Display: PLM)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of left rear
Possible causes Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble-
and standard 2
temperature sensor shooting for it.
value in normal
state
3
controller
20°C Approx. 0.9 – 1.2 V
(16) – (12)
500°C Approx. 2.6 – 3.5 V
74 HD785-7
HD785-7 75
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front
Action code Failure code Right front exhaust temperature sensor (2): Exhaust temperature
Trouble
— F@BZNR abnormal rise (VHMS controller system) (Display: PLM)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of right front
Possible causes Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou-
bleshooting for it.
value in normal sor
controller
20°C Approx. 0.9 – 1.2 V
(5) – (12)
500°C Approx. 2.6 – 3.5 V
76 HD785-7
HD785-7 77
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear
Action code Failure code Right rear exhaust temperature sensor (2): Exhaust temperature
Trouble
— f@BZNR abnormal rise (VHMS controller system) (Display: PLM)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Contents of
trouble
Action of
controller
Problem that
machine
Related
information

Abnormal rise of right rear
Possible causes Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble-
shooting for it.
value in normal sor
controller
20°C Approx. 0.9 – 1.2 V
(6) – (12)
500°C Approx. 2.6 – 3.5 V
78 HD785-7
HD785-7 79
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
80 HD785-7
SEN01948-04
HD785-7

HD785-7 7001 and up
Troubleshooting of electrical system
(E-mode)
Before troubleshooting of electric system ....................................................................................................... 3
E-1 Engine does not start ............................................................................................................................... 5
E-2 Automatic preheating does not operate ................................................................................................... 8
E-3 Machine monitor does not display all, when starting switch is turned ON.............................................. 12
E-4 Machine monitor does not operate when starting switch is OFF............................................................ 14
E-5 Alarm buzzer does not sound................................................................................................................. 16
E-6 Alarm buzzer does not stop sounding .................................................................................................... 18
E-7 Gauges of machine monitor, caution lamps or character display
section do not display properly. ............................................................................................................. 19
E-8 A selection of the display in character display section cannot be changed............................................ 21
E-9 Power mode selecting function does not operate properly .................................................................... 24
E-10 AISS function does not operate properly.............................................................................................. 25
E-11 Seat belt caution lamp does not display properly ................................................................................. 26
HD785-7 1
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly ................................................. 27
E-13 Night illumination (lighting) does not work properly .............................................................................. 30
E-14 Emergency steering does not operate.................................................................................................. 42
E-15 Hoist lever does not operate normally .................................................................................................. 47
E-16 Power supply system (Air conditioner does not operate) ..................................................................... 50
E-17 Compressor and refrigerant system (Air is not cooled) ........................................................................ 52
E-18 Blower motor system (Air does not come out or air flow is abnormal) ................................................. 54
2 HD785-7
Before troubleshooting of electric system 1

a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and slow-blow fuses to see if the power is supplied normally.
a When checking, see "Troubleshooting by failure code (General)", "Before carrying out troubleshooting
when failure code is displayed".
HD785-7 3

a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "Good"
or "No Good" about presumed causes.
1
• References for making judgement of "Good" or "No Good".
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wir-
ing harness has occurred.
• Grounding fault
2 A wiring harness that is not originally connected with a
grounding circuit is in contact with it.
• Failure due to short-circuiting
A wiring harness that is not originally connected with a
power source circuit (24 V) is in contact with it.
Possible causes Cause for presumed
and standard failure (The attached No. is <Points to remember in troubleshooting>
value in normal 3 for filing and reference 1) Connector denotation method and handling of T-adapters
state purpose only. It does not Insert or connect T-adapters in the following manner,
stand for any priority.) unless specifically owhterwise instructed.
• If there is no indication of "male" or "female" in the con-
nector No., pull off a connector and insert a T-adapter
into both sides of male and female
• If there is an indication of "male" and "female" in the
4 connector No., pull off a connector and insert a T-adapter
into only one side of "male" or "female".
2) Description sequence of pin No. and handling of circuit
tester leads
Connect the positive lead (+) and negative lead (-) for trou-
bleshooting in the following manner unless specifically
otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the
5
front or wiring harness.
• Connect the negative lead (-) to a pin No. marked at the
rear of wiring harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow ( ) : Roughly indicates the location in the machine where it is installed.
4 HD785-7
E-1 Engine does not start 1

Trouble Engine does not start.
Related • When failure code related to engine controller or transmission is present, troubleshooting the corre-
information sponding failure code first.

Gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
FUA2 and FUB2 or defec- When circuit breaker FUA2, FUB2 is shut off, or fuse BT2 (19) –
2 tive fuse BT2 (19) – (20), (20), BT3 (13) – (14) and BT3 (21) – (22) is blown, it is highly pos-
BT3 (13) – (14) and BT3 (21) sible that a defective grounding has occurred in the circuit.
– (22)
a Gearshift lever: Neutral
Defective engine starter
3 The problem is
relay (R01) Replace relay (R01) Defective relay
resolved.
with other relay
(5 terminals) The problem is not
Relay is normal
resolved.
Defective engine starting 2) Set gearshift lever in neutral and carry out troubleshooting.
4 relay (R01) coil, gearshift
lever or wiring Resistance 230 –
Between starting motor terminal B – ground
(Coil of R01) 350 z
Possible causes 2) Disconnect connector D01 (female) and D08 (male).
and standard 5 Defective diode (D01), (D08) Between (1) – (2) Continuity None
value in normal D01, D08 (male)
Between (2) – (1) Continuity Yes
state
• Troubleshooting in a diode range.
1) Turn starting switch OFF and carry out troubleshooting.
Defective alternator
6 Between alternator terminal R (E01) –
(regulator) Voltage Max. 12V
ground
1) Prepare with starting switch OFF.
7 Defective battery relay 2) Turn starting switch ON and carry out troubleshooting.
Between starting motor terminal B – ground Voltage 20 – 30 V
2) Disconnect battery ground cable, connector SF1, battery relay
and starting switch terminals.
Wiring harness between BT2 (19) – battery Resis-
Max. 1 z
Disconnection in wiring relay (76) terminal B tance
harness Wiring harness between BT3 (13) – battery Resis-
(Disconnection in wiring or Max. 1 z
8 relay (77) terminal M tance
Harness between battery (+) terminal – bat- Resis-
tor) Max. 1 z
(Power supply circuits) tery relay (76) terminal B tance
Harness between BT2 (20) – starting switch Resis-
Max. 1 z
(terminal B) tance
Resis-
Harness between BT3 (14) – SF1 (male) (1) Max. 1 z
tance
HD785-7 5

Harness between starting switch (terminal
Disconnection in wiring BR) – battery relay (61) terminal BR
Continuity Continue
harness (Troubleshooting in the diode range from
(Disconnection in wiring or starting switch (terminal BR) side)
8
defective contact in connec- Harness between battery relay (60) terminal Resis-
Max. 1 z
tor) (-) – frame ground (ER2) tance
(Power supply circuits) Harness between battery relay (77) terminal Resis-
Max. 1 z
M – starting motor (terminal B) tance
2) Disconnect connectors R01, E02A, and starting switch termi-
nals.
3) Connect T-adapter to connector of circuit to be measured.
Disconnection in wiring Harness between starting switch (terminal Resis-
Max. 1 z
harness C) – R01 (female) (5) tance
(Disconnection in wiring or Harness between R01 (female) (3) – E02B Resis-
9 defective contact in connec- Max. 1 z
(female) (1) tance
tor)
Harness between R01 (female) (3) – E02A Resis-
(Related circuit after starting Max. 1 z
switch terminal C) (female) (1) tance
Harness between R01 (female) (1) – SF1 Resis-
Max. 1 z
(male) (4) tance
and standard Between R01 (female) (2) – ground (ER1) Max. 1 z
tance
value in normal
2) Disconnect connectors R01, E02A, and starting switch termi-
nals.
Hot short of wiring harness Between ground and wiring harness
10
(a contact with 24 V circuit) between alternator (terminal R) – E02A Voltage Max. 1V
(male) (2)
Between ground and wiring harnesses
between CJE3 (female) (1) – ATC1 (female) Voltage Max. 1V
(24), BRC1 (female) (15) – D01 (female) (2)
1) Disconnect battery ground cable.
Defective starting switch 2) Disconnect starting switch terminals.
11 (Between terminals B – C or
Starting switch unit (between B – C), Resis-
BR) Max. 1 z
(between B – BR) tance
Between starting motor (B terminal) –
Voltage 20 – 30 V
ground
12 Defective starting motor
2) Insert T-adapter in connector E02A.
Between E02A (1) – ground Voltage 20 – 30 V
Between E02B (1) – ground Voltage 20 – 30 V
6 HD785-7
HD785-7 7
E-2 Automatic preheating does not operate 1

Auto-preheater does not operate when starting switch is turned ON while engine coolant temperature
Trouble
is below -5 °C.
• Carry out following troubleshooting when failure neither of codes [CA2555] and [CA2556] are dis-
played.
Related
(If either of these failure codes is displayed, carry out troubleshooting for it first.)
information
• While engine coolant temperature is above -5 °C, auto-preheater does not operate.
• Engine coolant temperature can be checked with monitoring function (Code: 04104 (°C))

Defective circuit breaker When the circuit breaker is shut off or the fuse is blown, it is highly
1 FUA2, FUB2 and defective possible that a defective grounding has occurred in the circuit
fuse BT2 (20), BT4 (4) (troubleshooting cause 8).
Defective high current fuse Fuse is normal if continuity exists between inlet and outlet of high
2
(200A) (fuse is blown) current fuse (disconnect the inlet and outlet terminals).
1) Prepare with starting switch OFF, then carry out troubleshooting
Defect intake air heater without turning starting switch ON.
(internal disconnection) Resis-
3 Between heater inlet terminal – ground Max. 1 z
(internal resistance: tance
Max.0.2 z) Resis-
Between heater (-) terminal – ground Max. 1 z
tance
1) Turn starting switch OFF and carry out troubleshooting.
Between heater relay coil side (-) terminal – Resis-
10 – 20 z
ground tance
2) Disconnect connector BT (input on heater relay primary side).
3) Prepare wire and connect battery relay terminal 75 to heater
relay terminal E11B.
Defective heater relay 4) Connect battery ground cable.
4 (Internal disconnection or 5) Turn starting switch ON and carry out troubleshooting.
defective contact) (a It does not turn ON 5 minites or more)
Possible causes
and standard Between heater relay terminal (E12B) –
Voltage 15 – 28 V
value in normal ground
state Between heater relay terminal (RLY) –
Voltage 15 – 28 V
ground
Between heater relay terminal (E11B) –
Voltage 15 – 28 V
ground
Defective auto preheater 2) Replace R37 with horn relay (R11).
5
relay (R37) 3) Turn starting switch ON.
Turn horn ON. Horn sounds.
2) Disconnect connector E17B.
There is
Between (1) + – (2) - Continuity not
6 Defective diode (E17B) continuity
E17B (male)
There is
Between (1) - – (2) + Continuity
continuity
• Check in diode check mode.
Between starting switch terminal B – ground Voltage 15 – 28 V
Defective starting switch
Between starting switch terminal ACC –
7 (Defective contact between Voltage 15 – 28 V
ground
contact points B and ACC)
• If no problem is found by above diagnoses, starting switch is
defective.
8 HD785-7

2) Disconnect terminals of circuit breaker, starting switch, slow-
blow fuse, and heater relay.
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (RLY) – air heater inlet terminal tance
Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (E12B) – high current fuse outlet terminal tance
Wiring harness between slow-blow fuse Resis-
Max. 1 z
inlet – battery relay terminal M (75). tance
harness Max. 1 z
nal M (75) – circuit breaker FUB2 terminal tance
defective contact in connec- Wiring harness between circuit breaker Resis-
tor) FUB2 terminal – fuse BT4 (3), (4) – R37 Max. 1 z
tance
(female) (5)
Max. 1 z
nal B (74) – circuit breaker FUA2 terminal tance
Wiring harness between circuit breaker
Resis-
FUA2 terminal – fuse BT2 (19), (20) – start- Max. 1 z
tance
ing switch terminal B
Wiring harness between starting switch ter-
Resis-
minal ACC-fuse BT3 (19), (20) – J2P Max. 1 z
tance
(female) (39)
2) Disconnect terminals of circuit breaker, slow-blow fuse, heater
Possible causes relay, heater terminal, and starting switch.
and standard Between ground and wiring harness
between heater relay terminal (RLY) – air Min. 1 Mz
state tance
heater inlet terminal
Resis-
between heater relay terminal (E12B) – high Min. 1 Mz
tance
current fuse outlet terminal
Resis-
between slow-blow fuse inlet – battery relay Min. 1 Mz
tance
terminal M (75).
Resis-
between battery relay terminal M (75) – cir- Min. 1 Mz
tance
cuit breaker FUB2 terminal (64)
Short circuit of harness
9
(Contact with ground circuit) Between ground and wiring harness Resis-
between circuit breaker FUB2 terminal – Min. 1 Mz
tance
fuse BT4 (3), (4) – R37 (female) (5)
Resis-
between battery relay terminal B (74) – cir- Min. 1 Mz
tance
cuit breaker FUA2 terminal
between circuit breaker FUA2 terminal – Resis-
Min. 1 Mz
fuse BT2 (19), (20) – starting switch terminal tance
B
Resis-
between starting switch terminal ACC – fuse Min. 1 Mz
tance
BT3 (19), (20) – J2P (female) (39)
Resis-
between starting switch terminal ACC – fuse Min. 1 Mz
tance
BT3 (19), (20) – J2C (female) (39)
HD785-7 9
10 HD785-7
HD785-7 11
E-3 Machine monitor does not display all, when starting switch is turned
ON 1
Trouble Lamps and gauges of machine monitor do not display all, when starting switch is turned ON.
Related
• When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information

Defective fuse BT2 (2), (20) When the fuse BT2 (2), (20) or (30) is blown or the circuit breaker
1 or (30) or defective circuit FUA2 is shut off, it is highly possible that a defective grounding has
breaker FUA2 occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female).
3) Disconnect fuse terminal of starting switch.
Wiring harness between DPC1 (female) (6), Resis-
Max. 1 z
(7) – fuse BT2 (2) tance
harness Wiring harness between BT2 (1) – starting Resis-
Max. 1 z
2 (Disconnection in wiring or switch terminal ACC tance
defective contact in connec- Wiring harness between BT2 (20) – starting Resis-
tor) Max. 1 z
switch terminal B tance
Wiring harness between circuit breaker Resis-
Max. 1 z
FUA2 – fuse BT2 (19) tance
Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
Possible causes ER tance
value in normal 2) Disconnect connector DPC1 and terminals of fuse and starting
state switch.
Resis-
between DPC1 (female) (6), (7) – fuse BT2 Min. 1 Mz
tance
(2)
Short circuit of harness Resis-
3 between BT2 (1) – starting switch terminal Min. 1 Mz
ACC
Resis-
between fuse BT2 (20) – starting switch ter- Min. 1 Mz
tance
minal B
Resis-
between circuit breaker FUA2 – fuse BT2 Min. 1 Mz
tance
(19)
Defective machine 2) Insert T-adapter in connector DPC1.
monitor
Between DPC1 (6), (7) – (9), (10) Voltage 20 – 30 V
12 HD785-7
HD785-7 13
E-4 Machine monitor does not operate when starting switch is OFF 1
Service meter and travel distance integrating meter, turn signal pilot lamp, and high beam pilot lamp
Trouble
do not flash, if the switches are operated with starting switch OFF.
Related
information

Defective fuse BT2 (30) or When the fuse BT2 (30) is blown or the circuit breaker FUA2 is
1 defective circuit breaker shut off, it is highly possible that a defective grounding has
FUA2 occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female).
3) Disconnect terminals of BT2 (30) and FUA2.
harness Wiring harness between DPC1 (female) (4), Resis-
Max. 1 z
2 (Disconnection in wiring or (5) – fuse BT2 (30) tance
defective contact in connec- Wiring harness between circuit breaker Resis-
tor) Max. 1 z
FUA2 – fuse BT2 (29) tance
Possible causes Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
and standard ER2 tance
value in normal 1) Disconnect battery ground cable.
state 2) Connect T-adapter to connector DPC1 (female).
3) Disconnect terminals of BT2 (30) and FUA2.
3 between DPC1 (female) (4), (5) – fuse BT2 Min. 1 Mz
(30)
Resis-
between circuit breaker FUA2 – fuse BT2 Min. 1 Mz
tance
(29)
2) Insert T-adapter in connector DPC1.
4 Defective machine monitor 3) Turn starting switch ON.
Between DPC1 (4), (5) – (9), (10) Voltage 20 – 30 V
14 HD785-7
HD785-7 15
E-5 Alarm buzzer does not sound 1

The alarm buzzer does not sound when the starting switch is ON, emergency stop item lamps are ON,
Trouble
and centralized warning lamp is ON.
Related
information

When the fuse BT2 (16) is blown, it is highly possible that a defective
1 Defective fuse BT2 (16)
grounding has occurred in the circuit (troubleshooting cause 3).
2) Connect T-adapter to connector DPC1 (female) and BZ2
(female).
harness Wiring harness between DPC1 (female) Resis-
Max. 1 z
2 (Disconnection in wiring or (13) – BZ2 (female) (2) tance
defective contact in connec- Wiring harness between BZ2 (female) (1) – Resis-
tor) Max. 1 z
fuse BT2 (16) tance
Between DPC1 (female) (9), (10) – ground Resis-
Max. 1 z
ER tance
Possible causes 2) Disconnect connector DPC1 and BZ2.
and standard 3) Connect T-adapter to DPC1 (female).
value in normal Short circuit of harness
state 3 Between ground and wiring harness between Resis-
DPC1 (female) (13) – BZ2 (female) (2) tance
Between ground and wiring harness Resis-
Min. 1 Mz
between BZ2 (female) (1) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC1.
Measurement
DPC1 Voltage
conditions
When the buzzer
20 – 30 V
does not sound
Between (13) – (9), (10)
When the buzzer
Max. 1V
sounds
* Set up the conditions to actuate the buzzer for the measurement.
16 HD785-7
HD785-7 17
E-6 Alarm buzzer does not stop sounding 1

When starting switch is turned ON, centralized warning lamp lights up and alarm buzzer does not stop
Trouble
sounding.
Related • Since causes 2 – 7 are alarms turned ON to avoid danger in operation, they are turned OFF if oper-
information ational problem is solved.

• When trouble is detected, centralized warning lamp lights up
and alarm buzzer sounds.
1 Trouble detection (Note: Some troubles do not turn lamp/buzzer ON.)
• In this case, perform troubleshooting for displayed code (check
trouble record, too).
• While engine is running and parking brake switch is in "Park"
position, if gear shift lever is set in position other than "N", cen-
2 Parking brake drag warning tralized warning lamp lights up and alarm buzzer sounds.
• If parking brake switch is set in "Travel" position or gear shift
lever is set in "N" position, alarm is turned OFF.
• If travel speed exceeds set speed or engine speed increases
abnormally, centralized warning lamp lights up and alarm buzzer
3 Overrun warning sounds.
• If travel speed lowers below set speed and engine speed
decreases to normal range, alarm is turned OFF.
• While engine is running, if body is raised (body pilot lamp in
machine monitor is lighting up) or gear shift lever is set in posi-
tion other than "N" with parking brake switch in "Travel" position,
4 Body up warning
centralized warning lamp lights up and alarm buzzer sounds.
• If body is lowered or parking brake switch is set in "Park" posi-
tion or gear shift lever is set in "N" position, alarm is turned OFF.
• While gear shift lever is not in "N" position, if starting switch is
Possible causes
turned from OFF position to ON, centralized warning lamp lights
and standard 5 Neutral safety warning
up and alarm buzzer sounds.
value in normal
• If gear shift lever is set in "N" position, alarm is turned OFF.
state
• If this function is set and body is raised (body pilot lamp in
Warning by body up caution machine monitor is lighting up) while the engine is running, cen-
6
function (if equipped) tralized warning lamp lights up and alarm buzzer sounds.
• If body is lowered, alarm is turned OFF.
• While gear shift lever is not in "N" position, if engine start signal
(key switch terminal C) is detected, centralized warning lamp
Warning for start in position
7 lights up and alarm buzzer sounds.
other than neutral
• If gear shift lever is set in "N" position or engine start signal is
turned OFF, alarm is turned OFF.
• When engine is started, if accumulator oil pressure is low,
retarder caution lamp (accumulator oil pressure reduction detec-
tion) and centralized warning lamp light up and alarm buzzer
Retarder oil pressure reduc-
8 sounds.
tion detection
(Reference: If 30 seconds pass, [2G42ZG] or [2G43ZG] and
[DHU2KX] or [DHU3KX] failure codes are turned ON.)
• Check retarder hydraulic circuit (accumulator oil pressure).
• If initialization is not performed normally after controller is
replaced, centralized warning lamp lights up and alarm buzzer
9 Defective initialization
sounds.
• Perform initialization correctly.
• If above causes are not detected, machine monitor or controller
Defective machine monitor
10 may be defective. (Since trouble is in system, troubleshooting
or controller
cannot be performed.)
18 HD785-7
E-7 Gauges of machine monitor, caution lamps or character display

section do not display properly 1
Trouble Gauges, lamps or character display section are malfunctioning
Related
information

Defective sensors or Troubleshooting corresponding sensors or switches by the failure
Possible causes 1
switches code.
and standard
value in normal Defective CAN communica-
2 Troubleshooting by the communication related failure code
state tion circuit
If no problem is found in above 1 and 2, machine monitor is defec-
tive (since this is an internal defect, it cannot be diagnosed).
HD785-7 19
20 HD785-7
E-8 A selection of the display in character display section cannot be

changed 1
Trouble (1) When the mode selector switch 1 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH1 (male).
Resis-
CH1 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [U]. Max. 1 z
selector switch 1 (CH1)
Between (3) – (2)
Switch is in the neutral. Min. 1 Mz
Press the switch [t]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH1
(female).
harness Wiring harness between CH1 (female) (1) – Resis-
Max. 1 z
3 (Disconnection in wiring or DPC2A (female) (14) tance
defective contact in connec- Wiring harness between CH1 (female) (2) – Resis-
tor) Max. 1 z
DPC2A (female) (8) tance
Possible causes
Wiring harness between CH1 (female) (3) – Resis-
value in normal fuse BT2 (30) tance
2) Disconnect connectors DPC2A and CH1.
3) Connect T-adapter to DPC2A.
Resis-
between CH1 (female) (1) – DPC2A Min. 1 Mz
Short circuit of harness tance
4 (female) (14)
Resis-
tance
(female) (8)
Min. 1 Mz
between CH1 (female) (3) – fuse BT2 (30) tance
2) Insert T-adapter in connector DPC2A.
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [U]. 20 – 30 V
Between (8) –
ground Switch is in the neutral. Max. 1V
Between (14) – Press the switch [t]. 20 – 30 V
HD785-7 21
Trouble (2) When the mode selector switch 2 circuit for machine monitor is defective
Related
information

2) Connect T-adapter to connector CH2 (male).
Resis-
CH2 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [>]. Max. 1 z
selector switch 2 (CH2)
Between (3) – (2)
Press the switch [<]. Max. 1 z
Between (3) – (1)
2) Connect T-adapter to connectors DPC2A (female) and CH2
(female).
harness Wiring harness between CH2 (female) (1) – Resis-
Max. 1 z
3 (Disconnection in wiring or DPC2A (female) (15) tance
defective contact in connec- Harness between CH2 (female) (2) – Resis-
tor) Max. 1 z
DPC2A (female) (6) tance
Possible causes
Wiring harness between CH2 (female) (3) – Resis-
value in normal fuse BT2 (16) tance
2) Disconnect connectors DPC2A and CH2.
Resis-
Short circuit of harness tance
4 (female) (15)
Resis-
tance
(female) (6)
Min. 1 Mz
between CH2 (female) (3) – fuse BT2 (16) tance
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [>]. 20 – 30 V
Between (6) –
Between (15) – Press the switch [<]. 20 – 30 V
22 HD785-7
HD785-7 23
E-9 Power mode selecting function does not operate properly 1

When power mode selector function does not operate properly, even if the power mode selector
Trouble
switch is operated.
Related
information

2) Connect T-adapter to connector PWM (male).
Defective power mode Resis-
2 PWM (male) Operation of switch (switch unit)
selector switch tance
Switch: down Max. 1 z
Between (1) – (3)
Switch: up Min. 1 Mz
Disconnection in wiring 2) Connect T-adapter to connectors DPC2A (female) and PWM
harness (female).
3 (Disconnection in wiring or Wiring harness between DPC2A (female) Resis-
Max. 1 z
Possible causes defective contact in connec- (13) – PWM (female) (3) tance
and standard tor) Wiring harness between PWM (female) (1) Resis-
– fuse BT2 (16) tance
state
2) Disconnect connectors DPC2A and PWM.
Short circuit of harness Between ground and wiring harness
4 Resis-
(Contact with ground circuit) between DPC2A (female) (13) – PWM Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between PWM (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (13) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
24 HD785-7
E-10 AISS function does not operate properly 1

Trouble When AISS function does not operate properly, even if the AISS LOW switch is operated.
Related • When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information • If the brake pilot lamp is not normally turned ON or OFF, carry out troubleshooting and repair first.

2) Connect T-adapter to connector AISS (male).
Resis-
2 Defective AISS switch AISS (male) Operation of switch (switch unit)
tance
Switch: up Min. 1 Mz
Between (1) – (3)
Switch: down Max. 1 z
Disconnection in wiring 2) Connect T-adapter to connectors DPC2A (female) and AISS
harness (female).
3 (Disconnection in wiring or Wiring harness between DPC2A (female) Resis-
Max. 1 z
Possible causes defective contact in connec- (2) – AISS (female) (3) tance
and standard tor) Wiring harness between AISS (female) (1) – Resis-
fuse BT2 (16) tance
state
2) Disconnect connectors DPC2A and AISS.
4 Resis-
(Contact with ground circuit) between DPC2A (female) (2) – AISS Min. 1 Mz
tance
(female) (3)
Min. 1 Mz
between AISS (female) (1) – fuse BT2 (16) tance
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (2) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
HD785-7 25
E-11 Seat belt caution lamp does not display properly 1

The lamp lights up even if the seat belt is fastened, or the lamp does not light up even if the seat belt is
Trouble
not fastened.
Related
information

2) Connect T-adapter to connector SBS (male).
3) Check switch unit.
2 Defective seat belt switch Resis-
SBS Seat belt
tance
Fastened Max. 1 z
Between (1) – (2)
Unfastened Min. 1 Mz
Disconnection in wiring 2) Connect T-adapter to connectors DPC2B (female) and SBS
harness (female).
3 (Disconnection in wiring or Wiring harness between DPC2B (female) Resis-
defective contact in connec- (11) – SBS (female) (2) tance
and standard tor) Wiring harness between SBS (female) (1) – Resis-
state fuse BT2 (16) tance
2) Disconnect connectors DPC2B and SBS.
4 Resis-
(Contact with ground circuit) between DPC2B (female) (11) – SBS Min. 1 Mz
tance
(female) (2)
Min. 1 Mz
between SBS (female) (1) – fuse BT2 (16) tance
2) Insert T-adapter in connector DPC2B.
5 Defective machine monitor DPC2B Seat belt Voltage
Between (11) – Fastened 20 – 30 V
ground Unfastened Max. 1V
26 HD785-7
E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly1
Trouble Turn signal lamp or turning lamp (hazard lamp) do not flash.
Explanation of circuit
1) If 24 V is input to pin (3), the flasher keeps outputting signals of 24 V and 0 V from pin (4) repeat-
edly.
2) The input of 24 V to flasher pin (3) is changed by relay (R17). It is supplied through BT1 for turn sig-
nal lamp and through BT2 for hazard lamp.
3) The flasher output is supplied constantly (regardless of the position of the switch) through connector
Related
(CM) to pin (6) of the turn switch and to pins (1) and (3) of hazard relay (R16).
information
4) When the turn switch is turned ON, the flashing signal is input to pin (6) of connector (CM) and the
turn switch sends that signal to the left side (pin (7)) or right side (pin (8)).
5) If the hazard switch is pressed, pins (1) and (3) of relay (HAZ) are connected and hazard relays 1
(R16) and 2 (R17) are turned ON. Hazard relay 2 (R17) changes the power supply from BT1 to
BT2 and hazard relay 1 (R16) connects the flashing signal from the flasher to both of the right side
and left side.

When the fuse BT1 (4) or BT2 (24) is blown, it is highly possible
Defective fuse BT1 (4) or
1 that a defective grounding has occurred in the circuit (troubleshoot-
BT2 (24)
ing cause 7).
Since the lamp can be suspected to be defective, visually check it
2 Defective lamp
or replace it with known good lamp to make a judgement.
2) Insert T-adapter in connector FLS.
3 Defective turn signal lamp FLS Voltage
Between (3) – ground 20 – 30 V
Between (4) – ground 20 – 30 V and 0 V repeatedly
2) Connect T-adapter to connector FLS (male).
3) Check switch unit.
Resis-
CM (male) Turn switch (lever)
4 Defective turn switch tance
Turned to the left Max. 1 z
Between (6) – (7)
Turned to the right Min. 1 Mz
Possible causes Turned to the right Max. 1 z
and standard Between (6) – (8)
Turned to the left Min. 1 Mz
value in normal
When the relay can be suspected to be defective, replace it with
state
another relay to make a judgement.
5 Defective relay • As for the relay R16 (6 terminals): Replace with the relay R21,
R40 or R05, etc.
• Relay R17 (5-pole): Replace with relay R11, R30, R31, etc.
2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Wiring harness between BT1 (4) – R17 Resis-
Max. 1 z
(female) (6) tance
Disconnection in wiring Wiring harness between BT2 (24) – R17 Resis-
harness Max. 1 z
(female) (5) – HAZ (female) (1) tance
Wiring harness between HAZ (male) (3) – Resis-
R17 (female) (1) – R16 (female) (5) tance
tor)
Wiring harness between R17 (female) (3) – Resis-
Max. 1 z
FLS (female) (3) tance
Max. 1 z
CM (female) (7) – DPC2A (female) (7) tance
Max. 1 z
CM (female) (8) – DPC2A (female) (16) tance
HD785-7 27

Wiring harness between R16 (female) (1), Resis-
Max. 1 z
(3) – FLS (female) (4) – CM (female) (6) tance
Wiring harness between CM (female) (7) – Resis-
Max. 1 z
PR03 (female) (3) (left front) tance
Max. 1 z
B03 (female) (1) (left rear) tance
Max. 1 z
PL03 (female) (3) (right front) tance
Max. 1 z
B02 (female) (1) (right rear) tance
Between PR03 (female) (2) – ground (left Resis-
front) tance
harness
Between PL03 (female) (2) – ground (right Resis-
front) tance
Between B03 (female) (6) – CJR (3), (6) – Resis-
tor) Max. 1 z
ground (B10) (right rear) tance
Between B02 (female) (6) – CJR (2), (6) – Resis-
Max. 1 z
ground (B10) (left rear) tance
Resis-
Between HAZ (male) (4) – ground (ER1) Max. 1 z
tance
Resis-
Between R17 (female) (2) – ground (ER1) Max. 1 z
tance
Resis-
tance
Resis-
Between FLS (female) (1) – ground (ER1) Max. 1 z
value in normal 2) Disconnect connectors HAZ, R17, R16, FLS, CM, DPC2A,
state PR03, PL03, CJR, B02, and B03.
3) Connect T-adapter to connector of circuit to be checked.
Min. 1 Mz
between BT1 (4) – R17 (female) (6) tance
Resis-
between BT2 (24) – R17 (female) (5) – HAZ Min. 1 Mz
tance
(male) (1)
Resis-
between HAZ (male) (3) – R17 (female) (1) Min. 1 Mz
tance
– R16 (female) (5)
Resis-
between R17 (female) (3) – FLS (female) Min. 1 Mz
tance
Short circuit of harness (3)
7
Resis-
between R16 (female) (4) – CM (female) (7) Min. 1 Mz
tance
– DPC2A (female) (7)
Resis-
between R16 (female) (2) – CM (female) (8) Min. 1 Mz
tance
– DPC2A (female) (16)
Resis-
between R16 (female) (1), (3) – FLS Min. 1 Mz
tance
(female) (4) – CM (female) (6)
Resis-
between CM (female) (7) – PR03 (female) Min. 1 Mz
tance
(3) (right front)
Resis-
between CM (female) (7) – B03 (female) (1) Min. 1 Mz
tance
(left front)
28 HD785-7

between CM (female) (8) – PL03 (female) Min. 1 Mz
and standard tance
Short circuit of harness (3) (right front)
value in normal 7
state Resis-
between CM (female) (8) – B02 (female) (1) Min. 1 Mz
tance
(right rear)
HD785-7 29
E-13 Night illumination (lighting) does not work properly 1

Trouble (1) Small lamps (clearance lamp, tail lamp), night illumination and head lamp do not light up at all.
Explanation of relay circuit
1) The 24V power source from fuse BT1 pin (2) is supplied to light switch pin (4), passing switch pin
(1), and small lamp relay (R46) pin (5).
2) If the light switch is set in the small position, small lamp relay (R46) is turned ON. The 24V power
supplied to R46 pin (5) is output through R46 pin (3). Then, the 24V power is supplied again
through fuse BT1 pin (17) to each small lamp.
3) If the light switch is set in the head (low) position, head lamp low relay (R31) is turned ON and 24V
power supplied through fuse BT1 pin (6) is output through R31 pin (3). Then, the 24V power is sup-
Related
plied again through fuse BT1 pin (9) to each low lamp.
information
4) If the light switch is set in the head (low) and high beam position, DPC1 pin (14) is grounded and
headlamp high relay (R30) is turned ON. The 24V power supplied through fuse BT1 pin (8) is out-
put through R30 pin (3). Then, the 24V power is supplied again through fuse BT1 pin (11) to each
high lamp.
5) If passing switch is turned ON, headlamp high pass relay (R29) is turned ON. The 24V power sup-
plied through fuse BT1 pin (8) is output through R29 pin (3) and connected to R30 pin (3) and then
supplied through the high beam circuit. (The 24V power is supplied again through fuse BT1 pin (11)
to each high lamp.)

Defective circuit breaker If fuse BT1 (2) or (17) is broken, circuit probably has ground fault.
1
FUB1 or fuse BT1 (2) or (17) (Check by Cause 4.)
2) Connect T-adapter to connector CM (male).
CM (male) Lamp switch Resistance
2 Defective lamp switch Between (1) – (2) Max. 1 z
1st detent
Between (1) – (3) Min. 1 Mz
2nd detent
Defective small lamp relay 2) Replace R46 with horn relay (R11).
(R46)
Possible causes
2) Connect T-adapter to connector CM (female)
and standard
3) Disconnect R46, J02 and J03.
value in normal
state Disconnection in wiring har- Wiring harness between circuit breaker Resis-
Max. 1 z
ness FUB1 (63) – CM (female) (1), (4) or R46 (5) tance
Between CM (female) (2) – R46 (female) (1) Max. 1 z
defective contact in connec- tance
tor) Resis-
Between R46 (female) (2) – ground ER1 Max. 1 z
tance
Between R46 (female) (3), J03 (28) – J02 Resis-
Max. 1 z
(3) tance
2) Disconnect connectors CM, R46, DPC2B, LS, RP, LP1, B01 and
B02.
Ground fault in wiring har- 3) Prepare and carry out troubleshooting with starting switch kept
5 ness OFF.
(Contact with ground circuit) Wiring harness between BT1 (2) – R46 Resis-
Min. 1 Mz
(female) (5) tance
Min. 1 Mz
30 HD785-7
HD785-7 31
Small lamps (clearance lamp and tail lamp) or night illumination do not light up at the "first detent"
Trouble (2)
position of the lamp switch.
Related • When the head lamps light up.
information a See circuit diagram (1).

2) Connect T-adapter to connector CM (female).
1 Defective lamp switch
Between (1) – (2) 1st detent Max. 1 z
2) Disconnect connectors CM, R46, and J02 and terminals of fuse.
Possible causes
and standard R46 (female) (1) tance
ness
value in normal Wiring harness between CM (female) (1), Resis-
state (4) – R46 (female) (5) (branch point) tance
tor) Wiring harness between R46 (female) (3) –
Resis-
BT1 (17) – (18) – J02 (female) (3) (to branch Max. 1 z
tance
point)
Resis-
tance
Defective small lamp relay 2) Replace R46 with horn relay (R11).
(R46)
Trouble (3) Left small lamp (clearance lamp and tail lamp) does not "left" light up.
Related • Carry out following troubleshooting when right small lamp and headlamps (right and left) light up.

When the lamp (bulb) can be suspected to be defective, judge by
1 Defective lamp (bulb)
visual check or replacing the lamp bulb.
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02, CJB, and PL03.
harness Wiring harness between J02 (male) (3) – Resis-
Max. 1 z
2 (Disconnection in wiring or CJB (female) (1) tance
Possible causes defective contact in connec- Wiring harness between CJB (female) (6) – Resis-
tor) Max. 1 z
and standard PL03 (female) (1) tance
value in normal Wiring harness between PL03 (female) (2) – Resis-
state Max. 1 z
ground (PL07) tance
2) Disconnect connectors J02, CJB, and PL03.
3) Connect T-adapter to J02 (male).
Short circuit of harness Between ground and wiring harness Resis-
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (6) – PL03 (female) Min. 1 Mz
tance
(1)
32 HD785-7
Trouble (4) Right small lamp (clearance lamp) does not "right" light up.
Related • Carry out following troubleshooting when left small lamp and headlamps (right and left) light up.

2) Disconnect connectors J02, CJB, and PR03.
Disconnection in wiring Wiring harness between J02 (male) (3) – Resis-
harness Max. 1 z
CJB (female) (1) tance
Wiring harness between CJB (female) (2) – Resis-
Possible causes defective contact in connec- Max. 1 z
tor) PR03 (female) (1) tance
and standard
value in normal Wiring harness between PR03 (female) (2) Resis-
Max. 1 z
state – ground (PR07) tance
2) Disconnect connectors J02, CJB, and PR03.
3) Connect T-adapter to J02 (male).
3 Min. 1 Mz
(Contact with ground circuit) between J02 (male) (3) – CJB (female) (1) tance
Resis-
between CJB (female) (2) – PR03 (female) Min. 1 Mz
tance
(1)
Trouble (5) Left small lamp (tail lamp) does not "left" light up.
Related • Carry out following troubleshooting when right tail lamp and headlamps light up.

2) Disconnect connectors J02, CJV, and B02.
3) Connect T-adapter to J02, CJV, and B02.
harness Wiring harness between J02 (branched Resis-
Max. 1 z
2 (Disconnection in wiring or point) (female) (3) – CJV (female) (4) tance
defective contact in connec- Wiring harness between CJV (female) (5) – Resis-
Possible causes tor) Max. 1 z
B02 (female) (5) tance
and standard
value in normal Wiring harness between B02 (female) (6) – Resis-
Max. 1 z
state ground (B10) tance
3) Connect T-adapter to J02 (female).
3 between J02 (male) (branch point) (3) – Min. 1 Mz
CJV (female) (4)
Resis-
between CJV (female) (5) – B02 (female) Min. 1 Mz
tance
(5)
HD785-7 33
Trouble (6) Right small lamp (clearance lamp) does not "right" light up.
Related
• Carry out following troubleshooting when left tail lamp and headlamps light up.
information

3) Connect T-adapter to J02, CJV, and B03.
harness Wiring harness between J02 (female) Resis-
Max. 1 z
2 (Disconnection in wiring or (branch point) (3) – CJV (female) (4) tance
defective contact in connec- Wiring harness between CJV (female) (3) – Resis-
Possible causes tor) Max. 1 z
B03 (female) (5) tance
and standard
value in normal Wiring harness between B03(female) (6) – Resis-
Max. 1 z
state ground (B10) tance
3) Connect T-adapter to J02 (female).
3 between J02 (male) (branched point) (3) – Min. 1 Mz
CJV (female) (4)
Resis-
between CJV (female) (3) – B03 (female) Min. 1 Mz
tance
(5)
34 HD785-7
HD785-7 35
Trouble (7) Head lamps "Lo beam" do not light up.

Related
• When the lamps light up in the Hi beam side.
information

When the fuse BT1 (6), (9) – (10) is blown, it is highly possible that
Defective fuse BT1(6), (9) –
1 a defective grounding has occurred in the circuit (troubleshooting
(10)
cause 5).
Defective headlamp low 2) Replace R31 with horn relay (R11).
relay (R31)
2) Disconnect connectors PR01, PL01, CJA, R31.
Wiring harness between PR01 (female) (1) Resis-
Max. 1 z
– CJA (female) (5) (right side) tance
Wiring harness between PL01 (female) (1) – Resis-
Max. 1 z
CJA (female) (3) (left side) tance
harness Wiring harness between CJA (female) (4) – Resis-
Max. 1 z
4 (Disconnection in wiring or fuse BT1 (10) tance
defective contact in connec- Wiring harness between fuse BT1 (9) – R31 Resis-
tor) Max. 1 z
(female) (3) tance
Possible causes
value in normal R31 (female) (1) tance
state Wiring harness between R31 (female) (5) – Resis-
Max. 1 z
BT1(6) tance
Between R31 (female) (2) – JCA(5), (16) – Resis-
Max. 1 z
ground (ER1) tance
2) Disconnect connectors PR01, PL01, CJA, R31, and CM and ter-
minals of fuse.
Resis-
between PR01 (female) (1) – CJA (female) Min. 1 Mz
tance
(5) (right side)
Resis-
Short circuit of harness between PL01 (female) (1) – CJA (female) Min. 1 Mz
5 tance
(Contact with ground circuit) (3) (left side)
Min. 1 Mz
between CJA (female) (4) – fuse BT1 (10) tance
Min. 1 Mz
between fuse BT1 (9) – R31 (female) (3) tance
Min. 1 Mz
between CM (female) (3) – R31 (female) (1) tance
Min. 1 Mz
between R31 (female) (5) – BT1 (6) tance
36 HD785-7
HD785-7 37
Trouble (8) Head lamps "Hi beam" do not light up.

Related • When the lamps light up in the Lo beam side.

When the fuse BT1 (8), (11) – (12) is blown, it is highly possible
Defective fuse BT1 (8), (11) –
1 that a defective grounding has occurred in the circuit (troubleshoot-
(12)
ing cause 4).
2) Disconnect connectors PR02, PL02, DPC1, and CM and termi-
nals of fuse.
Wiring harness between PR02 (female) (1) Resis-
Max. 1 z
– CJA (female) (2) (right side) tance
Wiring harness between PL02 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring CJA (female) (6) (left side) tance
harness Wiring harness between CJA (female) (1) – Resis-
fuse BT1 (12) tance
Wiring harness between fuse BT1 (11) – Resis-
tor) Max. 1 z
Max. 1 z
between R30 (female) (1) – CM (female) (3) tance
Wiring harness between DPC1 (female) Resis-
Max. 1 z
(14) – R30 (female) (2) *1 tance
Wiring harness between BT1 (8) (female) Resis-
Max. 1 z
Possible causes (1) – R30 (female) (5) tance
and standard
value in normal
2) Disconnect connectors PR02, PL02, DPC1, and CM and termi-
state
nals of fuse.
Resis-
between PR02 (female) (1) – CJA (female) Min. 1 Mz
tance
(2) (right side)
Resis-
between PL02 (female) (1) – CJA (female) Min. 1 Mz
tance
(6) (left side)
4 Min. 1 Mz
(Contact with ground circuit) between CJA (female) (1) – fuse BT1 (12) tance
Min. 1 Mz
between fuse BT1 (11) – R30 (female) (3) tance
Min. 1 Mz
CM (female) (3) tance
Resis-
between DPC1 (female) (14) – R30 (female) Min. 1 Mz
tance
(2) *1
Resis-
between BT1 (8) (female) (1) – R30 Min. 1 Mz
tance
(female) (5)
Defective headlamp high 2) Replace R30 with horn relay (R11).
relay (R30) *1
*1: Passing lamp lights up, even if head lamp "Hi beam" do not right up.
38 HD785-7
Trouble (9) Headlamp "low beam" and "high beam" do not light up.
Related • Carry out following troubleshooting when small lamps light up.

1 Defective lamp switch
Between (1) – (3) Turn to 2nd detent. Max. 1 z
Possible causes Disconnection in wiring 1) Turn starting switch OFF.

and standard harness 2) Disconnect connectors R31, and CM and terminals.
value in normal 2 (Disconnection in wiring or 3) Connect T-adapter to connector of circuit to be measured.
state defective contact in connec- Wiring harness between CM (female) (3) – Resis-
tor) Max. 1 z
2) Disconnect connectors R31, and CM and terminals.
Short circuit of harness 3) Connect T-adapter to connector of circuit to be measured.
3
Min. 1 Mz
between CM (female) (3) – R31 (female) (1) tance
Trouble (10) Passing lamp does not light up.

Related • When head lamps light up properly. (High beam lights up)

1 Defective passing switch CM (male) Passing switch Resistance
Operated Max. 1 z
Between (4) – (5)
Not operated Min. 1 Mz
2) Disconnect connectors CM, R29, and DPC2A (female).
3) Connect T-adapter to CM, R29, and DPC2A (female).
Possible causes
and standard Disconnection in wiring Max. 1 z
value in normal harness R29 (female) (1) tance
state 2 (Disconnection in wiring or Wiring harness between R29 (female) (5) – Resis-
Max. 1 z
defective contact in connec- R30 (female) (5) (up to branch point) tance
tor) Wiring harness between DPC2A (female) Resis-
Max. 1 z
(4) – CM (female) (5) (up to branch point) tance
Resis-
tance
Defective headlamp high 2) Replace R29 with horn relay (R11).
(pass) relay (R29)
HD785-7 39
Trouble (11) The brightness of the night illumination does not change, even if the rheostat is operated.
Related
information

2) Connect T-adapter to connector LS (male).
LS Rheostat Voltage
1 Defective rheostat Between (1) –
Neutral 20 – 30 V
ground
Between (2) – Left end 6 – 12 V
ground Right end 18 – 27 V
and standard Disconnection in wiring 2) Connect T-adapter to connectors LS (female) and DPC2B
state 2 (Disconnection in wiring or Wiring harness between LS (female) (2) – Resis-
Max. 1 z
defective contact in connec- DPC2B (female) (12) tance
tor) Resis-
Between LS (female) (3) – ground (ER1) Max. 1 z
tance
2) Disconnect connectors LS and DPC2B.
Short circuit of harness 3) Connect T-adapter to LS (female).
3
Resis-
between LS (female) (2) – DPC2B (female) Min. 1 Mz
tance
(12)
40 HD785-7
HD785-7 41
E-14 Emergency steering does not operate 1

When steering pump stops, machine cannot be steered manually (emergency steering switch does
Trouble (1)
not work).
a See Operation and Maintenance Manual, Operation volume, "Operating procedure", Testing and
Related
adjusting before starting engine", "Testing emergency steering" and "Testing automatic emergency
information
steering".

Defective fuse EMPR, BT2 If fuse EMPR, BT2 (26) is blown, it is highly possible that a defec-
1
(26) tive harness grounding has occurred in the circuit.
2) Disconnect switch terminal and check switch unit.
Defective manual switch Manual switch Manual switch
2 Resistance
(internal defective contact) terminal operation
Between ST1 – ST2 Switch (pressed) Max. 1 z
(Switch unit) Switch (not pressed) Min. 1 Mz
Resis-
Between relay terminal (55) – ground Max. 1 z
tance
1) Start engine.
Defective emergency 2) Turn parking brake ON.
3
steering relay 3) Turn emergency steering switch ON.
1) Between relay terminal (72) – ground Voltage 20 – 30 V
1) Start engine.
2) Turn parking brake ON.
3) Turn emergency steering switch ON.
Between motor terminal M and ground Voltage 20 – 30 V
Possible causes Defective emergency
and standard 4 1) Turn starting switch OFF.
steering motor
state Between motor terminal E and ground Max. 1 z
tance
• If no problem is found in above diagnoses, the steering motor is
defective.
Wiring harness between battery (+) (BT-2B) Resis-
Max. 1 z
– emergency steering relay (54) tance
Disconnection in wiring Wiring harness between relay terminal (71) Resis-
harness Max. 1 z
– motor terminal M tance
Wiring harness between motor terminal E – Resis-
tor) ground tance
Wiring harness between relay terminal (53) Resis-
Max. 1 z
– ground tance
Wiring harness between relay terminal (70) Resis-
Max. 1 z
1) Disconnect battery ground cable and battery (+) cable.
Short circuit (ground fault) of
Wiring harness between battery (+) (BT-2B) Resis-
6 harness Min. 1 Mz
– emergency steering relay (54) tance
Resis-
between relay terminal (71) – motor terminal Min. 1 Mz
tance
M
42 HD785-7
HD785-7 43
Trouble (2) Automatic emergency steering does not operate.

a See Operation and Maintenance Manual, Operation volume, "Operating procedure", Testing and
adjusting before starting engine", "Testing emergency steering" and "Testing automatic emergency
steering".
• Explanation of auto emergency steering circuit
1) When the parking brake is released, the parking brake switch is turned ON and a voltage (about 24
V) is generated at pin PSWR (2) (The power is supplied through fuse BT3 (16).)
Related 2) If the oil flow in the steering unit is lost and the steering pressure switch is turned ON, a voltage is
information generated at pin H01 (A).
3) The emergency steering timer operates and a voltage is generated at emergency steering timer
output pin (5).
a After the above operation, the steering circuit operates as in the manual operation (emergency
steering switch).
4) The emergency steering relay is turned ON and the emergency steering motor operates.
a For defects of the emergency steering relay and emergency steering motor, see Trouble (1).

2) Connect T-adapter to PSWF (male)
Defective parking brake
2 switch (rear) Resis-
PSWF (male) Parking brake operations
(Internal defective contact) tance
Released (CLOSE) Max. 1 z
Between (1) – (2)
Operated (OPEN) Min. 1 Mz
2) Connect T-adapter to PSWR (male)
Defective parking brake
3 switch (front) Resis-
PSWR (male) Parking brake operations
(Internal defective contact) tance
Released (CLOSE) Max. 1 z
Between (1) – (2)
and standard 2) Connect T-adapter to H01 (male)
value in normal 3) Start engine and carry out troubleshooting.
state Defective emergency steer-
4 ing oil pressure switch Resis-
H01 (male) Steering pump
(Internal contact) tance
Between (A) – (C)
Stopped (CLOSE) Max. 1 z
Resis-
Between EM (female) (1) – ground Max. 1 z
tance
Defective emergency 1) Turn starting switch OFF.

5 2) Insert T-adapter in connector EM.
steering timer
3) Turn parking brake ON. (Turn line to EM (3) OFF)
4) Check by supplying 24 V to EM (3).
a Check within 90 seconds.
Between EM (female) (5) – ground Voltage 20 – 30 V
harness 1) Turn starting switch OFF.
6 ((Disconnection in wiring or 2) Disconnect connectors PSWR, CJN, EM, and BT3 (16).
defective contact in connec- 3) Connect T-adapter to connector of circuit to be measured.
tor)
44 HD785-7

Wiring harness between fuse BT-3 (16) – Resis-
Max. 1 z
PSWR (female) (1) tance
Wiring harness between PSWR (female) (2) Resis-
– CJN (female) (4) tance
harness
Wiring harness between CJN (female) (3) – Resis-
H01 (female) (C) tance
tor) Wiring harness between H01 (female) (A) – Resis-
Max. 1 z
EM (female) (3) tance
Wiring harness between EM (female) (5) – Resis-
Max. 1 z
relay terminal (54) tance
Possible causes 2) Disconnect connectors PSWR, CJN, EM, and BT3 (16).
and standard 3) Connect T-adapter to connector of circuit to be measured.
value in normal
state Resis-
between fuse BT-3 (16) – PSWR (female) Min. 1 Mz
tance
(1)
Resis-
Short circuit (ground fault) of between PSWR (female) (2) – CJN (female) tance
Min. 1 Mz
7 harness (4)
Resis-
between CJN (female) (3) – H01 (female) Min. 1 Mz
tance
(C)
Min. 1 Mz
between H01 (female) (A) – EM (female) (3) tance
Resis-
between EM (female) (5) – relay terminal Min. 1 Mz
tance
(54)
a The 5 factors in causing the trouble that "the emergency steering operates by itself (while the switch is
turned OFF)" are as follows. (Factors 4) and 5) can cause this trouble only when they occur simulta-
neously.)
1) The emergency steering relay is kept turned ON for some vibration. (Replace the emergency
steering relay.)
2) The voltage at the (+) terminal of the emergency steering relay is 20 – 30 V. (This terminal should
be grounded normally.)
3) The wiring of the emergency steering relay on the M side comes in contact with that on the B side.
(Open the battery box and check the wiring.)
4) Parking brake oil pressure switch is stuck. (Replace the parking brake oil pressure switch.)
5) Steering flow switch is stuck. (Replace steering flow switch.)
HD785-7 45
46 HD785-7
E-15 Hoist lever does not operate normally 1

Hoist lever does not operate normally.
Trouble (1) Hoist lever is not fixed at RAISE position.
(2) Hoist lever raise fixing device (detent) is not reset before body raising position.
• Failure code [DW72KZ] checks kick-out solenoid and [DK54KX] checks body positioner sensor.
Accordingly, if these codes are not displayed, it is judged that there is not breakage in solenoid coil
or disconnection/short circuit in sensor and wiring is normal.
Related • If detent is not reset, hoist lever kick-out is judge to be normal (solenoid is turned ON and OFF nor-
information mally). It should be judged that signal from body positioner sensor is not sent to controller normally.
If body is not hoisted at all, see failure codes [DK52KX] and [DK53LX] (Troubleshooting for hoist
lever potentiometer sensor).
• If kick-out solenoid is defective, replace hoist lever.

1) Turn starting switch OFF and insert T-adapter in LK0.
2) Start engine.
1 Defective hoist lever kick-out 3) Set hoist lever in RAISE position and check.
LK0 Voltage
Between (1) – (2) 20 – 30 V
Possible causes
and standard 1) Turn starting switch OFF and insert T-adapter in BRC1 (or in
value in normal connector on route to body positioner sensor).
state Defective body positioner 2) Start engine.
2 3) Set hoist lever in RAISE position and check until body is raised.
sensor
0–5V
Between BRC1 (8) – (21) Voltage
(Change between)
out.)
HD785-7 47
48 HD785-7
HD785-7 49
E-16 Power supply system (Air conditioner does not operate) 1

Trouble • Air conditioner does not operate because of trouble in power supply system
Indication of • When main power of control panel is turned ON and air conditioner switch is pressed, LCD of con-
problem on trol panel does not light up.
machine • No air comes out (Blower motor does not rotate).
• If LCD of control panel does not light up, check fuse No. 27 (20 A) of BT3 for breakage, referring to
"Failure code table and fuse locations".
Related
• Air conditioner ground is connected together with electric equipment of machine in machine wiring
information
harness.
• Wiring harness fuse (5A) on air conditioner side is wound onto wiring harness.

2) Disconnect ground strap.
Defective wiring harness 3) Disconnect connector [2] from control amplifier and troubleshoot
1 without turning starting switch to ON position.
(ground)
Between connector [2] (1) and
Resistance Max. 1 z
chassis ground
2 Broken fuse
2) Check wiring harness fuse (5A) on air conditioner side.
2) Disconnect relay connector [12] and troubleshoot without turn-
Defective blower OFF relay ing starting switch to ON position.
3
(Short circuit in relay coil)
Between connector [12] (1) and
Resistance 320 z
(2)
a If fuse is broken, replace it.
2) Disconnect connectors [1] and [2] from control amplifier.
3) Turn starting switch to ON position and troubleshoot.
Between connector
Voltage 20 – 30 V A
[2] (7) and (1)
Possible causes a If fuse was broken again during above test A, perform following
and standard (Replace broken fuse in advance).
state 2) Disconnect ground strap.
4 Defective wiring harness
3) Disconnect control panel connectors [1] and [2] and trouble-
shoot without turning starting switch to ON position.
a If fuse was broken again during above test A and results B and
C below are normal, blower motor circuit may be cause of fail-
ure. See E-18.
Between connector Resis-
Min. 1 Mz B
[2] (7) and (1) tance
[2] (7) and chassis Min. 1 Mz C
tance
ground
a If fuse was broken again during above test A due to cause 4,
and results B and C below are abnormal, identify defective wir-
ing harness.
Ground fault of wiring har- 2) Disconnect ground strap.
5 ness 3) Disconnect connectors [1], [2] and [8] and troubleshoot without
(Contact with ground circuit) turning starting switch to ON position.
a The result indicated in Section D or E below is abnormal: There
is short circuit in air conditioner wiring harness.
a The result indicated in Section F or G below is abnormal: Short
circuit in machine wiring harness.
50 HD785-7

Min. 1 Mz D
[8] (1) and (5) tance
Ground fault of wiring har- [8] (1) and chassis Min. 1 Mz E
tance
Possible causes 5 ness ground
and standard (Contact with ground circuit) Between AC1 (1) and Resis-
Min. 1 Mz F
value in normal (5) tance
state Between AC1 (1) and Resis-
Min. 1 Mz G
Disconnection in wiring har- a If fuse is not broken and result A due to cause 4 is abnormal,
6
ness check circuit diagram.
If results due to causes 1 and 2 and result A due to cause 4 are
7 Defective control panel
normal, replace control panel.
HD785-7 51
E-17 Compressor and refrigerant system (Air is not cooled) 1

Trouble a Air is not cooled because of trouble in compressor or refrigerant system
Indication of • When engine is started and main power of control panel is turned ON and air conditioner switch is
problem on pressed, air is not cooled.
machine • Air conditioner compressor does not operate.
Related • Pressure switch is kept OFF while refrigerant pressure is abnormally low or high.
information • If ambient temperature is below 5°C, air conditioner may not be turned ON (normal).

2) Disconnect pressure switch connector [11] and troubleshoot
without turning starting switch to ON position.
1 Defective pressure switch
Between (1) and (2) on pressure switch side Resis-
Max. 1 z
of connector [11] tance
When replacing pressure switch, collect refrigerant in advance.
2) Disconnect connector E07 from air conditioner compressor and
troubleshoot without turning starting switch to ON position.
Defective air conditioner a Check ground connection of air conditioner compressor and
2
compressor
E10.
Between connector E07 (male) (1) and (2) Resis- Approx.
(Air conditioner compressor coil resistance) tance 15 z
2) Disconnect connectors [1] and [2] and troubleshoot without turn-
ing starting switch to ON position.
a Check that result due to cause 1 is normal (Pressure switch is
turned ON) and result due to cause 2 is also normal (Air condi-
tioner compressor is normal).
Possible causes Between wiring harness (AC1 (2) and E07 Resis-
(female)) and (1) tance
value in normal
state Disconnection in wiring har- Between connector [8] (2) and connector Resis-
3 Max. 1 z
ness [14] (3) tance
Between connector [14] (4) and connector Resis-
Max. 1 z
[8] (3) tance
Max. 1 z
[1] (15) tance
Max. 1 z
[11] (2) tance
Max. 1 z
[8] (1) tance
a Prepare with starting switch at OFF position, then turn starting
Defective compressor clutch switch to ON position and troubleshoot.
4
relay (It does not turn ON) Turn starting switch to OFF position and replace relay with another
one. If condition becomes normal, original relay is defective.
2) Disconnect connectors [14] and E07 and troubleshoot without
Ground fault of wiring har- turning starting switch to ON position.
5 ness a Check that result due to cause 2 is normal.
(Contact with ground circuit) Between wiring harness (between connec-
Resis- Min. 1
tor [14] (3) and E07 (female) (1)) and
tance Mz
ground
52 HD785-7

2) Disconnect connectors [14] and [11] and troubleshoot without
Short circuit (ground fault) of turning starting switch to ON position.
6 harness a Check that result due to cause 2 is normal.
Resis- Min. 1
Between connector [14] (4) and (3)
Possible causes tance Mz
and standard Disconnection in another wir-
value in normal 7 a Check with circuit diagram.
ing harness
state
2) Disconnect connector E07 and insert T-adapter into female side.
8 Defective control panel 4) Turn main power of control panel ON and turn air conditioner
switch ON.
Between connector E07 (female) (1) and
Voltage 20 – 30 V
ground
HD785-7 53
E-18 Blower motor system (Air does not come out or air flow is abnor-
mal) 1
Trouble • Air does not come out or air flow is abnormal because of trouble in blower motor system
Indication of • When main power of control panel is turned ON, LCD of control panel lights up but air does not flow
problem on out.
machine • Air flow does not reflect fan switch setting of control panel.
• If air flow becomes abnormal after a while in cooling mode, evaporator may have frozen.
Possible causes for this trouble are as follows.
1) Defective compressor clutch relay (It is kept ON).
Related 2) Evaporator temperature sensor mounting holder is removed (Remove and disassemble air condi-
information tioner unit).
3) Expansion valve is not adjusted properly (Remove air conditioner unit and replace expansion
valve).
• If air flows out, fuse and relay are normal and wiring harness is probably not defective.

2) Disconnect connector [24] and troubleshoot without turning
Defective manual switch
1 starting switch to ON position.
(internal defective contact)
Between terminals (1) and (2) on blower
Continuity
motor side wiring harness of connector [24]
2) Disconnect connector [24].
Defective blower OFF relay, 3) Turn starting switch to ON position and turn main power of con-
2 defective blower amplifier or trol panel ON. Then set fan switch to HI-MAX and troubleshoot.
defective wiring harness Between terminals (1) and (2) on control
amplifier side wiring harness of connector Voltage 20 – 30 V
[24]
a Prepare with starting switch at OFF position, then turn starting
switch to ON position and troubleshoot.
Defective blower OFF relay Turn starting switch to OFF position and replace blower OFF relay
3
(It does not turn ON) with another one. Then turn starting switch to ON position and turn
main power of control panel ON. If condition becomes normal,
blower OFF relay is defective.
Possible causes
value in normal 2) Disconnect connectors [24], [12] and [8] and troubleshoot with-
state out turning starting switch to ON position.
Defective wiring harness Between wiring harness (between connec- Min. 1
4 Resis-
(Ground fault) tor [24] (1) and connector [12] (3)) and
tance Mz
ground
Between wiring harness (between connec- Min. 1
Resis-
tor [12] (4) and connector [8] (1)) and
tance Mz
ground
2) Disconnect connector [2].
4) Turn main power of control panel ON (Turn blower OFF relay
ON (Output = GND) and apply voltage of about 10 V to base of
5 Defective control panel blower amplifier).
Between (3) on controller side of connector
Voltage 20 – 30 V
[1] and chassis ground
Between (20) on controller side of connector Approx.
Voltage
[1] and chassis ground 10 V
6 Check with circuit diagram.
ness
7 Defective blower amplifier If 1 – 6 are not causes of trouble, blower amplifier is defective.
54 HD785-7
HD785-7 55
HD785-7 Dump truck

© 2010 KOMATSU
All Rights Reserved
56 HD785-7
SEN01949-01
HD785-7

HD785-7 7001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
H-1 Machine does not start............................................................................................................................. 4
H-2 Machine does not travel smoothly (hunting) ............................................................................................ 6
H-3 Lockup cannot be cancelled..................................................................................................................... 6
H-4 Excessive shock when starting or shifting excessive ............................................................................... 7
H-5 Transmission does not shift up................................................................................................................. 8
H-6 Machine lacks power or speed when traveling ...................................................................................... 10
H-7 Time lag is excessive when starting or shifting gear .............................................................................. 14
H-8 Torque converter oil temperature is high................................................................................................ 16
H-9 Torque converter oil pressure is low....................................................................................................... 17
H-10 Front brake is ineffective ...................................................................................................................... 18
H-11 Rear brake is ineffective ....................................................................................................................... 19
H-12 Steering wheel is heavy ....................................................................................................................... 20
H-13 Steering wheel does not work .............................................................................................................. 21
HD785-7 1
H-14 Steering wheel vibrates ........................................................................................................................ 22

H-15 Dump body lifting speed is slow ........................................................................................................... 23
H-16 Dump body does not work.................................................................................................................... 24
H-17 Excessive hydraulic drift of dump body ................................................................................................ 25
2 HD785-7

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information
2
Possible causes Cause for presumed failure <Contents>
and standard (The attached No. is for fil-
value in normal • The standard values in normalcy by which to judge “Good“
3 ing and reference purpose
state or “No Good“ about presumed causes.
only. It does not stand for
any priority.) • References for making judgement of “Good“ or “No Good“
4
HD785-7 3
H-1 Machine does not start 1

Trouble Machine does not start at any gear speed.
• Before carrying out troubleshooting, check that transmission oil level is normal.
• If failure code related to input shaft speed sensor system or mechanical system is displayed, carry
Related
information
• Check that drive shaft etc. is free from abnormality.
• Check that parking brake is reset securely.

Defective power train pump
1 Power train pump strainer may be clogged. Check it directly.
strainer
Air in suction side of power Suction piping of power train pump may have sucked air. Check it
2
train pump directly.
a Prepare with engine stopped, then carry out troubleshooting at
following engine speed.
Defective power train pump • Engine speed: 1,900 rpm (Rated speed)
3
main relief valve N, F1 – F3, RL, 3.53 ± 0.2 MPa
Relief oil RH {36.0 ± 2.0 kg/cm2}
pressure 2.16 ± 0.2 MPa
F4 – F7
{22.0 ± 2.0 kg/cm2}
• Engine speed: 1,900 rpm (Rated speed)
Defective torque converter a For details, refer to "Standard value table".
4
oil pressure (relief valve)
Max. 0.85 MPa
Torque converter inlet pressure
{Max. 8.67 kg/cm2}
Possible causes
and standard Torque converter outlet pres- 0.49 ± 0.04 MPa
value in normal sure {5.0 ± 0.41 kg/cm2}
state a Prepare with engine stopped, then carry out troubleshooting at
5 Defective torque converter
Stall speed (Power mode, high
1,845 ± 100 rpm
load)
1.61 ± 0.2 MPa
Lo, Hi, 4th clutch
{16.5 ± 2.0 kg/cm2}
Defective gear speed clutch 2.01 ± 0.2 MPa
6 3rd clutch
ECMV {20.5 ± 2.0 kg/cm2}
3.29 ± 0.25 MPa
2nd clutch
{33.5 ± 2.5 kg/cm2}
3.43 ± 0.2 MPa
1st clutch
{35.0 ± 2.0 kg/cm2}
* Since gear speed clutches are combined and operated 2 sets by
2, see combinations in Table 1.
4 HD785-7

• If oil pressure checked in Cause 6 is low, oil may be leaking
through clutch seal ring.
7 Defective gear speed clutch
Possible causes • If oil pressure checked in Cause 6 is normal, clutch may be slip-
and standard ping.
value in normal • If check result of Cause 3 is abnormal, disconnect power train
state 8 Defective power train pump pump outlet hose and crank engine to see if oil flows out.
• Check line filter for foreign matter to judge.
Internal defect in transmis-
9 Transmission may have defect in it. Check it directly.
sion
Table 1
Operated clutches
Lo Hi 1st 2nd 3rd 4th R
F1 q q
F2 q q
F3 q q
F4 q q
Gear speed
F5 q q
F6 q q
F7 q q
N
RH q q
RL q q
HD785-7 5
H-2 Machine does not travel smoothly (hunting) 1

Trouble Machine does not travel smoothly (hunting).
Related • Check that the transmission oil level is correct.
information • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
Possible causes • Oil temperature: 80 °C
and standard Defective power train pump • Engine speed: 1,900 rpm (Rated speed)
value in normal 3
state RH {36.0 ± 2.0 kg/cm2}
Relief oil
F4 – F7
{22.0 ± 2.0 kg/cm2}
• If the oil pressure is low in the item 3, wear of the gear speed
clutch piston seal ring or wear of the ring groove can be sus-
4 Defective gear speed clutch pected.
• If the oil pressures are within the ranges in the item 3, a slip of
the clutch can be suspected.
H-3 Lockup cannot be cancelled 1

Trouble Torque converter lockup cannot be cancelled.

Possible causes • Oil temperature: 80 °C
Defective lockup solenoid
and standard 1
valve • Engine speed: 1,900 rpm (Rated speed)
value in normal
state Lockup solenoid valve output 1.52 ± 0.2 MPa
pressure {15.5 ± 2.0 kg/cm²}
If the oil pressure is within the range in the item 1, a seizure of the
2 Defective lockup clutch
lockup clutch can be suspected.
6 HD785-7
H-4 Excessive shock when starting or shifting excessive 1

Trouble Shock when starting or shifting is excessive.
Related
• If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information

* There is some shock, but it is difficult to judge if the shock is
excessive or not, so judge that it is excessive in the following
Possible causes cases.
and standard • When it is apparent that the shock suddenly became severer
value in normal Defective gear speed clutch than before.
1
state ECMV
• The shock is severer compared with other machines of the same
class.
Since the operation of the gear speed clutch ECMV can be
suspected to be defective, check it directly.
HD785-7 7
H-5 Transmission does not shift up 1

Trouble Transmission does not shift up.
Related
information • If the brake lamp lights up while the foot brake (service brake), retarder brake or secondary brake
isnot operated, carry out repair first.

1
F4 – F7
{22.0 ± 2.0 kg/cm2}
Defective lockup solenoid • Oil temperature: 80 °C
2
Lockup solenoid valve output 1.52 ± 0.2 MPa
If the shit up operations take place when traveling down a slope,
3 Defective lockup clutch
Possible causes a slip of the lockup clutch can be suspected.
and standard a Prepare with engine stopped, then carry out troubleshooting at
value in normal following engine speed.
state
1.61 ± 0.2 MPa
Lo, Hi, 4th clutch
{16.5 ± 2.0 kg/cm2}
Defective gear speed clutch 2.01 ± 0.2 MPa
4 3rd clutch
ECMV {20.5 ± 2.0 kg/cm2}
3.29 ± 0.25 MPa
2nd clutch
{33.5 ± 2.5 kg/cm2}
3.43 ± 0.2 MPa
1st clutch
{35.0 ± 2.0 kg/cm2}
Defective gear speed clutch
5 pected.
piston
• If the oil pressure is within the range in the item 4, a slip of the
gear speed clutch piston can be suspected.
8 HD785-7
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
F4 q q
Gear speed
F5 q q
F6 q q
F7 q q
N
RH q q
RL q q
HD785-7 9
H-6 Machine lacks power or speed when traveling 1

Trouble (1) When abnormality is present at all gear speeds (when traveling in lockup range).
• Check that the transmission oil level is correct.
Related • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information • Check that the parking brake is completely released and also check for dragging of the retarder brake.
• Check that the tire inflation pressure is proper.

Defective power train pump The power train pump strainer is suspected to be clogged, check it
1
strainer directly.
Air sucked in at the suction Since the air can be suspected to be sucked in from the suction
2
side of the power train pump piping of the power train pump, check it directly.
3
F4 – F7
{22.0 ± 2.0 kg/cm2}
Possible causes a Prepare with engine stopped, then carry out troubleshooting at
and standard
value in normal
state Defective lockup solenoid • Oil temperature: 80 °C
4
Lockup solenoid valve output 1.52 ± 0.2 MPa
• If the oil pressure is low in the item 4, wear of the lockup clutch
piston seal ring or wear of the ring groove can be suspected.
5 Slip of lockup clutch
• If the oil pressures are within the ranges in the item 4, a slip of
the lockup clutch piston can be suspected.
If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
Check for aluminum worn powder etc. residing on the line filter.
If no problem is found in item 1 through 6, measure the torque
converter stall speed (in the power mode: 1,910 ± 100 rpm). If it is
7 Decrease of engine output
below the standard value, the deterioration of the engine unit per-
formance can be suspected.
10 HD785-7
Trouble (2) When machine lacks power or speed while traveling in torque converter range.
information • Check for oil leaking from the piping to the outside.
• Check that the parking brake is completely released and also check for dragging of the retarder brake.

1
F4 – F7
{22.0 ± 2.0 kg/cm2}
Possible causes following engine speed.
and standard • Oil temperature: 85 °C
value in normal • Engine speed: 1,900 rpm (Rated speed)
Defective torque converter
state a For details, refer to "Standard value table".
2 oil pressure
(relief valve) Max. 0.85 MPa
{Max. 8.67 kg/cm2}
Torque converter outlet pres- 0.49 ± 0.04 MPa
sure {5.0 ± 0.41 kg/cm2}
Stall speed (Power mode, high
1,845 ± 100 rpm
load)
HD785-7 11
Trouble (3) Machine lacks speed or power when traveling in certain gear speeds.

• Oil leak tester: 80 °C
1.61 ± 0.2 MPa
Lo, Hi, 4th clutch
{16.5 ± 2.0 kg/cm2}
2.01 ± 0.2 MPa
Defective gear speed clutch 3rd clutch
1 {20.5 ± 2.0 kg/cm2}
Possible causes ECMV
3.29 ± 0.25 MPa
and standard 2nd clutch
{33.5 ± 2.5 kg/cm2}
value in normal
state 3.43 ± 0.2 MPa
1st clutch
{35.0 ± 2.0 kg/cm2}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
F4 q q
Gear speed
F5 q q
F6 q q
F7 q q
N
RH q q
RL q q
12 HD785-7
HD785-7 13
H-7 Time lag is excessive when starting or shifting gear 1

Trouble Time lag is excessive when starting or shifting gear.
Related
• Check for oil leaking from the piping to the outside.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
3
F4 – F7
{22.0 ± 2.0 kg/cm2}
Possible causes • Engine speed: 1,900 rpm (Rated speed)
and standard 1.61 ± 0.2 MPa
value in normal Lo, Hi, 4th clutch
{16.5 ± 2.0 kg/cm2}
state
2.01 ± 0.2 MPa
Defective gear speed clutch 3rd clutch
4 {20.5 ± 2.0 kg/cm2}
ECMV
3.29 ± 0.25 MPa
2nd clutch
{33.5 ± 2.5 kg/cm2}
3.43 ± 0.2 MPa
1st clutch
{35.0 ± 2.0 kg/cm2}
• It can be also diagnosed by replacing the ECMV.
gear speed clutch can be suspected.
• If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
14 HD785-7
Table 1
Operated clutches
F1 q q
F2 q q
F3 q q
F4 q q
Gear speed
F5 q q
F6 q q
F7 q q
N
RH q q
RL q q
HD785-7 15
H-8 Torque converter oil temperature is high 1

Trouble Torque converter oil temperature is high.
Related
information • If the oil temperature goes up when the torque converter is stalled and goes down when the trans-
mission is returned to the neutral position, the machine is normal and overload operation is a cause
of the problem.

1
strainer directly.
2
Defective power train pump
3 The filter can be suspected to be clogged; visually check it.
line filter
4
F4 – F7
Possible causes {22.0 ± 2.0 kg/cm2}
and standard • If a defect is found in the item 4, the power train pump can be
value in normal 5 Defective power train pump suspected to be defective.
state Check for aluminum worn powder etc. residing on the line filter.
Defective torque converter • Oil temperature: 80 °C
6
relief valve • Engine speed: 1,900 rpm (Rated speed)
Max. 0.85 MPa
{Max. 8.67 kg/cm²}
Max. 0.85 MPa
{Max. 8.67 kg/cm²}
Torque converter outlet 0.49 ± 0.04 MPa
16 HD785-7
H-9 Torque converter oil pressure is low 1

Trouble Torque converter oil pressure is low.
Related
information
• Check for oil leaking from the piping to the outside.

1
strainer directly.
2
3
F4 – F7
{22.0 ± 2.0 kg/cm2}
Possible causes • If a defect is found in the item 3, the power train pump can be
and standard 4 Defective power train pump suspected to be defective.
value in normal Check for aluminum worn powder etc. residing on the line filter.
state
Defective torque converter • Oil temperature: 80 °C
5
relief valve • Engine speed: 1,900 rpm (Rated speed)
Max. 0.85 MPa
{Max. 8.67 kg/cm²}
Max. 0.85 MPa
{Max. 8.67 kg/cm²}
Torque converter outlet 0.49 ± 0.04 MPa
HD785-7 17
H-10 Front brake is ineffective 1

Trouble Front brake is ineffective.
Related
information

Air sucked in at the suction
Since the air can be suspected to be sucked in from the suction
1 side of the brake control
piping of the brake control pump, check it directly.
pump
a Prepare with the engine stopped and measure with the engine
running at high idle.
Defective accumulator 11.8 (+0.98/0) MPa
2 Charge valve cut-in pressure
charge valve {120 (+10/0) kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
front brake * [Reference] Charged gas pressure: 6.2 ± 0.2 MPa {63 ± 2 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective front brake valve
Brake actuat- Brake pedal 9.8 ± 0.69 MPa
ing pressure operated {100 ± 7 kg/cm²}
Defective front brake running at high idle.
5 retarder pressure reducing
valve Brake actuat- Retarder lever 6.4 (+0.69/-0.59) MPa
ing pressure operated {65 (+7/-6) kg/cm²}
When the initial response time of brake system is excessively long
Defective front brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective front disc brake
• If the oil pressures are within the range in the item 4 or 5, a slip
of the brake disc is suspected.
18 HD785-7
H-11 Rear brake is ineffective 1

Trouble Rear brake is ineffective.
Related
information

1 side of the brake control
piping of the brake control pump, check it directly.
pump
running at high idle.
Defective accumulator 11.8 (+0.98/0) MPa
2 Charge valve cut-in pressure
charge valve {120 (+10/0) kg/cm²}
20.6 (+0.98/0) MPa
Charge valve cut-out pressure
{210 (+10/0) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
rear brake * [Reference] Charged gas pressure: 6.2 ± 0.2 MPa {63 ± 2 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective rear brake valve
Brake actuat- Brake pedal 9.8 ± 0.69 MPa
ing pressure operated {100 ± 7 kg/cm²}
Defective rear brake retarder running at high idle.
5
pressure reducing valve Brake actuat- Retarder lever 6.4 (+0.69/-0.59) MPa
ing pressure operated {65 (+7/-6) kg/cm²}
When the initial response time of brake system is excessively long
Defective rear brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective rear wheel brake
• If the oil pressures are within the range in the item 4 and 5, a slip
of the brake disc is suspected.
HD785-7 19
H-12 Steering wheel is heavy 1

Trouble Steering wheel is heavy.
• Check that oil level in hydraulic tank is proper.
• If failure code related to mechanical system is displayed, carry out troubleshooting for it first.
• Check that play of steering wheel is normal (max. 150 mm).
Related • Check that hinge pins etc. are greased thoroughly.
information • Before starting carry out troubleshooting, adjust tire inflation pressure to proper level.
"Standard tire"
27.00-R49 (Front and rear wheels) (0.69 ± 0.01 MPa {7.0 ± 0.1 kg/cm2})
"Option tire"
31/90-R49 (Front and rear wheels) (0.69 ± 0.01 MPa {7.0 ± 0.1 kg/cm2})

Air in suction side of steering Suction piping of steering and work equipment pump may have
1
and work equipment pump sucked air. Check it directly.
Defective steering and work Steering and work equipment pump strainer may be clogged.
2
equipment pump strainer Check it directly.
a Prepare with engine stopped, then start engine and carry out
Defective relief valve of troubleshooting at high idle.
3
demand valve Relief pressure (Cylinder stroke 20.6 (+0.98/0) MPa
end) {210 (+10/0) kg/cm2}
troubleshooting at high idle.
Possible causes 4 Defective steering valve
and standard Relief pressure (Cylinder stroke 20.2 – 21.1 MPa
value in normal end) {206 – 215 kg/cm2}
state Malfunction of demand valve If oil pressure is normal, demand valve spool may be malfunction-
5
spool ing. Check it directly.
troubleshooting at high idle.
Relief pressure (Cylinder stroke 20.6 (+0.98/0) MPa
6 Defective steering cylinder end) {210 (+10/0) kg/cm2}
If oil pressure is low, disconnect hydraulic hose on steering cylin-
der head side and relieve at stroke end. If oil flows from cylinder
side, piston ring of cylinder is defective.
If oil pressure check in Causes 3 and (4) is low, steering and work
Defective steering and work
7 equipment pump may be defective. Check line filter for aluminum
equipment pump
chips.
20 HD785-7
H-13 Steering wheel does not work 1

Trouble Steering wheel does not work.
• Check that the oil level in the hydraulic tank is correct.
information • Check that the steering wheel play is correct (less than 150 mm).
• Check that the hinge pin, etc. are greased fufficiently.

If the dump body also does not work, the PTO can be suspected to
1 Defective PTO
be defective.
2 side of the steering and work
side of the steering and work equipment pump, check it directly.
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
3
equipment pump strainer clogged, visually check it.
a Prepare with the engine stopped and troubleshooting with the
Defective relief valve of engine running at high idle.
4
demand valve Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
stroke end) {210 (+10/0) kg/cm²}
Possible causes
engine running at high idle.
and standard 5 Defective steering valve
value in normal Relief oil pressure (cylinder 22.5 ± 0.98 MPa
state stroke end) {230 ± 10 kg/cm²}
Defective operation of If the oil pressure is within the range, the operation of the demand
6
demand valve spool valve spool can be suspected to be defective: check it directly.
Relief oil pressure (cylinder 20.6 (+0.98/0) MPa
7 Defective steering cylinder
When the oil pressure is low, disconnect the hydraulic hose in the
steering cylinder head side and relieve the pressure at the stroke
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If the oil pressure is low in the item 4 or 5, the steering and work
Defective steering and work
8 equipment pump can be suspected to be defective.
equipment pump
HD785-7 21
H-14 Steering wheel vibrates 1

Trouble Steering wheel vibrates.
Related • Check that the oil level in the hydraulic tank is correct.

1 Defective oil Check for deterioration of oil.
Possible causes stroke end) {210 (+10/0) kg/cm²}
and standard 2 Defective steering cylinder
value in normal
steering cylinder head side and relieve the pressure at the stroke
state
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If relief pressure (demand valve relief pressure) of steering circuit
Defective crossover relief is normal and piston rings of hydraulic cylinder checked in Cause 2
3
valve is also normal, "crossover relief valve" may be defective. (Replace
valve.)
22 HD785-7
H-15 Dump body lifting speed is slow 1

Trouble When lifting dump body, the speed is slow and the power is insufficient.
Related
information
• Check that the dump lever moves smoothly.

1 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
2
and steering pump strainer clogged, visually check it.
3
demand valve Relief oil pressure (steering 20.6 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
4 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
If the oil pressure is low in the item 4, the operation of the dump
Possible causes Defective operation of dump
5 EPC valve can be suspected to be defective; visually check the
and standard EPC valve
valve.
value in normal
If the oil pressure is low in the item 4, the pilot pump for the dump
state Defective pilot pump for
6 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
7
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 7,
Defective operation of the
8 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
9 Defective dump cylinder
dump cylinder head side and relieve the pressure at the raise
stroke end. If the oil comes out from the cylinder side, the cylinder
piston ring is defective.
HD785-7 23
H-16 Dump body does not work 1

Trouble Dump body does not work.
Related
information
• Check that the dump lever moves smoothly.

If the steering also does not work, the PTO can be suspected to be
1 Defective PTO
defective.
2 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
3
and steering pump strainer clogged, visually check it.
4
demand valve Relief oil pressure (steering 20.6 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
5 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
Possible causes If the oil pressure is low in the item 5, the operation of the dump
and standard Defective operation of dump
6 EPC valve can be suspected to be defective; visually check the
value in normal EPC valve
valve.
state
If the oil pressure is low in the item 5, the pilot pump for the dump
Defective pilot pump for
7 EPC valve circuit can be suspected to be defective; check it
dump EPC valve
directly.
Defective hoist valve relief engine running at high idle.
8
valve Relief oil pressure (dump 20.6 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 8,
Defective operation of the
9 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
dump cylinder head side.
If the oil comes out from the cylinder side at the raise stroke end,
the cylinder piston ring is defective.
24 HD785-7
H-17 Excessive hydraulic drift of dump body 1

Trouble Hydraulic drift of dump body is excessive.
Related
information

a Raise the dump body and troubleshooting with the engine
stopped.
Defective oil tightness of Raise the dump body and disconnect the hydraulic hose in the
Possible causes 1
hoist valve main spool dump cylinder head side.
and standard
value in normal If the oil flows out from the cylinder side, the oil tightness of the
state spool is defective.
Raise the dump body and disconnect the hydraulic hose in the
dump cylinder head side.
If the oil does not flow out from the cylinder side, the cylinder piston
ring is defective.
HD785-7 25
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
26 HD785-7
SEN01950-01
HD785-7

HD785-7 7001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22
HD785-7 1
S-15 Abnormal noise is made ....................................................................................................................... 23

S-16 Vibration is excessive ........................................................................................................................... 24
2 HD785-7
Method of using troubleshooting [Troubleshooting]:

Items to finally verify whether the narrowed
charts 1 down causes are undoubtedly the real causes
The troubleshooting chart consists of the "ques- using the troubleshooting tools and direct
tions", "check items", "causes", and "troubleshoot- inspections.
ing" blocks.
The questions and check items are used to pinpoint Items listed in the [Questions] and [Check items]
high probability causes by simple inspection or and related to the [Causes] are marked with E, Q,
from phenomena without using troubleshooting or w.
tools. E: Causes to be referred to for questions and
Next, troubleshooting tools or direct inspection are check items
applied to check the narrowed causes in order from Q: Causes related to questions and check
the most probable one to make final confirmation items
according to the troubleshooting procedure. w: Causes highly probable among ones marked
[Questions]: with Q
Items to be drawn from the user or operator. a When narrowing the "auses", apply the items
They correspond to A and B in the chart on the marked with w before those marked with Q.
right. When narrowing the causes, do not apply the
The items in A are basic ones. items marked with E. (If no items have other
The items in B can be drawn from the user or marks and the causes cannot be narrowed,
operator, depending on their level. however, you may apply them.)
[Check items]:
Simple check items used by the serviceman to
narrow down the causes.
They corresponds to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
HD785-7 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
4 HD785-7
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
HD785-7 5
S-1 Starting performance is poor 1

General causes for poor starting performance are Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
Defective intake air heater system

q Improper selection of fuel (particularly during winter)
Defective or deteriorated battery

Clogged feed pump gauze filter
Coolant in exhaust pipe
Worn piston ring and cylinder

q
Clogged air cleaner element

a The common rail fuel injection system (CRI) recognizes
Clogged fuel filter element

the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of
machine operation
Operated for long period E E E E
Starting perfor- Became worse gradually Q w w Q Q

mance Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance
Manual w w w Q Q
Engine oil replenished more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy E w Q Q
Starting motor cranks engine slowly w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is removed w w
cranked with start-
ing motor, If spill hose from injector is disconnected,
Q w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Carry out troubleshooting for "Supply pump pressure is low pressure (*1)" indicated
by failure code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Check if there is voltage (20 – 30 V) between alternator B terminal and E Yes q

terminal during low idle operation None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Code [CA559], [CB559] and code [CA2249], [CB2249]
6 HD785-7
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

q Engine seized inside
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operations".
q Water hammer caused by coolant which entered cylinder

q
Defective steering circuit wiring

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of machine opera- Operated for long period

tion E E
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages w
Makes rattling noise and does not turn Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting on

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 - 30 V) between battery relay terminal B and

terminal E q
installed machine
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF,
engine starts q
connect cord, turn the
switch ON and carry out When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
HD785-7 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
Leaking, clogging and entry of air to fuel piping

q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft spline
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Defective injector
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy w Q Q
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting for "Supply pump pressure is low pressure (*1)" indi-
q q q
cated by failure code
Carry out troubleshooting for "PCV1 error (*2) or PCV2 error (*3)" indicated by
q
failure code
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

8 HD785-7
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor and/or wiring harness

General causes why exhaust smoke comes out but engine
Worn dynamic valve system (Valve, rocker lever, etc.)

does not start
q Lack of rotating force due to defective electrical system
Leaking, clogging of fuel system, and entry of air

q Insufficient supply of fuel
Stuck and/or seized supply pump plunger

Improper selection of fuel
Clogged injector and/or defective spray

q
Worn piston ring and/or cylinder liner
Defective intake air heater system

Clogged fuel filter and/or strainer

Use of improper fuel

Degree of machine
operation
Suddenly failed to start w w Q
Questions

Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is no fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting for "Supply pump pressure is low pressure (*1)" indicated
by failure code q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
HD785-7 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Maximum leakage from injector)

q Defective spray condition of fuel
q Improper selection of fuel
q Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electri-
Seized turbocharger or interference of turbocharger

cal system)
Leaking, clogging of or entry of air to fuel piping

Clogged injector and/or defective spray


Improper valve clearance

Degree of
machine operation Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters not carried out according to Operation and Maintenance Manual w w w
some cylinders is low Q w
Color of exhaust Blue under light load w

Check items
gas is Black w Q w w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect feed pump gauze filter directly
Carry out troubleshooting for "Supply pump pressure is low pressure (*1)" indicated by
failure code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders q q
Adjusting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10 HD785-7
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
q Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

Problem in drive devices on installed machine side

q There is overheating
Broken or seized piston and/or connecting rod

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side

Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping

Broken supply pump shaft spline

Broken or seized feed pump
Broken or seized gear train
Degree of machine
operation
Operated for long period EE
Abnormal noise was heard and engine stopped sud-
denly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
Engine stopped after hunting w Q Q Q Q
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Carry out troubleshooting on
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

installed machine

Inspect feed pump directly q
cated by failure code q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
HD785-7 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Defective operation of flow damper (Maximum leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector)
Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness
Leaking or clogging or entry of air to fuel piping

Low setting of low idle speed
Clogged fuel filter or strainer

Degree of machine
operation Operated for long period E E
Questions
Occurs at a certain speed range Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w w
Check items
Rust and water are found when fuel tank is drained Q Q


Troubleshooting

Carry out troubleshooting for “Abnormality in engine Ne speed sensor (*1)“ indicated by failure
code q
Carry out troubleshooting for “Abnormality in engine Bkup speed sensor (*2)“ indicated by fail-
ure code q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Code [CA689] and [CB689]

*2: Code [CA778] and [CB778]
12 HD785-7
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of boost pressure sensor (air leakage)

Insufficient supply of fuel
Defective fuel temperature sensor and/or wiring harness

q
Defective boost pressure sensor and/or wiring harness

Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal and/or solenoid)
q Overheat
o See "S-14 Coolant temperature becomes too

high (Overheating)"

Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping

error in electrical system)

Degree of machine
operation Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
When engine is cranked, interference sound is emitted from around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when
load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w Q
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting for "Supply pump pressure is low pressure
(*1)" indicated by failure code q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for "Charge pressure sensor error (*2)" indi-
cated by failure code q
Carry out troubleshooting for "Fuel temperature sensor error (*3)" indi-
cated by failure code q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
HD785-7 13

*2: Code [CA122] and code[CA123]
14 HD785-7
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Defective coolant temperature sensor or wiring harness

Leakage of air between turbocharger and cylinder head
q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)

q Overheat

o See "S-14 Coolant temperature becomes too high

(Overheating)"
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector
Improper injection timing

Degree of
machine operation Operated for long period E E E E
Suddenly became black w Q Q Q
Questions
Color of exhaust Gradually became black

gas w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low Q w
Check items

Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust sound improves q
cated by failure code q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder q
Inspect fuel spill piping (on cylinder head side) directly q q
Carry out troubleshooting for "Coolant temperature sensor error (*2)" indicated
by failure code
Adjusting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean

HD785-7 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal combustion of oil
Turbocharger 1
q Long-time operation of engine at low idle or high idle
Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
(Do not run engine continuously at idle without load for
more than 20 minutes)

Clogged breather or breather hose
External leakage of oil
Dust sucked in from intake system

q
q Wear of parts in lubrication system
Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of machine oper-
E E E E
Questions
Operated for long period

ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 HD785-7
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
Clogged breather and/or breather hose

q Use of improper fuel

q Use of improper oil
q Operation under excessive load
Worn valve and/or valve guide
Defective oil filter safety valve
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of machine operation Operated for long period E E E
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
installed) w Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
HD785-7 17
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel
Defective coolant temperature sensor or wiring harness

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of
E E E
Questions
Operated for long period

machine operation
More than other machines of same model Q Q Q Q
Condition of fuel
consumption
Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low w
Check items
Low idle speed is high Q

Torque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting for "Supply pump pressure is low pressure (*1)" indicated by failure
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting for "Coolant temperature sensor error (*2)" indicated by failure code q
Check with monitoring function q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

18 HD785-7
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring and/or hole caused by pitting

q Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler

Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner

Broken oil cooler core and/or O-ring
Cracks inside cylinder block
Degree of machine Operated for long period E E
Questions
operation
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Hydraulic oil or power train oil on installed machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q
Carry out troubleshooting

Troubleshooting
on installed machine
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
—
HD785-7 19
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, and/or wear of lubrication system
Defective oil pressure sensor and/or defective wiring harness

q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Opera-
tion and Maintenance Manual is not observed.
q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness

Leaking, crushed, clogged hydraulic piping
Clogged and/or broken pipe in oil pan
Defective oil pump relief valve

Coolant and fuel mixing in oil
Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of
E E E
Questions
machine operation Operated for long period

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters not carried according to Operation and Maintenance Manual w
Indicates pressure drop at low idle time w Q
Oil pressure Indicates pressure drop at low and high idle times Q w w w Q
monitor
(if installed) Indicates pressure drop on slopes w
Indicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of oil pump relief valve are fatigued and damaged q
Inspect oil filter directly q
Carry out troubleshooting for "Oil pressure sensor error (*1)" indicated by failure code q
If oil level sensor is replaced, oil level monitor indicates normally q
Adjusting
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 HD785-7
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-

ant".
Defective seal of auxiliary equipment (pump, compressor)

Broken oil cooler core and/or O-ring

Fuel leakage inside head cover
Worn or damaged rear oil seal

Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of
machine operation
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in damper chamber is low w
Oil level in hydraulic tank is low w

Remove and inspect head cover directly q
q q
Troubleshooting
Inspect cylinder block and/or liner directly

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
HD785-7 21
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, and/or damages of fan)

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Rise in oil temperature in power train
Slipping fan belt and/or worn fan pulley

Defective radiator cap (pressure valve)
Defective coolant temperature gauge
Rise in power train oil temperature

Defective operation of thermostat
Clogged or crushed radiator fins
Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of
machine operation
Questions
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud or undercover is filled with dirt and sand w w

Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge reaches red range earlier than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed)

Inspect cylinder liner directly q
q
Carry out troubleshooting
Inspect oil cooler directly

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

on installed machine
When operation of thermostat is tested, it does not open at cracking temperature q

Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 HD785-7
S-15 Abnormal noise is made 1

General causes why abnormal noise is emitted Causes
q Abnormality due to defective parts
Improper fuel injection timing (abnormality in coolant temperature sensor)

q Abnormal combustion
q Air leakage from air intake system
Deformed cooling fan and/or looseness or interference of fan belt

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated
Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve and/or rocker lever)
Leakage of air between turbocharger and cylinder head
in the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
Excessive wear of piston ring and/or cylinder liner

a When the engine is accelerated, the engine sound rises
slightly for approx. 3 seconds maximum. This is no abnor-
mality, however.
Interference or seizure of turbocharger
Removed or seized gear train bushing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of
machine operation
Operated for long period E
Questions
Condition of Gradually increased Q Q

abnormal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items

some cylinders is low w Q
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is heard only when engine is started q
Check with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
HD785-7 23
S-16 Vibration is excessive 1

General causes why vibration occurs Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on installed machine side

q Misalignment between installed machine
q Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts and/or broken cushions

Worn main bearing and/or connecting rod bearing
Broken output shaft and/or parts in damper

Worn front support spigot joint portion
Improper gear train backlash

Worn camshaft bushing
Degree of
E E E E
Questions
machine operation Operated for long period

Condition of vibra- Suddenly increased Q Q
tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
q
Troubleshooting
Inspect gear train directly

Inspect camshaft bushing directly q
Check with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 HD785-7
HD785-7 25
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
26 HD785-7
SEN01951-03
HD785-7

HD785-7 7001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 10
HD785-7 1
SEN01951-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2008.12)
1. Removal and installation of assemblies
Special tools Removal

q The special tools necessary for the q The [Removal] section contains procedures
removal and installation work are indi- and precautions for implementing the work,
cated by symbols as A1 ••• X1 and their know how and the amount of oil or coolant to
part Nos., part names, and quantity are be drained.
described in the table. q The common tools necessary for the removal
q In the special tools table, the following work are indicated [1], [2] ••• and their part
information is described, as well as the Nos ., pa rt nam es, an d qu anti ty ar e n ot
above items. described.
1) Necessity q Various symbols used in the Removal Section
t : Special tools that cannot be substituted are explained and listed below.
and should always be used (installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
N: Tools newly developed for this 6 : This mark shows the amount of oil or coolant
model. They respectively have a to be drained.
new part number. 4 : Weight of part or component
R: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Installation
Blank: Tools already available for other
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the reverse order of removal.
q Instructions and precautions for installing parts
3) Circle mark Q in sketch column:
are shown with [*1] mark in the Installation
q The sketch of the special tool is pre-
Section, identifying which step the instructions
sented in the section of "Sketches of
are intended for.
special tools".
q The common tools necessary for the installa-
q Part No. of special tools starting with
tion work are indicated [1], [2] ••• and their part
79 T- - :
* *** ****
means that they are not available
Nos ., pa rt nam es, an d qu anti ty ar e n ot
described.
from Komatsu in Japan (i.e. must be q Marks shown in the Installation Section stand
made locally). for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
2 HD785-7
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q The special tools necessary for the disas- those procedures, and quantity of the oil and
sembly and assembly work are indicated coolant drained are described.
by symbols as A1 ••• X1 and their part q The common tools necessary for the disas-
Nos ., par t na me s, a nd q ua nti ty ar e sembly work are indicated [1], [2] ••• and their
described in the table. part Nos., part names, and quantity are not
q In the special tools table, the following described.
information is described, as well as the q The meanings of the symbols used in Disas-
above items. sembly section are as follows.
1) Necessity k : This mark indicates safety-related precau-
t : Special tools that cannot be substituted tions that must be followed when imple-
and should always be used (installed). menting the work.
q : Special tools that will be useful if avail- a : Know-how or precautions for work
able and are substitutable with com- 6: Quantity of oil or coolant drained
mercially available tools.
2) Distinction of new and existing special
tools
N : Tools newly developed for this Assembly
model. They respectively have a q In Assembly section, the work procedures, pre-
new part number. cautions and know-how for carrying out those
R : Tools with upgraded part numbers. procedures, and quantity of the oil and coolant
They are remodeled from already added are described.
available tools for other models. q The common tools necessary for the assembly
Blank : Tools already available for other work are indicated [1], [2] ••• and their part Nos.,
models. They can be used without part names, and quantity are not described.
any modification. q The meanings of the symbols used in Assem-
3) Circle mark Q in sketch column: bly section are as follows.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work
special tools". a : This mark gives guidance or precautions
q Part No. of special tools starting with when doing the procedure.
79 T- - : 2 : Type of coating material
* *** ****
means that they are not available 3 : Tightening torque
from Komatsu in Japan (i.e. must be 5 : Quantity of oil or coolant to be added
made locally).
Sketches of special tools
q Various special tools are illustrated for the con-
venience of local manufacture.
HD785-7 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
Gasket sealant
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 HD785-7
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
HD785-7 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 HD785-7
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available part
a New/Remodel: N. . . . . . Tools newly developed for this model and given new part Nos.
: R. . . . . . Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
Removal and installa- Disassembly, assembly of
3 795-102-2103 Spring pusher t 1
tion of cylinder head cylinder head
assembly 4 790-331-1110 Wrench q 1 Installation of cylinder head
5 792T-600-1120 Hanger t 1 N Q
Removal and installa- Removal and installation of
Engine assembly lifting
tion of engine assembly 6 792T-600-1110 t 1 N Q engine assembly
tool
Removal of engine front
7 795-931-1100 Seal puller assembly t 1
seal
795T-621-1430 Plate t 1 N Q
A
795T-621-1441 Push tool t 1 N Q
Installation of engine front
8 01050-32240 Bolt t 3
seal
Disassembly, assem- 01050-32225 Bolt t 3
bly of engine 01640-02232 Washer t 3
Removal of engine rear
7 795-931-1110 Seal puller assembly t 1
seal
795T-621-1531 Push tool t 1 N Q
Installation of engine rear
9 01050-32060 Bolt t 5
seal
01640-02032 Washer t 5
1 792T-601-1030 Plate t 1 N Q
Removal and installa- 2 792T-601-1040 Pipe t 1 N Q
tion of output shaft B
3 792T-601-1010 Push tool t 1 N Q
assembly
4 792T-601-1020 Plate t 1 N Q
Centering engine and
1 792-620-1400 Centering tool t 1 N
torque converter
Removal and installation of
Disassembly, assem- 2 790-413-1131 Nut wrench t 1 round nut of stator shaft
bly of torque converter, C bearing
PTO assembly Removal and installation of
3 791-346-1400 Wrench t 1
PTO pump shaft
Installation of bushing to
4 792-413-1131 Installer t 1 N
stator outer race
Disassembly, assem- Operation check of disk
1 799-301-1600 Oil leak tester kit (A) t 1
bly of transmission and plate
Disassembly, assem- D 3 790-425-1670 Adapter t 1
bly of differential Bearing preload adjustment
assembly 4 792-525-3000 Micrometer t 1
HD785-7 7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-501-2001 Repair stand t 1 Disassembly, assembly of
3
792-622-1110 Bracket t 1 N differential assembly
Disassembly, assem-
bly of differential H 4 790-425-1660 Wrench t 1
assembly preload adjustment nut
5 792-201-7010 Wrench t 1
pinion gear nut
01011-61670 Bolt t 3
1 Lock of floating seal
Disassembly, assem- 01643-31645 Washer t 3
bly of front brake
J 01017-51620 Bolt t 9
assembly, rear brake Parking brake manual
assembly 2 01580-31613 Nut t 9
releasing
01643-31645 Washer t 9
792T-650-1110 Push tool t 1 Q Press fitting of front, rear
1 790-101-5421 Grip t 1 suspension cylinder coil
Disassembly, assem- bushing
01010-51240 Bolt t 1
bly of front, rear sus- Q
pension 792-610-1000 Suspension tool t 1
Charging suspension
2 792-610-1100 • Pump assembly 1
cylinder with oil, gas
792-610-1200 • Charging tool 1
Disassembly, assem- 1 790-452-1200 Pilot ring tool t 1 Centering housing
T
bly of steering valve 2 790-452-1100 Installer set t 1 Installation of spacer
790-502-1003 Repair stand t 1
1
790-101-1102 Hydraulic pump t 1
Removal, installation of
2 790-102-3802 Wrench assembly t 1
cylinder round head
3 790-302-1340 Socket t 1 nylon nut
(Width across flats: 80 mm)
790-201-1811 Push tool kit t 1
Disassembly, assem- 790-201-1810 • Push tool 1
4 Press fitting of coil bushing
bly of steering cylinder U 790-101-5021 • Grip 1
assembly
01010-50816 • Bolt 1
790-201-1620 • Push tool 1
5 Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 790-720-1000 Expander t 1
7 796-720-1660 Ring t 1 Installation of piston ring
8 07281-01159 Clamp t 1
8 HD785-7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
9
10 790-720-1000 Expander t 1
11 796-720-1690 Ring (for cylinder ) t 1
Disassembly, assem- 12 07281-02059 Clamp (for cylinder ) t 1 Installation of piston ring
bly of hoist cylinder U 792-630-1300 Push tool (for cylinder ) t 1
assembly 790-101-5421 Grip (for cylinder ) t 1
01010-51240 Bolt (for cylinder ) t 1
13 Press fitting of suspension
790-445-4210 Push tool (for cylinder ) t 1
cylinder coil bushing
790-101-5421 • Grip (for cylinder ) 1
01010-51240 • Bolt (for cylinder ) 1
Disassembly, assem-
bly of hoist cylinder V 1 792T-674-1010 Body sling pin t 4 N Q
assembly
HD785-7 9
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
A5. Hanger (792T-600-1120)
A6. Engine assembly lifting tool
10 HD785-7

A8 Plate
A8 Push tool
HD785-7 11

A9 Push tool
12 HD785-7

B1 Plate
B2 Pipe
HD785-7 13

B3 Push tool
B4 Plate
14 HD785-7

Q1 Push tool
V1 Body sling pin
HD785-7 15
HD785-7 Dump truck

© 2009 KOMATSU
All Rights Reserved
16 HD785-7
SEN01952-02
HD785-7
SEN01952-02
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ............................................................................ 2

Removal and installation of fuel injector assembly ..................................................................................... 4
Removal and installation of cylinder head assembly .................................................................................. 5
Removal and installation of engine hood assembly .................................................................................... 18
Removal and installation of radiator assembly ........................................................................................... 19
Removal and installation of engine assembly ............................................................................................. 28
Removal and installation of engine front oil seal......................................................................................... 33
Removal and installation of engine rear oil seal ......................................................................................... 36
HD785-7 1
Removal and installation of fuel

supply pump assembly
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
k Close the supply valve of the fuel tank.
a The following is the removal and installation pro-
cedure for the left bank fuel supply pump assem-
bly. The removal and installation procedure for
the right fuel supply pump assembly is the same,
unless otherwise specified.
1. Disconnect engine wiring connectors (1), (2) and

(3).
4. Removal of supply pump
1) Remove pump mounting bracket (14). [*6]
2. Removal of tubes and hoses connected to
supply pump
1) Remove fuel return tube (4). [*1]
2) Remove oil tube (5) between the pump and
cylinder block. [*2]
3) Remove fuel tube (6) between the priming
pump and pump. [*3]
4) Remove fuel tube (7) between the pump and
controller cooler. [*3]
5) Remove fuel hose (8) between the main fuel
filter and pump. [*3]
2) Remove oil tube (15).

3) Remove supply pump assembly mounting
bolts (16). [*7]
4) Remove supply pump assembly (17).
4 Supply pump assembly: 20 kg
3. Removal of high-pressure pipes (between

supply pump and common rail)
1) Make positioning marks at the installed posi-
tions of clamps (9) – (10) in paint.
2) Remove bracket (13).
3) Remove clamps (9) and (10). [*4]
4) Disconnect high-pressure pipes (11) and
(12). [*5]
2 HD785-7
Installation a Tighten mounting bolts (16) to the speci-

q Carry out installation in the reverse order to re- fied torque after tightening the sleeve
moval. nuts of the high-pressure pipe (between
the supply pump and common rail).
[*1] 2 Supply pump assembly mounting bolt:
3 Joint bolt of fuel return tube (4): Adhesive (LT-2)
14.9 – 19.6 Nm {1.5 – 2.0 kgm} 2) Install the high-pressure pipe temporarily to
the supply pump and common rail and then
[*2] tighten the sleeve nut to the specified torque.
3 Joint bolt of fuel tube (5): a Tighten the nut to the specified torque
7.9 – 12.7 Nm {0.8 – 1.3 kgm} with a slitted ring wrench or a span-
ner-type torque wrench (commercially
[*3] available).
3 Joint bolts of fuel tubes (6), (7) and (8): 3 High-pressure pipe sleeve nut (Supply
24.5 – 34.3 Nm {2.5 – 3.5 kgm} pump side):
39.2 – 49 Nm {4 – 5 kgm}
[*4] 3 High-pressure pipe sleeve nut (Com-
3 Mounting bolts of high-pressure pipe clamps mon rail side):
(9) and (10): 9.8 ± 1 Nm {1.0 ± 0.1 kgm} 39.2 – 58.8 Nm {4 – 6 kgm}
3) Install the pump mounting bracket.
[*5] a Tighten the mounting bolts on the pump
3 Sleeve nuts of high-pressure pipes (11) and side and bracket side alternately so that
(12) they will be torqued evenly.
Supply pump side: 4) Install the high-pressure pipe clamps
39.2 – 49 Nm {4 – 5 kgm} according to the following procedure.
Common rail side:
1] Tighten all the stays and upper and lower
39.2 – 58.8 Nm {4 – 6 kgm}
clamps of the high-pressure pipe with the
[*6]
3
fingers.
Supply pump bracket mounting bolt:
2] Tighten the upper and lower clamps
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
permanently.
(Pump bottom side)
a Before tightening the stays perma-
59 – 74 Nm {6.0 – 7.5 kgm}
nently, deflect the rubber.
(Bracket side)
a When tightening, avoid applying ex-
[*7] [*4]
cessive force to the mounting part of
Position and install the supply pump and high-pres-
the supply pump as long as possible.
3 Upper and lower clamps:
sure pipes according to the following procedure.
1) Install supply pump assembly (17) tempo-
9.8 ± 1 Nm {1 ± 0.1 kgm}
rarily.
3] Tighten each stay permanently.
a Insert the supply pump shaft in the supply
pump drive case, setting the positioning 5) Install the rubber cover to the high-pressure
sector of the former to positioning sector pipe sleeve nut.
(A) of the latter. a When installing the cover, set the slits in
a If the supply pump cannot be inserted the following directions.
q Supply pump side: Down
easily, rotate the crankshaft to change the
q Common rail side:
position of positioning sector (A).
In (Opposite directions)
k Ensure that the high-pressure pipe is
at least 10 mm apart from the wiring
harness through its length.
HD785-7 3
Removal and installation of fuel

injector assembly
Removal
k Stop the machine on a level ground, set the
parking brake switch in the "PARK" position,
k Raise the body and fix it with the lock pin.
Remove the fuel injector assembly. For details, see

"Removal and installation of cylinder head assem-
bly".
a Do not drain the coolant.
a Note that some parts will be obstacles to remov-
al of the fuel injector assemblies of some cylin-
ders.
a It is not necessary to remove the turbocharger
assembly when removing the fuel injectors of the
No. 1, No. 2, No. 6 and No. 7 cylinders.
Installation
a Carry out installation in the reverse order to re-
moval.
a Install the fuel injector assembly. For details,
see "Removal and installation of cylinder head
assembly".
4 HD785-7
Removal and installation of 4. Air duct assembly

cylinder head assembly 1) Disconnect air cleaner clogging sensor
switch connector (4) and remove mounting
Special tools bolts (5) of air duct assembly (6).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
3 795-102-2103 Spring pusher t 2
A
4 790-331-1110 Wrench q 2
Removal
2) Sling air duct assembly (6) and loosen rubber
elbow mounting clamp (7) on the turbo-
1. Drain the engine coolant.
6 Radiator lower tank: 283 l
charger side of the duct. [*2]
3) Sling and remove air duct assembly (6).
4 Air duct assembly: 45 kg
2. Engine hood
a See "Removal of engine hood assembly".
1) Remove the reservoir tank from the top of the
engine hood.
4 Reservoir tank: 15 kg
2) Remove the engine hood.
4 Engine hood: 110 kg
3. Air cleaner assemblies

1) Remove mounting bolts (2) of each air
cleaner assembly (1).
2) Loosen rubber elbow mounting clamps (3).
[*1]
3) Remove 3 air cleaner assemblies (1).
4 Air cleaner assembly (1 piece): 4) Removal of exhaust brake control bracket (if
15 kg equipped)
1] Loosen mounting nut (10) of exhaust
brake cable (11), remove pin (8) and lock
pin (9) from the lever yoke, and discon-
nect cable (11). [*3]
HD785-7 5
2] Remove mounting bolt (13) of cable

mounting bracket (12).
2) Disconnect cooling tubes (109) and (111)

and lubrication hoses (110) and (112) from
turbocharger assembly (106). [*7]
5. Exhaust connectors between turbocharger 3) Remove heat insulation cover (113).
and muffler
1) Remove coupling band (103) of exhaust
connectors (101) and (102). [*4]
2) Loosen clamp (105) on the rubber hose side
of the exhaust connector. [*5]
3) Remove U-bolt (104) which is fixing the
exhaust connector.
4) Pull out exhaust connectors (101) and (102),
while prying their rubber tube ends.
4) Sling turbocharger assembly (106) and

remove mounting bolts (114) and (115). [*8]
4 Turbocharger: 35 kg
6. Turbocharger assembly
1) Loosen air piping rubber hose coupling band
(107) of turbocharger assembly (106) and
remove U-bolt (108) which is fixing the
piping. [*6]
6 HD785-7
7. Air intake manifold (left bank) 5) Sling air intake manifold (25).
1) Loosen clamp (15) of the tube coming from 1] Remove fuel tubes (26) and (27) installed
the aftercooler and remove elbow tube (16). to the air intake manifold.
2) Disconnect electrical intake air heater switch [*9]
wire (17) and remove electrical intake air
heater wirings (18) and (19).
3) Remove mounting bolts (21) of air intake
connector (20).
4) Remove water hose clamp (22) and
connector mounting bolts (23) and (24).
a Install a guide bolt to the lower air intake
manifold mounting bolt hole to prevent
the electrical intake air heater from falling.
2] Remove clamp (29) of engine wiring (28).

3] Remove wiring cover (31) and mounting
bolts (33) and (34) of inside wiring bracket
(32).
4] Disconnect wiring connector (35) and
remove it from the air intake manifold.
HD785-7 7
5] Remove high-pressure pipe bracket (30). 10. Injector external wiring

6] Sling the air intake manifold and remove 1) Remove mounting bolts (44) of cover plate
manifold mounting bolts (26) and (27). (43).
a Move the air intake manifold to the 2) Remove clamp bolt (46) of wiring (45).
right to remove. [*10] 3) Remove mounting bolts (48) of connector
4 Air intake manifold: 35 kg mounting bracket (47).
8. Remove brackets (38) and (39). 11. Air vent tube

1) Remove mounting bolts (50) of tube (49).
[*11]
2) Remove mounting bolts (52) of tube
assembly (51).
9. Remove the mounting bolts of exhaust mani-

folds (40) and (41).
4 Exhaust manifold assembly: 22 kg
12. Remove the clamps, fuel high-pressure injection

tube (53) and spill tube (54). [*12][*13]
8 HD785-7
13. Remove mounting bolts (56) of head cover (55).
16. Injector wiring harness

14. Rocker arm assembly 1) Remove injector terminal mounting nuts (65)
1) Loosen locknut (57) and then loosen adjust- and clamp mounting bolts (66).
ment screw (58) fully. 2) Push connector (67) into the cylinder head
a Check that the rocker arm is not affected and remove injector wiring harness (68).
by the valve tension and is free.
2) Remove rocker arm assembly (59).
a Use a tag to record the mounting position
of each rocker arm assembly to prevent it
from being mistaken.
17. Fuel injector

1) Remove holder mounting bolts (69).
3) Remove intake rocker arm (60), spacer (61)

and exhaust rocker arm (62) from rocker
shaft (63).
15. Remove push rod (64) and remove crosshead

(64-1).
HD785-7 9
2) Put small L-bar [B] under the fuel connector 3) Remove the cylinder head gasket.
and pry out fuel injector (70) slowly. 4) Disassemble the cylinder head assembly
a Do not hold the solenoid valve at the in- according to the following procedure.
jector top with pliers, etc. to pull out the in- 1] Using tool A3, compress the valve spring
jector. and remove cotter (72).
2] Remove upper seat (73), outer spring
(74) and inner spring (75).
18. Cylinder head assembly

1) Remove the water tube.
2) Lift off cylinder head assembly (71). 3] Remove lower seat (76).
4 Cylinder head assembly: 30 kg 4] Raise the cylinder head and remove
a If the cylinder head assembly is removed valve (77).
without removing the fuel injector, the in-
jector tip projects from the bottom of the
cylinder head. Accordingly, use a block,
etc. to prevent the injector from interfering
with the stand.
10 HD785-7
Installation a Use tool A4 to retighten the mounting bolts.

Cylinder head assembly When not using tool A4, make marks on the
a Install the cylinder head assembly in the reverse bolts and cylinder head, and then retighten
order to removal. each bolt by 90 – 120°.
1. Install the cylinder head gasket.
2. Sling and install cylinder head assembly (76).

4 Cylinder head assembly: 30 kg
a After tightening the bolts, make punch mark

(a) on the main bolt head (Do not make it
when new bolts are used, however).
a If there are 5 punch marks on the head of a

bolt, do not reuse that bolt but replace it.
a Length of mounting bolt
(1), (2), (4): 166 mm
(3), (5), (6): 201 mm
a Tighten the mounting bolts in the numerical
order shown in the figure.
3 Cylinder head assembly mounting bolts
(1) – (6):
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time: 284 – 294 Nm {29 – 30 kgm}
3rd time: Retighten by 90 – 120°.
3 Cylinder head assembly mounting bolt
(7): 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
HD785-7 11
Fuel injector Crosshead

a Check that there is no dirt in the injector sleeve. 1. Install crossheads (69).
2 O-ring: Engine oil (EO30) 2 Sliding parts of crosshead:
Engine oil (EO30)
1. Fit O-rings (77) and (78) to fuel injector (75).
a Take care not to fit O-ring (78) to center
groove (A).
2. Install gasket (79) to fuel injector (75).
3. Insert fuel injector (75) and injector holder (80)

together in the cylinder head.
2. Adjust the crosshead according to the following

procedure.
1) Loosen locknut (102) and then loosen adjust-
ment screw (103) to a position where it will
not touch valve stem (104).
2) Hold the contact face to the rocker arm with
the finger to keep crosshead in contact with
valve stem (105) on the push rod side.
4. Install spherical washer (81) to injector holder 3) Tighten adjustment screw (103) slowly and
mounting bolt (74) and tighten injector holder check the point at which adjustment screw
(80) temporarily. (103) touches valve stem (104).
2 Spherical washer: Engine oil (EO30) 4) Tighten adjustment screw (103) further by 20
a Tighten injector holder (80) permanently after – 30° from the above point.
tightening the high-pressure pipe temporari- 5) While holding adjustment screw (103),
ly. tighten locknut (102).
3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
12 HD785-7
3. Injector wiring harness

1) Push out connector (72) from inside of the
cylinder head and install injector wiring
harness (73) in the cylinder head.
2) Tighten injector terminal mounting nuts (70)
and clamp mounting bolt (71).
a Tighten injector terminal mounting nuts
(70) alternately.
3 Injector terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tightening the injector terminal
mounting nuts, press the wiring harness
against the injector body to take up the
slack.
3 Tightening torque of locknut:
4. Install push rods (68). 52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a Check that each push rod end is fitted in the a After tightening the locknut, check the valve
receiving area of the cam follower. clearance again.
2 Both ends of push rod:
Engine oil (EO30)
6. Install spill tube (63).

3 Joint bolt:
5. Install rocker arm assembly (67). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2 Rocker shaft: Engine oil (EO30)
2 Threaded part and seat of rocker arm as- 7. Install cylinder head cover (64) temporarily.
sembly mounting bolt: (Install it to prevent dirt from entering. It will need
Engine oil (EO30) to be removed again.)
a Check that the ball of adjustment screw (66)
is fitted in the push rod socket.
a When tightening the mounting bolt, check
that adjustment screw (66) does not press
the push rod.
93 – 103 Nm {9.5 – 10.5 kgm}
a Tighten locknut (65) after adjusting the valve
clearance.
a Adjust the valve clearance. For details, see
Testing and adjusting, "Testing and adjusting
valve clearance".
HD785-7 13
8. Fuel injector and high-pressure pipe 3) Tighten sleeve nut (84) on the common rail
(between common rail and fuel injector) side temporarily, too.
k When handling the high-pressure pipe 4) Tighten injector holder (80) permanently.
and clamp, observe the following. 3 Injector holder mounting bolt (74):
q Never bend the high-pressure pipe to col- 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
lect before installing or use it for another 5) Tighten the sleeve nut to the specified
section. torque.
q Install the specified clamp to the specified a Using a slitted ring wrench or a span-
position securely and tighten it to the ner-type torque wrench (commercially
specified torque. available), control the tightening torque.
q Do not apply lubricant to the high-pres- 3 Sleeve nut of high-pressure pipe (46)
sure pipe sleeve nut and the threads of (Injector side):
the mating part. 39.2 – 49 Nm {4 – 5 kgm}
a If lubricant is applied, the axial ten- Sleeve nut of high-pressure pipe (46)
sion is increased too much and the (Common rail side):
high-pressure pipe may be broken 39.2 – 49 Nm {4 – 5 kgm}
when the sleeve nut is tightened. a After tightening each sleeve nut (82),
k Before installing the high-pressure pipe, check that O-rings (77) and (83) are not
check it. If it has any defect, replace it projected from the sleeve nut.
since fuel may leak.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
1) Fit O-ring (83) to sleeve nut (82).

2 O-ring: Engine oil (EO30)
2) Tighten sleeve nut (82) temporarily into fuel
injector (75).
a If sleeve nut (82) does not catch the
threads, press its end with a small rod,
etc. toward the injector and turn the span-
ner.
14 HD785-7
6) Install the cylinder head cover. 10. Install the high-pressure pipe clamps (between
3 Cylinder head cover mounting bolt: the common rail and fuel injector).
14.7 – 34.3 Nm {1.5 – 3.5 kgm} 1) Tighten brackets (41-1) – (41-7) and clamps
7) Install rubber covers (44) and (45) to the (42) with the fingers from under the air intake
sleeve nuts of high-pressure pipes (46). manifold.
a Install the rubber covers so that their slits 2) Tighten brackets (43-1) – (43-3) and the
will be directed as follows. clamps with the fingers from above the air
q Injector side (44): Down intake manifold.
q Common rail side (45): 3) Tighten the upper and lower clamps perma-
Cylinder block side nently.
3 Upper and lower clamps:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
4) Tighten brackets (41-1) – (41-7) and (43-1) –
(43-3) permanently.
5) Tighten clamp (40) and bracket (39) tempo-
rarily, then permanently.
3 Mounting bolt of bracket (39):
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a Install the brackets and clamps of the L
bank similarly.
9. Air intake manifold assembly

1) Install the gasket.
a Direct the side having the mark of "UP" up
and direct it toward the air intake mani-
fold.
2 Threaded part and seat of mounting
bolt: Molybdenum disulfide grease
(LM-P)
a Tighten the mounting bolts in the numeri-
cal order shown in the figure.
3 Air intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
HD785-7 15
11. High-pressure pipes (between common rail

and fuel supply pump)
a For precautions, see the section of the
high-pressure pipe (between the common
rail and fuel injector).
a Using a slitted ring wrench or a spanner-type
torque wrench (commercially available), con-
trol the tightening torque.
1) Tighten high-pressure pipes (38) with the
fingers, then tighten them permanently.
3 High-pressure pipe sleeve nut
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
High-pressure pipe sleeve nut
(Supply pump side): [*4]
39.2 – 49 Nm {4 – 5 kgm} 3 Exhaust connector coupling band:
2) Tighten bracket (35) and clamps (36) and 14.7 – 16.95 Nm {1.5 – 1.73 kgm}
(37) with the fingers.
3) Tighten high-pressure pipe clamps (36) and [*5]
(37) permanently. 3 Clamp on exhaust connector rubber hose
3 High-pressure pipe clamp bolt: side: 6.9 – 8.3 Nm {0.7 – 0.85 kgm}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*6]
3
4) Tighten high-pressure pipe bracket (35)
permanently. Turbocharger air piping coupling band:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
3 Turbocharger piping fixing U-bolt
29.4 – 44.1 Nm {3.0 – 4.5 kgm}
[*7]
3 Turbocharger coolant tube:
24.5 – 34.3 Nm {2.3 – 2.5 kgm}
3 Turbocharger lubrication tube:
Turbocharger mounting bolt:
[*8]
3 Turbocharger mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
2 Threaded part and seat of bolt:
Molybdenum disulfide grease (LM-P)
12. Carry out the following installation in the reverse
order to removal. [*9]
3 Fuel tube of air intake manifold
[*1] [*2] q Head side:
3 Air duct rubber hose (elbow) mounting 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
clamps on air cleaner side and turbocharger q Manifold side (27):
side: 0.88 Nm {90 kgcm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
q Manifold side (26):
[*3] 24.5 – 34.7 Nm {2.5 – 3.5 kgm}
a Install pin (8) and lock pin (9) of the lever.
a Adjust turnbuckle (106) of the cable to set di-
mension (a) to the following.
Right side of moving direction: 31 – 41 mm
Left side of moving direction: 62 –72 mm
3 Exhaust brake cable mounting bolt:
109 – 173 Nm {11.1 – 17.6 kgm}
3 Turnbuckle: 12 – 19 Nm {1.2 – 1.9 kgm}
16 HD785-7
[*10]
q Install the gasket.
a Direct the side having the mark of "UP" up and
direct it toward the air intake manifold.
3 Air intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2 Threaded part and seat of bolt:
Molybdenum disulfide grease (LM-P)
a Tighten the mounting bolts in the numerical or-
der shown in the figure.
[*11]
3 Air vent tube mounting bolt:
9.8 – 11.7 Nm {1.0 – 1.3 kgm}
[*12] [*13]
3 Fuel high-pressure injection tube head and
clamp
q Head: 39.2 – 49 Nm {4.0 – 4.5 kgm}
q Clamp: 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
q Refilling with coolant

Add coolant to the specified level. Run the
engine to circulate the coolant through the
system. Then, check the coolant level again.
HD785-7 17
Removal and installation of engine

hood assembly
Removal
1. Radiator coolant reservoir tank

1) Loosen reservoir tank hose clamps (2) and
(3) and disconnect the hose. [*1]
2) Remove reservoir tank mounting bolt (4) and 4) Install eyebolts to the bolt holes of engine
reservoir tank (1).
4 Reservoir tank (1): 15 kg
hood (5) and lift off the engine hood with a
chain block and belts, etc.
4 Engine hood (5): 110 kg
2. Engine hood
1) Remove reservoir tank hose clamp (6) and Installation
bracket (7) installed to the back side of the q Carry out installation in the reverse order to re-
engine hood. moval.
2) Remove air conditioner hose clamp bracket
(8). [*1]
3) Remove caps (9) of the engine hood Reservoir tank hose
mounting bolt holes and mounting bolts (10) a Adjust the hose insertion length of reservoir tank
in the holes. (1) as shown in the following figure.
18 HD785-7
Removal and installation of radi-

ator assembly
Removal
k If the coolant temperature in the radiator is
high, wait until it decreases to avoid scalding
yourself and then drain the coolant.
k If the coolant temperature is high, wait until it
decreases to avoid scalding yourself with the
hot coolant, and then disconnect the heater 4. Radiator guard top handrail and radiator
hose and drain the coolant. guard
k Collect the refrigerant (air conditioner gas: 1) Sling handrail (13) with belts, remove
R134a) from the air conditioner circuit. mounting bolts (15).
k If the refrigerant (air conditioner gas: R134a) 4 Handrail: 20 kg
gets in your eyes, you may lose your sight. 2) Install eyebolts to the mounting holes of the
Accordingly, you must put on safety glasses handrail and sling radiator guard (14).
while you are collecting the refrigerant or 3) Remove caps (17) and bolts (16) on the radi-
charging the air conditioner with the refriger- ator guard top.
ant. 4) Remove radiator guard lower mounting bolts
q Precautions for handling refrigerant (18) and remove radiator guard (14).
a Ask a "refrigerant collection" contractor 4 Radiator guard (14): 120 kg
who is registered in the local government. a Tighten mounting bolt (18) temporarily so
(Only the registered contractors can col- that shim (19) of the lower mounting seat
lect the refrigerant.) will not be lost.
a Discharging the refrigerant (air condition-
er gas: R134a) into the atmosphere is vio-
lation of the law.
1. Drain the coolant

6 Coolant: 283 l
2. Engine hood
a See "Removal and installation of engine
hood assembly".
3. Radiator grille
1) Lift off ladder (11).
4 Ladder: 110 kg
2) Sling grille (12) and remove the mounting
bolts.
4 Grille: 45 kg
HD785-7 19
5. Stay connecting right and left fenders

1) Remove hose clamp bracket bolts (21),
clamp (22) and hose clip (23) between the
reservoir tank and radiator upper tank
mounted on the frame.
2) Sling stay (20) with belts and remove right
and left mounting bolts (24) and (25) to
remove the stay.
a Use an extension to remove mounting
bolt (26).
4 Stay: 100 kg
6. Disconnection of air conditioner hoses and

hot water circuit hoses
1) Remove the mounting bolts of hose clamps
a Cover the ends of the removed air condi-
(27), (28), (29) and (30) between the air
tioner hoses and hot water circuit hoses
conditioner unit and compressor, and then
with caps or vinyl tapes to prevent dirt
disconnect the hose on the suction side of
from entering them.
compressor (31).
2) Disconnect delivery hose (33) of compressor
(31).
3) Remove hose clamp bolts (34), (35), (36) and
(37) between condenser (39), receiver tank
(41) and air conditioner unit. [*1]
4) Remove mounting bracket bolts (40) of
receiver (41).
5) Remove hose clamp mounting bolts (42),
(43), (44) and (45) of the hot water circuit and
then remove hose clamps (46), (47) and (48).
20 HD785-7
7. Air conditioner condenser and steering oil 8. Remove wiring clamp (60), mounting bolts (59)
cooler and horn and bracket assembly (58).
1) Remove mounting bolts (49) and air condi-
tioner condenser (39).
2) Remove mounting bolts (51) and steering oil
cooler (50).
3) Remove oil cooler hose clamp mounting
bolts (52) – (57).
a Fix condenser (39) and oil cooler (50) and
their hoses to the middle of the cab ladder
with strings so that they will not be obsta-
cles to slinging of the radiator assembly.
9. Disconnect connector (62) of radiator coolant

level sensor (61) and remove wiring clamp
mounting bolts (63), (64) and (65).
HD785-7 21
10. Removal of radiator coolant piping 12. Removal of engine aftercooler air piping
1) Remove lower tank hose clamp (66), coolant 1) Remove engine-side clamps (91) and (93)
pump hose clamp (67) and bracket mounting and then remove cooler-side clamps (90)
bolts (68) to remove hose assembly (80) and (92) to remove aftercooler pipings (88)
between the radiator left lower tank and and (89). [*3]
engine coolant pump. a After removing the aftercooler air pipings,
2) Remove hose clamps (69), (70), (71) and cover the openings on the engine side
(72) between the coolant pump and radiator and cooler side with vinyl sheets and fix
right and left upper tanks. them with adhesive tapes.
3) Remove upper tank hose clamp (73) and
hose clamp mounting bolts (74), (75) and
(76) to remove bypass hose assembly (79)
between the radiator upper tank and lower
tank.
4) Remove radiator right lower tank hose clamp
(77) and engine-side piping mounting bolts
(78) to disconnect the hose assembly. [*2]
11. Engine fan shroud

1) Remove left belt guard (85) and then remove
right belt guards (86) and (87).
2) Remove upper left shroud (82) and upper
right shroud (83).
3) Remove lower left shroud (81) and lower
right shroud (84).
22 HD785-7
13. Removal of brake oil cooler piping of radiator 15. Radiator assembly
lower tank 1) Replace radiator upper tank right and left
Remove return filter piping joints (97) and (98) mounting bolts (B) and (A) with eyebolts and
and then remove brake oil cooler inlet piping sling the radiator assembly.
(99).
a Since there is oil left in the lower tank oil cool-
er, place a pan under the piping to be discon-
nected.
a After all the oil is drained from the piping, re-
move piping bracket mounting bolts (95) and
(96).
2) Remove radiator assembly right and left

upper mounting bolts (102). [*4]
14. Remove mounting bolts (101) of windshield

plate (100) under the radiator.
3) Remove radiator assembly right and left

lower mounting bolts (103). [*5]
HD785-7 23
4) Lift off radiator assembly (104). [*6] Installation

4 Radiator assembly: 950 kg q Carry out installation in the reverse order to re-
moval.
[*1]
Air conditioner hose
a When connecting each refrigerant hose, apply
compressor oil to the threads and tighten with 2
spanners.
a Install each hose so that it will not be twisted,

bent forcibly or slackened excessively.
a After connecting the hoses, charge the system
with refrigerant (air conditioner gas: R134a) and
check that the refrigerant is not leaking.
[*2]
Coolant piping
a Do not apply adhesive to the hose insertion
parts. (If the hoses cannot be inserted, apply
neutral detergent.)
a When using 2 clamps, install them in opposite di-
rections.
3 Clamp tightening torque:
13.7 ± 0.5 Nm {140 ± 5 kgcm}
a Start the engine and check the tightness of each

clamp. If necessary, retighten.
24 HD785-7
[*3] [*4], [*5]

Engine aftercooler piping Radiator assembly mounting bracket
a The hose insertion length must be as shown in a Tighten the radiator assembly mounting bracket
the following figure. to the dimensions shown in the following figure.
3 Lower mounting bracket mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
[*6]
If the raditor core was disassembled, assemble
it according to the following procedure.
1. Install eight sets of cushions (106) and collars
(107) on brackets (105) in advance.
3 Clamp tightening torque:

10.5 ± 0.5 Nm {107 ± 5 kgcm}
a When the tightening torque is 9.8 Nm (1.0 kgm),
the projection of the screw must be as shown in
the following figure.
2. Fix tank (109) to make the top surface horizontal,

using working platform, etc.
3. Stick bottom cushions (108) to the four places on

the top of the tank.
2 Sticking face of bottom cushion: LT-1A
a When sticking the bottom cushions, pay at-

tention to their directions.
There is a level difference 155 mm in diam-
eter on the face (a) to be stuck to the tank.
HD785-7 25
6. Install right support (113) and left support (114)

to the tank.
a Install the supports vertically to the tank top.
4. Install packing (111) to core (110).

a Install the packing so that there is no clear-
ance between the four cores when they are
installed to the tank.
5. Install O-ring (112) to core and insert the core

into the tank.
a When installing O-ring or inserting the core in
the tank, apply soap water (undiluted) to the
O-ring and insertior.
(Do not use engine oil, etc.)
a Check the O-ring and insertion portion for
dirt, etc. and ensure that the O-ring is not
twisted or projected.
a Insert the core sufficiently and check that
there is no clearance between bottom cush-
ion and core.
7. Install bracket (115) to the support.
8. Place the bracket assembly (116) prepared in

step 1 on the core and tighten bolts (117a) and
(117b) temporari.
9. Tighten core mounting bolts (117a) perma-

nently.
3 Core mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
26 HD785-7
a When the core mounting bolts are tightened

permanently, the cushion shrinks and core
(110) is raised.
Push the bolt head to press the core again (c)
and ensure that there in no clearance
between the core anc bottom cushion (118).
10. Tighten mounting bolts (117b) permanently to fix

bracket (116).
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
11. Repeat the procedure from 8 to 10 for each core

to install all of the four cores.
HD785-7 27
Removal and installation of 7. Engine auxiliary equipment wiring

engine assembly 1) Disconnect alternator power supply wiring
(1).
Removal
2) Disconnect air conditioner compressor wiring
connector (2).
parking brake switch in the "Park" position,
k If the coolant temperature is high, wait until it

decreases to avoid scalding yourself with the
hot coolant, and then disconnect the heater
hose and drain the coolant.
k Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
k If the refrigerant (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
Accordingly, you must put on safety glasses
while you are collecting the refrigerant or 3) Remove wiring (3) between the electrical
charging the air conditioner with the refriger- intake air heater and battery.
ant.
a Precautions for handling refrigerant
q Ask a "refrigerant collection" contractor
who is registered in the local government.
(Only the registered contractors can col-
lect the refrigerant.)
q Discharging the refrigerant (air condition-
er gas: R134a) into the atmosphere is vio-
lation of the law.
1. Close the fuel supply valve.
2. Drain the coolant.

6 Coolant: 283 l
4) Disconnect 2 starting motor wiring connec-

3. Drain the hydraulic oil. tors (4).
6 Hydraulic oil: 270 l 5) Disconnect engine oil level sensor connector
(5).
4. Engine hood assembly
Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
5. Radiator assembly
Remove the radiator assembly. For details, see
"Removal and installation of radiator assembly.

Remove the front drive shaft assembly. For
details, see "Removal of front drive shaft
assembly".
28 HD785-7
6) Remove engine ground wiring (6). 9. Exhaust brake control bracket

7) Remove engine controller cover (7). 1) Loosen mounting nut (21) of exhaust brake
8) Disconnect the connectors of wirings (8) and cable (20) and remove the yoke pin and
(9) on the controller side and remove wiring cotter pin of the lever. [*3]
clamp (10) on the machine side. 2) Disconnect cable (20).
9) Disconnect tubes (11) and (13) connected 3) Remove mounting bolt (23) and cable
into the engine controller and remove clamps bracket (22).
(12) and (14) to remove those tubes.
10. Exhaust connector between turbocharger

8. Intake air duct and muffler
1) Disconnect air cleaner clogging sensor 1) Remove connecting band (26) of exhaust
switch connector (16). connectors (24) and (25). [*4]
2) Loosen air cleaner rubber elbow clamp (15). 2) Loosen clamp (27) on the rubber tube side of
[*1] the exhaust connector. [*5]
3) Sling air duct (18) and remove mounting 3) Remove U-bolt (28) which is fixing the
bolts (17). exhaust connector.
4) Remove rubber elbow clamp (19) on the
turbocharger side of air duct (18). [*2]
a While prying the air duct, pull out the rub-
ber elbow.
4 Air duct: 45 kg
4) Pry out the rubber tube side of the connector.
HD785-7 29
11. Left bank fuel hose 12. Right bank fuel hose
1) Disconnect hose (29) between the priming 1) Disconnect hose (35) between the priming
pump and feed pump. pump and feed pump.
2) Disconnect overflow hose (30) connected to 2) Disconnect overflow hose (36) connected to
the supply pump. Disconnect return hose the supply pump. Disconnect return hose
(31) connected to the injector. (37) connected to the injector.
3) Disconnect hose (32) between the feed 3) Disconnect hose (38) between the feed
pump and fuel filter. pump and fuel filter.
4) Disconnect hose (33) between the fuel filter 4) Disconnect hose (39) between the fuel filter
and supply pump. and supply pump.
5) Disconnect hose (34) between the fuel tank 5) Remove hose (40) between the fuel tank and
and water separator. water separator.
30 HD785-7
13. Engine assembly Installation

1) Remove engine mounting bolt (front) (41) a Carry out installation in the reverse order to re-
and mount rubber (42). moval.
2) Remove engine mounting bolt (rear) (43) and a Install the drive shaft. For details, see "Removal
mount rubber (44). [*6] and installation of front drive shaft".
a Install the radiator assembly. For details, see
"Removal and installation of radiator assembly".
a Install the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
[*1] [*2]
3 Air cleaner rubber elbow clamp and elbow
clamp on turbocharger side of air duct:
8.8 Nm {90 kgcm}
[*3]
a Adjust turnbuckle (46) of the cable to set dimen-
sion (a) to the following.
3) Remove the engine rear hanger and install Right side of moving direction: 31 – 41 mm
tool A5. Left side of moving direction: 62 –72 mm
4) Sling engine assembly (45) with tool A6 and 3 Exhaust brake cable mounting bolt:
remove it forward. 109 – 173 Nm {11.1 – 17.6 kgm}
4 Engine assembly: 3,400 kg 3 Turnbuckle:12 – 19 Nm {1.2 – 1.9 kgm}
[*4]
3 Exhaust connector connecting band:
14.7 – 16.95 Nm {1.5 – 1.73 kgm}
a When installing the engine assembly, set cush-
ions (42) and (44).
a Align the engine assembly and torque converter
and transmission assembly. For details, see
"Removal and installation of front drive shaft".
[*5]
3 Clamp on exhaust connector rubber hose
side: 6.9 – 8.3 Nm {0.7 – 0.85 kgm}
[*6]
3 Engine mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
HD785-7 31

Add coolant to the specified level. Run the
engine to circulate the coolant through the
system. Then, check the coolant level again.
q Refilling with oil

Add oil to the specified level. Run the engine to
circulate the oil. Then, check the oil level.
q Charging with refrigerant

(air conditioner gas: R134a)
Charge the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
32 HD785-7
Removal and installation of engine 4. Move the tension pulley to loosen and remove
front oil seal the fan belt. For details, see Testing and
adjusting, "Replacement and adjustment fan
Special tools belt".
New/Remodel
5. Lift off drive pulley (6) and damper together. [*2]
Necessity
4 Pulley and damper assembly: 75 kg
Sym-
Part No. Part name
Sketch
bol
Q'ty
Seal puller assem-
7 795-931-1100 t 1
bly
795T-621-1430 Plate t 1 N Q
A 795T-621-1441 Push tool t 1 N Q
8 01050-32240 Bolt t 3
01050-32225 Bolt t 3
01640-02232 Washer t 3
Removal
k Disconnect the cable from the negative (–) 6. Remove front oil seal (7) according to the
terminal of the battery. following procedure.
a Take care not to damage the seal fitting part
1. Remove the engine hood assembly. For details, of the flywheel housing and the seal contact
see "Removal and installation of engine hood surface of the crankshaft.
assembly". a Before pulling out the seal, drive in it a little to
separate.
2. Remove alternator belt cover (1) and fan belt
covers (2) and (3).
3. Remove fan nets (4) and (5) and lower right and
left nets. [*1]
a The clamps of each wiring harness and hose
are fixed with the fan net mounting bolts. Re-
cord the positions and lengths of those bolts.
HD785-7 33
1) Change the tip of tool A7 to the hook type. Installation

2) Hitch the hook to the metal ring of front seal 1. Clean, degrease, and dry the contact faces of
(7). the front cover and oil seal.
3) Remove the rear seal with impacts of slide
hammer (SH). 2. Remove the matter sticking to the crankshaft
q Tool A7 flange with clean cloths.
a Clean, degrease, and dry the seal lip surface
(peripheral surface of the crankshaft).
a Ensure that the end corner and lip sliding sur-
face of the crankshaft are free from flaw of
the housing, burr, sharp fin, rust, etc.
3. Install front oil seal (7) according to the following

procedure.
a Before installing the seal, ensure that the end
corner and lip sliding surface of the crank-
shaft are free from flaw of the housing, burr,
sharp fin, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft and seal lip. Wipe off
oil from the shaft thoroughly.
a CS: Crankshaft
4. Apply gasket sealant evenly and thinly to the
inside surface of the front oil seal.
2 Inside surface front oil seal:
Gasket sealant (LG-7 or equivalent)
a Direct the stamp of "PN" (Part No.) out of the
engine.
34 HD785-7
1) Using tool A8 (plate), tighten the bolt to press [*2]

fit oil seal (1) to the end of the shaft. Installation of damper and crankshaft pulley
assembly
1) Install the damper and crankshaft pulley
assembly, setting it to the dowel pin of the
crankshaft.
2) Tighten the mounting bolts in the numerical
order shown below in 3 times.
2 Damper and crankshaft pulley assembly
mounting bolt and washer:
Engine oil (EO30)
3 Damper and crankshaft pulley assembly
mounting bolt:
1st time: 73.5 ± 19.6 Nm {7.5 ± 2 kgm}}
2nd time: 245 ± 19.6 Nm {25 ± 2 kgm}
3rd time: 744.8 ± 19.6 Nm {76 ± 2kgm}
2) Using tool A8 (push tool), tighten the bolt to
press fit oil seal (1) to the front case up to
dimension (a) shown in the figure.
a Press fitting dimension of oil seal
a: 17 mm (from shaft end)
b: 25.1 mm (from front cover end)
a If the damper and crankshaft were disassem-

bled, assemble them and tighten the mount-
ing bolts in the following numerical order.
2 Damper mounting bolt and washer:
Engine oil (EO30)
a Carry out the following installation in the 3 Damper mounting bolt:
reverse order to removal. 98 – 122 Nm {10 – 12.5 kgm}
[*1]
a Install the right lower fan net earlier than the
other fan nets since it is larger in size.
a Install the clamp of the wiring harnesses and
hoses to the positions before removal.
a First, lightly tighten all the mounting bolts of
the fan nets and fan belt cover, and then
tighten them permanently.
a Adjust tension of fan belt. For details, see

Testing and adjusting, "Replacement and ad-
justment of fan belt".
HD785-7 35
SEN01952-02 50 Disassem bly and assem bly
Removal and installation of engine 3. Using forcing screws (M12 x P1.75), pull out
rear oil seal damper assembly (2) to this side and lift it off
with shackles, wires, etc.
Special tools 4 Damper assembly: 100 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Seal puller assem-
7 795-931-1110 t 1
bly
A 795T-621-1531 Push tool t 1 N Q
9 01050-32060 Bolt t 5
01640-02032 Washer t 5
Removal
4. Lift off flywheel (3). [*2]
4 Flywheel assembly: 130 kg
a Before disconnecting the pipings and wiring har-
nesses, put tags to them and write the mounting
positions.
a Plug the disconnected hoses to prevent the oil
from leaking.
1. Remove the damper cover. For details, see

"Removal and installation of output shaft
assembly".
2. Remove a mounting bolt (1) and install guide bolt

[2] to damper assembly (2).
a Make a positioning mark (A) in paint etc.
[*1] 5. Remove rear oil seal (4) according to the
a Take care not to damage the seal fitting part
of the flywheel housing and the seal contact
surface of the crankshaft.
a Before pulling out the seal, drive in it a little to
separate.
36 HD785-7
1) Change the tip of tool A7 to the hook type. Installation

2) Hitch the hook to the metal ring of front seal 1. Clean, degrease, and dry the contact faces to
(4). the flywheel housing.
3) Remove the rear seal with impacts of slide
hammer (SH). 2. Remove the matter sticking to the crankshaft
q Tool A7 flange with clean cloths.
a Clean, degrease, and dry the seal lip surface
(peripheral surface of the crankshaft).
a Ensure that the end corner and lip sliding sur-
face of the crankshaft are free from flaw of
the housing, burr, sharp fin, rust, etc.
3. Install rear oil seal (4) according to the following

procedure.
a Before installing the seal, ensure that the end
corner and lip sliding surface of the crank-
shaft are free from flaw of the housing, burr,
sharp fin, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft and seal lip. Wipe off
oil from the shaft thoroughly.
a CS: Crankshaft
1) Apply gasket sealant evenly and thinly to the
inside surface of the rear oil seal.
2 Inside surface rear oil seal:
Gasket sealant (LG-7 or equivalent)
2) Direct the stamp of "IN" inside of the engine
and the stamp of "OUT" out of the engine.
3) Using tool A9, press fit rear oil seal (4) to
flywheel housing (FHW) up to dimension (a)
shown in the figure.
a Press fitting dimension of oil seal
a: 5 mm
(from flywheel housing end)
HD785-7 37
a Carry out the following installation in the reverse a After installing the flywheel, check its facial
order to removal. runout and radial runout with dial gauge [2].
q Standard facial runout: Max. 0.25mm
[*1] q Standard radial runout: Max. 0.25mm
a Install to the positions marked before removal.
(If not installed to the original positions, vibra-
tions and noises may occur.)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
[*2]
a Install the flywheel assembly, setting it to the
dowel pin of the crankshaft.
a When tightening the mounting bolt, fix the fly-
wheel and flywheel housing with plate [1] so that
the crankshaft will not rotate.
a Tighten the mounting bolts in the numerical or-

der shown below.
2 Flywheel assembly mounting bolt:
Engine oil (EO30)
3 Flywheel assembly mounting bolt:

1st time: 98 ± 19.6 Nm {10 ± 2 kgm}
2nd time: 294 ± 19.6 Nm {30 ± 2 kgm}
3rd time: 539 ± 19.6 NM {55 ± 2 kgm}
38 HD785-7
HD785-7 39
HD785-7 Dump truck
©2009 KOMATSU
All Rights Reserved
40
SEN01953-02
HD785-7

HD785-7 7001 and up

Power train, Part 1
Removal and installation of front drive shaft ................................................................................................... 2
Removal and installation of rear drive shaft .................................................................................................... 4
Removal and installation of output shaft assembly ......................................................................................... 5
Disassembly and assembly of damper assembly ......................................................................................... 10
Removal and installation of torque converter and transmission assembly ................................................... 12
Disconnection and connection of torque converter assembly and transmission assembly .......................... 15
Disassembly and assembly of torque converter PTO assembly................................................................... 22
Disassembly and assembly of transmission assembly ................................................................................. 35
HD785-7 1
Removal and installation of front a Drive shaft guards (1) and (2) are
assembled with pin (3a) as shown in
drive shaft 1 the figure.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
C1 792-620-1400 Centering tool t 1 N
Removal
parking brake switch in the "PARK" posi-
tion, and lock the tires with chocks.
k Raise the body and fix it with the lock pin. 2. Removal of front drive shaft
k Disconnect the cable from the negative (–) 1) Make positioning marks on the mounting
terminal of the battery. positions of the spider cap and coupling.
(If they are not installed to the original
1. Remove the drive shaft guard according to the positions, vibrations and noises may
following procedure. occur.)
1) Loosen drive shaft guard mounting bolts 2) Sling front drive shaft (4), remove mount-
(3). ing bolts (5), and shorten the yoke to dis-
2) While taking care that drive shaft guards connect the front drive shaft while prying
(1) and (2) will not fall, remove mounting key way (6) of the spider cap with a flat-
bolts (3). head screwdriver etc. [*1], [*2]
3) Lower drive shaft guards (1) and (2) a If the spider cap holding wire has
around the drive shaft. been cut, fix the spider cab with a belt
or a vinyl tape firmly. (Do not use a
cloth tape sine it may be broken.)
2 HD785-7
3) Lift off drive shaft assembly (4) while bal- Installation

ancing it. q Carry out installation in the reverse order to
4 Drive shaft assembly: 45 kg removal.
[*1]
a Ensure that the spider cap key is fitted to the
key way of the coupling, then tighten the bolts.
[*2]
2 Mounting bolt: Adhesive (LT-2)
k Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
a Align the engine assembly and torque con-
verter and transmission assembly according to
the following procedure.
1. Install the flange and collar of tool C1 between

engine-side coupling (20) and torque con-
verter-side coupling (21).
2. Adjust the position of the torque converter and

transmission assembly so that the collar will
move smoothly between both flanges while
torque converter-side coupling (21) rotates 1
turn.
Reference: The allowable error between both
flanges is 3 mm in vertical and lat-
eral directions.
HD785-7 3
Removal and installation of rear 6. Loosen mounting bolts (8) of front spider cap
(7) and disconnect the rear drive shaft while
drive shaft 1 prying key way (9) of the coupling with a flat-
head screwdriver etc.
Removal
a If the spider cap holding wire has been
cut, fix the spider cab with a belt or a vinyl
tape firmly. (Do not use a cloth tape sine it
k
may be broken.)
Raise the body and fix it with the lock pin.
7. Lift off the rear drive shaft assembly while bal-
ancing it.
4 Rear drive shaft assembly: 220 kg
1. Loosen mounting bolt (2) of guard (1) and sling
the guard with wires etc.
2. Sling drive shaft guard (1) and lower it around

the drive shaft.
4 Guard: 35 kg
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3. Sling drive shaft (3).
a Precautions for installing rear drive shaft
1. Ensure that the spider cap key is fitted to the
4. Remove rear mounting bolts (4) of drive shaft
key way of the coupling, then tighten the bolts.
(3). [*1]
3 Mounting bolt:
5. Shorten yoke (6) of drive shaft (3) to discon-
343 – 427 Nm {35 – 43.5 kgm}
nect the drive shaft while prying key way (5) of
a Ensure that the lateral radial runout
the spider cap with a flat-head screwdriver etc.
between the rear axle and transfer is less
than 3 mm. If the runout is 3 mm or lager,
adjust the positions of the transfer cushion
and transfer mount to align.
4 HD785-7
Removal and installation of 2) Remove mounting bolt (6) and cable

mounting bracket (5).
output shaft assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 792T-601-1030 Plate t 1 N Q
2 792T-601-1040 Pipe t 1 N Q
B
3 792T-601-1010 Push tool t 1 N Q
4 792T-601-1020 Plate t 1 N Q
Removal 3. Removal of exhaust connector between tur-

k Stop the machine on a level ground, set the bocharger and muffler
parking brake switch in the "PARK" posi- 1) Remove connecting band (9) of exhaust
tion, and lock the tires with chocks. connectors (7) and (8). [*2]
k Raise the body and fix it with the lock pin. 2) Loosen clamp (10) on the rubber hose
k Disconnect the cable from the negative (–) side of the exhaust connector. [*3]
terminal of the battery. 3) Remove U-bolt (11) which is fixing the
exhaust connector.
1. Lift of the engine hood. 4) Pull out exhaust connectors (7) and (8)
For details, see "Removal and installation of while prying the rubber tube side.
engine hood assembly".
2. Removal of exhaust brake control bracket

1) Loosen mounting nut (2) of exhaust brake
cable (1) and remove pin (3) and lock pin
(4) of the lever yoke to disconnect cable
(1). [*1]
4. Removal of cover and piping

1) Sling cover (12) and loosen the bolts to
remove the cover.
4 Cover: 35 kg
HD785-7 5
2) Lift off cover (13). 5. Remove front drive shaft assembly (18).
3) Loosen bolt (15) of exhaust pipe mounting a See "Removal and installation of front
bracket (14). drive shaft assembly".
4 Front drive shaft assembly: 45 kg
6. Remove engine controller cover (19).

a Since the mounting bolts are also used to
install the controller, take care that the
controller will not fall.
a Move the engine controller aside without
disconnecting the wiring.
4) Sling exhaust pipe (16) with a belt etc. to

lift off.
4 Exhaust pipe: 35 kg
7. Disconnect 3 pipings (20).
5) Remove undercover (17).
8. Remove cover assembly (21) according to the

1) Loosen mounting bolts (22). [*4]
6 HD785-7
2) Install an eyebolt to cover assembly (21) 7) Place cover (21) in the reverse direction.
and sling it. Using tools B1 and B2, remove bearing
3) Remove the mounting bolts and lift off (27), spacer (28) and bearing (27).
cover (21).
4 Cover assembly: 80 kg
8) Remove bolts (29) and louver (30).
4) Remove oil seal (22) and snap ring (23)

on the reverse side of cover assembly
(21).
5) Pull out output shaft (24) with a press.
6) Remove oil seal (25).
HD785-7 7
Installation 2. Install snap ring (26).
3. Fill the bearings with grease.

2 Bearing (22):
NES grease (G2-U-S), 160 cc
2 Bearing (25):
NES grease (G2-U-S), 80 cc
4. Using tool B4, install oil seal (22).
1. Cover assembly
Using tools B1 and B3, press fit bearing (27),
spacer (28) and bearing (27).
a Do not reuse bearing (27) and oil seals
(22) and (25) but replace them with new
ones.
a Do not reuse cover (21) but replace it with
new one (Part No.: 561-01-71153).
5. Place cover (21) in the reverse direction.
Using tool B3, install oil seal (25).
6. Apply grease to oil seals (22) and (25) and

shaft (24).
2 Oil seals and shaft:
ENS grease (G2-U-S)
7. Using tool B2, insert shaft (24) in cover (21)

and install snap ring (23).
2 Shaft and spline: ENS grease (G2-U-S)
8 HD785-7
8. Remove all rust and dirt from the mating faces

of cover assembly (21) and flywheel housing.
[*1]
9. Place cover (21) in the reverse direction. a Adjust turnbuckle (29) of the cable to set
Using tool B3, install oil seal (25). dimension (a) to the following.
Right side of moving direction: 31 – 41 mm
10. Install louver (30). Left side of moving direction: 62 – 72 mm
3 Exhaust brake cable mounting nut:
109 – 173 Nm {11.1 – 17.6 kgm}
3 Turnbuckle: 12 – 19 Nm {1.2 – 1.9 kgm}
11. Install cover assembly (21) to the flywheel

housing.
4 Cover assembly: 80 kg
2 Mating faces of cover assembly and fly-
q Carry out the following installation in the revers
order to removal.
wheel: Gasket sealant (LG-6)
3 Mounting bolt:
[*2]
3
99 – 123 Nm {10.0 – 12.5 kgm}
Exhaust connector connecting band:
a After installing the cover assembly,
14.7 – 16.95 Nm {1.5 – 1.73 kgm}
remove its grease filler bolt and fill grease.
a Remove 2 plugs (38) and insert a thin rod
[*3]
3
in the plug holes to check that the holes
Clamp on exhaust connector rubber hose
are filled with grease.
2 Cover assembly:
side: 6.9 – 8.3 Nm {0.7 – 0.85 kgm}
ENS grease (G2-U-S) of approx. 1.2 kg
3 Bolt: 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
[*4]
3 Cover mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
HD785-7 9
Disassembly and assembly of damper assembly 1

Disassembly
1. Before disassembling, make positioning marks 3. Remove inner body (36) and rubber parts (34)
on flange (32), inner body (36) and outer body and (35) from outer body (37).
(37) in paint etc. a Since rubber parts (34) and (35) are differ-
(If they are not installed to the original posi- ent in size, record their installed positions.
tions, vibrations and noises may occur.)
4. Remove snap ring (30) and cap (29) from inner
2. Remove mounting bolts (31) from flange (32). body (36).
a Don't disconnect spacer (33).
10 HD785-7
Assembly
1. Install flange (32) to the flywheel side of outer

body (37).
2 Mating face of flange:
Gasket sealant (LG-6)
3 Mounting bolt:
156 – 196 Nm (15.9 – 19.9 kgm)
2. Install inner body (36) and rubber parts (34)

and (35) to outer body (37).
a Install the outer body, inner body and
flange to the marks made before disas-
sembly.
a When installing, check the installed posi-
3. Install the other flange (32).
2 Mating face of flange:
tions of rubber parts (34) and (35).
a Before installing, apply grease.
2 Outer body, body assembly and
3 Mounting bolt:
rubber parts:
ENS grease (G2-U-S)
156 – 196 Nm {15.9 – 19.9 kgm}
a Install the outer body, inner body and
flange to the marks made before disas-
sembly.
4. Install cap (29) and snap ring (30).

2 Cap: ENS grease (G2-U-S)
HD785-7 11
Removal and installation of 5. Disconnect the brake cooling pump high-pres-

torque converter and sure hose (6).
transmission assembly 1 6. Remove the high-pressure hose mounting

bracket (7) of the torque converter and trans-
Special tools mission brake control pump. Remove high-
pressure hoses (8) and (9) from the pump.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
C1 792-620-1400 Centering tool t 1 N
Removal
k Stop the machine in a level place. Set the
parking brake switch to "PARK" and put
k Raise the body and apply lock pin to fix.
k Disconnect the cable from the negative (-)
a Drain the transmission oil and hydraulic oil. 7. Disconnect brake cooling pump suction piping
6 Transmission case: 368 l
(10) and (11).
6 Quantity of oil in hydraulic tank: 270 l
1. Remove transmission underguard.

4 Underguard: 120 kg
2. Remove front drive shaft by referring to the

"Removal of front drive shaft."
3. Remove wiring clamp (1) and disconnect wir-

ing connectors (2) (TM2 and TM3).
4. Remove breather hose clamp (3) and discon-

nect hoses (4) and (5).
8. Sling the brake cooling pump. Remove the
mounting bolt and remove pump (12).
4 Brake cooling pump: 45 kg
12 HD785-7
9. Removal of torque converter and transmis- 11. Disconnect tubes (21) and (22) connecting to
sion brake control pump piping and hoses the transmission oil pan. Disconnect tube (23)
1) Remove tubes (14) and (15) on the pump connecting to the transmission case.
suction side.
2) Remove the brake control suction tube
(16) and remove the hose (17) on the
high-pressure side.
3) Remove the torque converter and trans-
mission brake control pump (18).
12. Remove tubes (24), (25) and (25-1) connecting

to the front of transmission oil pan.
10. Disconnect split flanges at the joint section to

the piping of torque converter valve hoses (19)
and (20).
HD785-7 13
13. Disconnection of rear drive shaft 16. Sling and remove the torque converter and
1) Temporarily sling rear drive shaft (26) and transmission assembly (31).
remove the mounting bolts (27). [*1] a When removing the engine assembly,
2) Pry the cross joint key (28) with a bar to check that no wires and pipes are con-
contract and disconnect the drive shaft. nected to the chassis and remove the
assembly carefully avoiding interference
with the chassis.
a Check the number and thickness of shims
installed to the rear mount.
q Standard shim thickness: 2 mm
q Shim thickness and type: 0.5 mm (one
type only)
4 Torque converter and transmission assem-
bly: 2,500 kg
14. Remove the rear mount bracket mounting bolts

(29). [*2]
a Temporarily retain the shim with a mount
bolt to prevent missing.
15. Temporarily sling the torque converter and

transmission assemby and remove the front
mount bracket bolts (30). [*3]
Installation
q Carry out installation in reverse order of
removal.
[*1]
a Degrease and dry bolts. Apply LT-2 and tighten
the coupling.
a Before tightening the mounting bolts, check
that the key way of the spider cap is fitted
securely to the key way of the mating yoke.
2 Mounting bolt: Liquid adhesive (LT -2)
3 Mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
[*2] [*3]
a Degrease and dry bolts. Apply LT-2.
2 Mounting bolt: Liquid adhesive (LT -2)
3 Mounting bolt:
147 – 309 Nm {15 – 31.5 kgm}
14 HD785-7
Disconnection and connection of

torque converter assembly and
transmission assembly 1
Disconnection
a Remove the oil pump assembly.
a Put a tag to each wiring connector and record
the connector No. and connection point on it.
1. Sling the torque converter and transmission

assembly horizontally.
2. Loosen drain valve (2) of oil pan (1) to drain

the oil. 9. Disconnect ECMV wiring connectors (18) -
(32).
3. Remove covers (3) and (4). * Connector Nos. (from left)
(18) 1. PS (26) 4. PS
(19) 1. SW (27) 4. SW
(20) 2. PS (28) L/U. PS
(21) 2. SW (29) L. PS
(22) 3. PS (30) L. SW
(23) 3. SW (31) H. PS
(24) R. PS (32) H. SW
(25) R. SW
4. Disconnect wiring connectors (5) – (8).

(5) T/C. P
(6) N2
(7) N1
(8) T/C. T
5. Remove clamps (9) – (13A).
6. Remove intermediate shaft speed sensor (14)

and input shaft speed sensor (15).
7. Remove torque converter oil pressure sensor

(16).
8. Remove torque converter oil temperature sen-

sor (17).
HD785-7 15
10. Disconnect wiring connectors (33) - (36) of the 17. Remove cover (45).
torque converter relief valve.
(33) M/P. PS
(34) M/P. SW
(35) VOL. PS
(36) VOL. SW
11. Disconnect clamps (37) and (38).
18. Disconnect wiring connectors (46), (47) and

(48).
(46) T/M. T
(47) LUB. PS
(48) LUB. SW
19. Disconnect clamps (49) - (56).

12. Disconnect tube (39).
20. Remove tube (57).
21. Remove lubrication valve assembly (58).
16. Remove lubrication tube block (44).
16 HD785-7
23. Disconnect wiring connector (60). 29. Sling torque converter and transmission
assembly and remove oil pan (68).
24. Remove clamps (61) - (63).
25. Remove output shaft speed sensor (64).
30. Place torque converter and PTO assembly

(69).
a This assembly is not stabilized by simply
26. Remove oil filter (65). setting blocks under its right and left por-
tions. Set hydraulic jacks under the front
27. Remove ECMV assembly (66). and rear portions of the assembly and
adjust their height to stabilize the assem-
bly.
28. Remove torque converter relief valve (67).
31. Sling torque converter and PTO assembly (69)

and remove the bolts.
32. Lift off torque converter and PTO assembly

(69).
HD785-7 17
Connection 4. Place oil pan assembly (68) horizontally and

1. Place transmission assembly (71) with trans- install gasket (74).
mission input shaft (70) up. 2 Oil pan connecting face:
2. Fit O-rings (72) to the connecting face to the

torque converter assembly. 5. Place the torque converter and transmission
assembly on its side and install oil pan (68).
a Sling torque converter and transmission
assembly and tighten the bolts (40 pieces)
lightly.
a Place the assembly horizontally and
tighten the bolts permanently.
3. While slinging torque converter (69), install the

bolts.
18 HD785-7
6. Install torque converter relief valve assembly 9. Install oil filter (65) to ECMV assembly (66).
(67).
a When installing the bolts (2 pieces), take
care not to damage the wiring.
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
10. Install output shaft speed sensor (64).

a Lightly press the speed sensor against the
gear, then return it by 1/2 – 2 turns and
tighten the locknut.
2 Threaded part of sensor:
7. Fit O-rings (75) to the mounting face of ECMV Gasket sealant (LG-5)
assembly (66) on the transmission side. 3 Mounting bolt:
49.0 – 68.6 Nm {5.0 – 7.0 kgm}
11. Install wiring connector (60).
12. Install clamps (61) - (63).
8. Sling and install ECMV assembly (66).

2 Mounting bolt: Gasket sealant (LG-5)
13. Install cover (59).
HD785-7 19
14. Install lubrication valve assembly (58). 19. Install lubrication tube block (44).
3 Mounting bolt: 3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
15. Install tube (57). 20. Install tube (43).

3 Mounting nut: 3 Mounting bolt:
54.0 – 78.0 Nm {5.5 – 8.0 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
16. Install clamps (49) – (56). 21. Install lubrication tube (41).
a Clamp (56) has a spacer and its bolt 3 Mounting bolt:
length is different from the others. Take 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
care.
22. Install tube (40).
17. Install wiring connectors (46), (47) and (48).
(46) T/M. T 23. Install tube (39).
(47) LUB. PS
(48) LUB. SW
24. Install wiring connectors (33) – (36) of the

torque converter relief valve.
18. Install cover (45). (33) M/P. SW
(34) M/F. PS
(35) VOL. PS
(36) VOL. SW
25. Install clamps (37) and (38).
20 HD785-7
26. Install ECMV wiring connectors (18) – (32). 31. Install wiring connectors (5) – (8).
* Connector Nos. (from left) (5) T/C. P
(18) 1. PS (26) 4. PS (6) N2
(19) 1. SW (27) 4. SW (7) N1
(20) 2. PS (28) L/U. PS (8) T/C. T
(21) 2. SW (29) L. PS
(22) 3. PS (30) L. SW
(23) 3. SW (31) H. PS
(24) R. PS (32) H. SW
(25) R. SW
32. Install covers (3) and (4).
33. Tighten drain plug (2) of oil pan (1).
27. Install torque converter oil temperature sensor

(17).
3 Mounting nut:
29.4 – 49.0 Nm {3.0 – 5.0 kgm}
28. Install torque converter oil pressure sensor

(16).
Elbow: 84.0 – 132.0 Nm {8.5 – 13.5 kgm}
Sensor: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
29. Install intermediate shaft speed sensor (14)

and input shaft speed sensor (15).
a Lightly press the speed sensor against the
gear, then return it by 1/2 – 2 turns and
tighten the locknut.
3 Mounting bolt:
49.0 – 68.6 Nm {5.0 – 7.0 kgm}
30. Install clamps (9) – (13A).
HD785-7 21
Disassembly and assembly of 4. Loosen all of PTO assembly mounting bolts (7)
and then remove them, leaving 4 positioned at
torque converter PTO assembly 1 equal intervals.
a Remove orifice lug (a).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
2 790-413-1131 Nut wrench t 1
C 3 791-346-1400 Wrench t 1
4 792-613-1100 Installer t 1 N
Disassembly
1. Relief valve assembly 5. PTO assembly

Remove the accessories and relief valve 1) Place the PTO assembly with torque con-
assembly (1). For details, see "Disconnection verter housing assembly (6) down.
and connection of torque converter assembly 2) Remove input coupling (8).
and transmission assembly".
3) Using forcing screws, remove cage

2. Remove drain plug (2) to drain the oil. assembly (9).
3. Remove mounting bolts (4) of pump assembly

(3).
a When PTO assembly (5) is removed,
torque converter housing assembly (6) is
directed down and the pump assembly
mounting bolts cannot be removed eas-
ily. Accordingly, remove the mounting bolt
at this point.
22 HD785-7
4) Disassembly of cage assembly 7) Remove 4 remaining PTO assembly

1] Remove O-ring (10). mounting bolts (7).
2] Remove oil seal (11). 8) Using forcing screws, separate PTO
3] Remove dust seal (12). assembly (5) from the housing.
9) Lift off the PTO assembly.
5) Lock the pump drive gear and loosen nut

(14) with tool C3. 6. Disassembly of PTO assembly
a The nut is difficult to loosen after the 1) Using forcing screws, remove pump drive
pump drive gear assembly is gear cage assemblies (15), (16) and (17).
removed. Accordingly, loosen it at
this point.
6) Remove snap ring (13).
HD785-7 23
2) Disassembly of pump drive gear cage 7. Disassembly of PTO case assembly

assembly Remove bushing (67) and outer race (65) from
a The following is the disassembly pro- PTO case (65).
cedure of pump drive gear cage (15).
Disassemble (16) and (17) according
to this procedure, too.
a When reusing the bearings, record
their positions and match marks.
1] Remove nut (14).
2] Remove snap ring (18) and plate
(19).
3] Using forcing screws [1], remove gear
(20).
4] Remove bearings (21) and (22).
8. Turbine and clutch assembly

Remove turbine and clutch assembly (26).
5] Using the push tool, remove outer

races (23) and (24) from cover (25).
9. Disassembly of turbine and clutch assem-

bly
1) Drive gear assembly
1] Remove gear mounting bolts (27).
2] Using forcing screws, remove drive
gear assembly (28).
3] Remove seal ring (63).
4] Remove inner race (62).
24 HD785-7
2) Turbine assembly 3] Remove inner gear mounting bolts

1] Remove snap ring (29) and spacer (35) from turbine (34).
(30).
3) Housing
2] Reverse turbine and clutch assembly 1] Lift off housing assembly (36) with the
(31), drive bearing inner race (32) out housing side up.
of hole (p1) on the boss side, and
remove turbine assembly (33).
a Place a block about 50 mm high
on the turbine boss.
2] Remove piston (37) and bearing (68)

from housing (36).
HD785-7 25
4) Disc and plate

Remove disc (38) and plate (39).
2) Reverse the pump and torque converter

housing assembly.
10. Stator a Place a block about 200 mm under
While rotating stator assembly (57) to the the torque converter housing.
"right" (r), lift up and remove it. 3) Remove plug (41) and drive out down the
pump assembly by hitting inner race (42)
through plug hole (p2).
a Spread soft material on the floor to
receive the pump assembly.
4) Sling torque converter housing (6) and
remove pump assembly (3).
11. Pump assembly

1) Using tool C2, remove nut (40).
5) Disassembly of pump assembly

1] Remove mounting bolts (43) of
retainer (69).
2] Remove retainer (69).
3] Remove guide (44).
4] Take bearing (45) out of pump (46).
26 HD785-7
12. Shaft
1) Remove mounting bolts (48) of shaft (47).
2) Reverse torque converter housing assem-
bly (6).
3) Drive out shaft (47).
4) Remove seal ring (49).
a If the shaft is not being replaced, do
not remove it.
HD785-7 27
Assembly 2) Install inner race (42) to shaft (47).

1. Shaft a Set face (b) of inner race (42) indi-
1) Place torque converter housing (6) on a cated with match mark "A" to match
block. mark "A" indicated on face (a) of
a The block must be about 200 mm bearing (45) installed to guide (44).
high. a The same product No. is indicated on
2) Install seal ring (49). faces (a), (b) and (c) of the bearing.
3) Install shaft (47).
3 Mounting bolt (48):
98 – 123 Nm {10.0 – 12.5 kgm}
3) Install pump assembly (3).

a Fix seal ring (49) with grease so that it
will project evenly from the shaft.
4) Reverse the shaft and torque converter 4) Install remaining inner races (42).
housing assembly. 5) Using tool C2, install nut (40).
2 Threaded part of nut:
2. Pump assembly Adhesive (LT-2)

a When installing the bearing and inner 3 Nut on bearing side (Nut installed
race, check the product Nos. and match first):

marks made on their end faces. 196 – 245 Nm {20.0 – 25.0 kgm}
1) Assemble the pump assembly according 3 Nut on stator side (Nut installed
to the following procedure. next):

1] Install bearing (45) to guide (44). 441 – 490 Nm {45.0 – 50.0 kgm}
a Install the bearing with the prod-
uct No. side up in the figure.
2] Install pump (46).
3] Install retainer (69) and tighten bolts
(43).
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
28 HD785-7
3. Assembly of stator assembly

1) Cool bushing (50) in dry ice etc.
2) Install snap ring (51) and ball (53) to bush-
ing (50).
3) Install bushing (50) to outer race (52).
a While preventing snap ring (51) from
opening out with tool C4, insert bush-
ing (50) in outer race (52) until snap
ring (51) is set to outer race (52).
7) Install outer race and one-way clutch

assembly (55) to stator (39).
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
4) Remove tool C4 and insert bushing (50) to

outer race (52) perfectly.
5) Reverse outer race (52).
6) Install one-way clutch (54) to outer race
(52).
a Take care not damage sprag (e).
a Install the one-way clutch so that the
free rotation direction arrow will be on
the right "(f)" when viewed from the
outer race flange side. Never remove
8) Install bushing (56) by expansion fit.
sprang (e).
a Fix ball (53) with grease and install it
to the correct position.
a Take care not to scratch the contact
face of the bushing.
HD785-7 29
4. Installation of stator assembly 2) Disc and plate

Install stator assembly (57) while rotating it to Install disc (38) and plate (39).
the right "(r)".
a Apply power train oil (TO10 or TO30) to
the sliding surface of the one-way clutch
of the shaft.
3) Piston
Fit seal rings (59) and (60) and install pis-
ton (37) to housing (36).
5. Assembly of turbine assembly

Install inner gear (100) to turbine (34).
2 Mounting bolt (35): Adhesive (LT-2)
98 – 123 Nm {10 – 12.5 kgm}
6. Assembly of turbine clutch assembly

1) Turbine
Set case (58) and turbine assembly (33).
a Place a block under the turbine to
flush the disc mounting faces.
30 HD785-7
4) Housing 6) Drive gear assembly

Install housing (36). 1] Using a press fitting tool, press fit
2 Mounting bolt: Adhesive (LT-2) inner race (62) to shaft (20).
3 Mounting bolt: 2] Install seal ring (63).
98 ± 123 Nm {10 ± 12.5 kgm} 3] Install drive gear assembly (27) to tur-
bine clutch assembly (26) and tighten
the mounting bolts evenly.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 kgm {25 – 31.5 kgm}
5) Bearing
1] Press fit bearing (61).
a Press fit the inner race and outer
race simultaneously.
2] Set spacer (30) and install snap ring
(29).
HD785-7 31
7. Installation of turbine and clutch assembly 8. Assembly of PTO case assembly

1) Sling the shaft end, set the drain plug of Install outer race (66) and bushing (67) to PTO
the pump to the drain groove of the case, case assembly (65).
and install turbine and clutch assembly
(26).
9. Assembly of PTO assembly

Assembly of pump drive gear cage assembly
2) Tighten pump mounting bolt (4) and drain a After assembling, drop power train oil
plug (2). (TO10 or TO30) of 6 cc onto the bearing
2 Mounting bolt: Adhesive (LT-2) and rotate the bearing 10 turns.
3 Mounting bolt: 1) Using the push tool, press fit outer races
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm} (24) and (23) to cover (25).
3 Drain plug:
11.28 ± 1.47 Nm {1.15 ± 0.15 kgm}
3) Install orifice plug (a).
2 Plug: Adhesive (LT-2)
3 Plug: 4.9 – 9.8 Nm {0.5 – 1.0 kgm}
32 HD785-7
2) Using the push tool, press fit bearing (22) 10. Installation of PTO assembly
to gear (20) and install them to cover (25). 1) Set the O-ring and install PTO assembly
3) Install bearing (21) and tighten nut (14) (5), while meshing the PTO gear.
temporarily. 2 O-ring: Grease (G2-LI)
2 Nut: Adhesive (LT-2)
4) Install plate (19) and snap ring (18).
2) Install bearing (64) and fix it with snap ring

(13).
5) Tighten nut (14) temporarily. 3) Lock the pump drive gear and tighten nut
6) Install pump drive gear cage assemblies (14) with tool C3.
(17), (16) and (15) to the case. 3 Nut: 313 – 392 Nm {32 – 40 kgm}
HD785-7 33
4) Assembly of cage assembly 5) Installation of cage assembly

Using push tool [9], install dust seal (12) Install cage assembly (9) to PTO case (5)
and oil seal (11) to cage (9). and tighten the bolts.
1] Thinly apply gasket sealant (LG-5) to
the seal fitting face inside the cage.
2] Install the seals so that dimensions
from the cage top to each seal top will
be as follows.
q Dimension a: 46.5 ± 0.25 mm
q Dimension b: 31.5 ± 0.25 mm
a After installing, wipe off the pro-
jected gasket sealant.
3] Apply grease to the clearance
between the oil seal and dust seal
and to the oil seal lips.
a Fill the space between the lips
with grease to by 40 – 60% so
6) Install coupling (8).
that the grease will not be pro-
jected from the lips.
2 Seal: Grease (G2-LI) or sili-
cone grease (ThreeBond
1855)
4] Install O-ring (10).
34 HD785-7
Disassembly and assembly of

transmission assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Oil leak tester kit
D 1 799-301-1600 t 1
(A)
Disassembly 3. Sleeve
a Remove the accessories and disconnect the Using forcing screws, remove 5 sleeves (3).
torque converter assembly. For details, see a Put tags to the sleeves and record the
"Disconnection and connection of torque con- removed positions on them.
verter assembly and transmission assembly".
a When disassembling the clutch discs and
plates, classify them into groups by the No.
and put identification tags to those groups.
a Pile up the clutch discs and plates horizontally.
(If they are inclined against something, they
will be warped.)
1. Set transmission assembly (1) with input shaft

(2) side up.
a Support the right and left portions of the
transmission assembly on bocks 250 –
300 mm high as shown in the photo and
adjust the heights of the front and rear 4. No. 1 clutch assembly
portions with hydraulic jacks to stabilize Using an eyebolt, remove No. 1 clutch assem-
the whole assembly vertically. bly (4).
2. Check of piston operation

Using tool D1, check the operating condition of
the No. 1, 2 and 3 clutch pistons.
(The operation of the No. 2 and 3 clutch pis-
tons cannot be checked directly, however.
Check it by the movement of the discs or
plates.)
a Air pressure:
0.29 – 0.59 MPa {3 – 6 kg/cm2}
a Standard stroke of No. 1 clutch piston:
6.3 mm
HD785-7 35
5. Disassembly of No. clutch assembly 2) Housing piston

1) Input shaft 1] Loosen all mounting bolts (11) and
1] Remove bolts (5) and remove plate remove them, leaving 2 at diagonal
(6) from input shaft assembly (7). positions.
2] Lift off input shaft assembly (7). 2] Reverse the clutch assembly.
a Place the clutch assembly on
blocks about 100 mm high so
that the left bolts can be
removed.
3] Remove 2 bolts (11) left in the above
procedure and remove housing piston
assembly (12).
a When removing the housing pis-
ton assembly, take care not lose
the spacer installed to the spring
guide pin.
4] Remove piston (13) and seal ring
from the housing.
3] Remove snap ring (8) from the input
shaft and remove bearing (9).
4] Remove seal ring (10).
36 HD785-7
3) Guide spring, disc, spring, plate and guide

pin
1] Remove springs (14), spring guide
pins (19) and spacers.
2] Remove discs (15), springs (16) and
plates (17).
3] Remove guide pins (18).
6. No. 2 clutch assembly

Using eyebolts, remove No. 2 clutch assembly
(26) and sun gear (179).
a Remove the inner race and spacer from
sun gear (179).
4] No. 1 clutch ring gear

Remove ring gear (21) and dowel
pins (22) and (23) from cage (20).
a Remove snap ring (183) from
ring gear (21).
7. Disassembly No. 2 clutch assembly

1) Housing assembly
1] Remove mounting bolts (27) and
housing assembly (28).
5) Bearing
Remove snap ring (24) and remove bear-
ing (25) from cage (20).
HD785-7 37
2] Remove snap ring (29) and bushing 6] Remove seal ring (36) from piston
(30). (35).
a When removing the bushing take
care not to lose the stopper ball.
3] Remove inner race (31).
7] Remove seal rings (37) and (38) from

housing (34).
8] Remove bearing (39) from housing
4] Remove mounting bolts (32) and (34).
remove cylinder (33) from housing
(34).
2) Disc, plate and spring

Remove discs (40), plates (41) and
5] Remove piston (35) from housing springs (42).
(34).
38 HD785-7
3) Transmission input shaft speed sensor

plate
1] Reverse the clutch assembly.
2] Remove mounting bolts (43) and
plate (44).
4) Planetary gear
1] Remove carrier assembly (46) from
drum (45).
5] Remove inner race (177) and seal

ring (178) from carrier assembly (46).
2] Remove shaft (47).

a Take care not to lose ball (48).
3] Remove gear (49), bearing (50) and
thrust washer (51).
4] Remove bearing (52).
HD785-7 39
8. Transmission case 9. Check of piston operation

1) Using eyebolts, remove transmission case Using tool D1, check the operating condition of
(53). the No. 4, 5, 6 and 7 clutch pistons.
a Sling the transmission case vertically. a Air pressure:
0.29 – 0.59 MPa {3 – 6 kg/cm2}
Piston No. Stroke (mm)
4 4.0
5 6.3
6 6.8
7 6.0
2) Remove the following parts from transmis-

sion case (53).
1] Cage (54)
2] Bearing (55)
3] Collar (56)
3) Remove seal ring (57) from collar (56).
10. No. 3 clutch housing assembly

Using eyebolts, remove No. 3 clutch housing
assembly (58).
a For disassembly of the housing assembly,
see "Disassembly of No. 2 clutch assem-
bly".
40 HD785-7
11. No. 3 ring gear

1) Remove No. 3 ring gear (59).
2) Remove inner race (60) and seal ring (61)
from No. 3 ring gear (59).
15. No. 4 sun gear and plate

1) Remove plate (68).
2) Remove snap ring (69).
3) Remove sun gear (70).
12. Tie bolt
Remove tie bolts (62).
13. No. 4 clutch plate

Using eyebolts, remove plate (63).
16. No. 4 housing, piston and ring gear

Using eyebolts, remove No. 4 housing (71),
piston (72) and ring gear (73) together.
a If the dowel pin is hard to disconnect and
the housing needs to be pried up, take
14. Nol. 4 clutch disc, plate and spring care not to damage the housing.
1) Remove springs (64).
2) Remove discs (65), plates (66) and
springs (67).
HD785-7 41
17. No. 5 spring disc, plate and spring 19. Disassembly of No. 4 carrier and No. 5 ring
1) Remove discs (74), plates (75) and gear assembly
springs (76) and (77). 1) No. 4 carrier assembly
Disconnect No. 4 carrier assembly (80)
and No. 5 ring gear (81).
a Disconnect the carrier assembly and

ring gear according to the following
procedure.
1] Sling NO. 4 carrier assembly (80).
2] While pushing in snap ring (82)
evenly through 3 holes (p3) around
No. 5 ring gear (81), lift off No. 4 car-
rier.
18. No. 4 carrier and No. 5 ring gear

Using eyebolts, remove No. 4 carrier and No. 5
ring gear assembly (79).
42 HD785-7
2) No. 4 planetary gear 21. Disassembly of No. 5 and No. 6 carrier

1] Pull out shaft (83) toward the ball. assembly
2] Remove ball (84). 1) Remove collar (180) and remove snap
3] Remove gear (85), bearing (86) and ring (181) and inner race (182) from the
thrust washer (87). collar.
a Check the installed direction (vertical)
of the collar.
2) Remove bolts (91) from carrier assembly
(90) and remove cover (92).
4] Remove bearing (89) from carrier

(88).
3) Remove bearing (93) and seal ring (94)

from cover (92).
20. No. 5 carrier and No. 6 carrier assembly

Lift off No. 5 carrier and No. 6 carrier assembly
(90).
4) Lift off shaft and sun gear assembly.

5) Pull sun gear (95) out of shaft (96).
HD785-7 43
6) Shaft
1] Remove snap ring (97) from the shaft.
2] Remove inner race (98) from the
shaft.
22. No. 5 housing , piston and spring guide pin

1) Remove spring guide pin (111).
2) Using eyebolts, remove No. 5 housing
(110) and piston (90) together.
7) Disassembly of No. 5 carrier assembly a If the dowel pin is hard to disconnect
For disassembly of the No. 5 carrier and the housing needs to be pried up,
assembly, see "Disassembly of No. 4 take care not to damage the housing.
planetary gear". Remove shaft (99), ball
(100), bearings (101), thrust washers
(102) and gear (103).
23. No. 6 clutch disc, plate and spring

1) Remove discs (112), plates (113) and
springs (114) and (115).
8) Disassembly of No. 6 carrier assembly
1] Remove snap ring (181) from the No.
6 carrier assembly.
2] For disassembly No. 6 carrier assem-
bly, see "Disassembly of No. 4 plane-
tary gear". Remove shaft (104), ball
(105), bearings (106), thrust washers
(107) and gear (108).
3] Remove inner race (182) from the No.
6 carrier assembly.
44 HD785-7

3) Remove guide pin (117).
2] Drive out down No. 7 gear (121).

3] Lift off housing assembly (118).
24. No. 6 and 7 housing and piston
Using eyebolts, remove No. 6 and 7 housing
assembly (118).
a If the dowel pin is hard to disconnect and
the housing needs to be pried up, take
care not to damage the housing.
a Make positioning marks on housing
assembly (118) and cover assembly (119)
in paint etc.
4] Remove No. 6 piston (122) and No. 7

piston (161) from housing (118).
25. Disassembly of No. 6 ring gear and housing

1) Housing
1] While pushing in the snap ring
through 3 holes (p4) around sun gear
(120), lift up the sun gear to remove.
a For removal procedure, see "Dis-
assembly of No. 4 carrier assem-
bly".
HD785-7 45
5] Remove snap ring (123). 26. No. 7 plate

6] Remove bearing (124). Remove plate (128).
2) No. 7 gear 27. No. 7 clutch disc, plate and spring

1] Remove No. 6 ring gear (125) and 1) Remove discs (129), plate (130) and
No. 7 gear (121). springs (131) alternately.
a See "Disassembly of No. 4 car- 2) Remove guide springs (132).
rier assembly".
28. No. 7 guide pin and No. 7 clutch ring gear

2] Remove snap ring (126) from No. 7 1) Remove guide pins (133).
gear (121). 2) Remove No. 7 clutch ring gear (134).
3] Remove bearing (127) from No. 7
gear (121).
46 HD785-7
29. Output shaft assembly 30. Disassembly of output shaft assembly

When replacing the oil seal, you can remove 1) Remove collar (137) from the output shaft.
only the output shaft assembly.
1) Reverse cover assembly (119).
a Place blocks of about 100 mm under
the cover assembly to secure a space
for driving out down the No. 7 carrier
assembly.
2) Remove cage mounting bolts (135).
2) Support cage (138) and push out output

shaft (139) from the bearing with a press.
3) Remove output shaft and cage assembly

(136) from cover assembly (119).
a When removing the oil seal, perform
only step (29) and replace.
3) Remove bearing (140) from output shaft

(139).
HD785-7 47
4) Remove bearing (141) from cage (138). 32. Disassembly of No. 7 carrier assembly
5) Remove oil seal (142) from cage (138). 1) Remove mounting bolts (149) and plate
(150).
31. Output sensor gear and No. 7 carrier

assembly 2) Remove seal ring (151).
1) Remove output shaft speed sensor gear 3) Remove shaft (152), ball (153), bearings
(143). (154), thrust washers (155) and gear
2) Remove the O-ring. (156). For details, see "Disassembly of
No. 4 planetary gear".
3) Remove dowel pin (144).

4) Remove snap ring (145) and spacer (146). 33. Bearing
5) Drive out down carrier assembly (147) to 1) Reverse cover assembly (119).
remove. 2) Remove cage mounting bolts (157) and
a Spread soft material on the floor to cage (158).
receive the carrier assembly. 3) Remove seal ring (159).
6) Remove bearing (160). 4) Remove bearing (160) from cover (119).
48 HD785-7
Disassembly of oil pan Assembly

1. Cover Clean all the parts and remove sharp edges etc.
Remove cover (1) of oil pan (2).
a Apply grease (G2-LI) to the oil seals, O-rings
and seal rings, unless otherwise specified.
a Apply power train oil to the rotary parts and
sliding parts before installing.
a Before installing the discs, soak them in clean
power train oil (TO10 or TO30) for at least 2
minutes.
a When installing each seal ring (a) for the piston
of the clutch assembly, direct the pressure
receiving side (b side) toward housing (c).
a When installing each bearing by expansion fit,
drop power train oil (TO10 or TO30) of about 6
cc to it and rotate it 10 turns before putting it in
dry ice.
2. Spring and magnet screen
Pull out spring (3) and magnet screen (4).
1. Cover assembly
1) Install bearing (160) to cover assembly
(119).
2) Install cage (158).
3) Install cage mounting bolts (157).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
HD785-7 49
4) Install seal ring (159) to cage (158). 4] Install plate (150).

Adhesive (LT-2)
58.3 – 73.5 Nm {6 – 7.5 kgm}
2. Assembly of No. 7 carrier assembly

1) No. 7 planetary gear
1] Install gear (156), bearings (154) and
thrust washers (155) as an assembly
to carrier assembly (147). For details, 3. Cover and carrier assembly
see "Assembly of No. 4 planetary 1) Sling and install cover assembly (119).
gear".
2] Fix ball (153) to shaft (152) with
grease and insert the shaft in carrier
assembly (147).
a See "Assembly of No. 4 carrier
and No. 5 ring gear assembly",
step 1).
a Check that the mounting hole of
shaft ball (153) is set to the hole
of the carrier and install so care-
fully that the bearings and thrust
washers will not be damaged.
a Check that the gear rotates
smoothly.
2) Install spacer (146) and fix it with snap
3] Install seal ring (151).
ring (145).
3) Install dowel pin (144) to carrier assembly
(147).
4) Install O-ring (148).
50 HD785-7
5) Install output shaft speed sensor gear 4) Set output shaft (139) on the press stand
(143). and press the inner race of the bearing to
install cage (138).
4. Assembly of output shaft assembly

Assemble the output shaft assembly according 5) Install collar (137) to the output shaft.
to the following procedure.
1) Press fit bearing (140) to output shaft
(139).
5. Output shaft assembly

1) Sling and install output shaft assembly
(136) to cover assembly (119).
2) Install bearing (141) to cage (138). 2 Output shaft spline: Molybdenum
3) Install oil seal (142) to cage (138). disulfide grease (LM-G)
2 Oil seal lip: Grease (G2-LI)
2 Press fitting face on cage side:
a After press fitting, wipe off the pro-
jected gasket sealant.
HD785-7 51
2) Install cage mounting bolts (135) to cover 7. Guide pin

assembly (119). Install guide pins (133).
3 Mounting bolt:
245.2 – 309 Nm {25 – 31.5 kgm}

1) Install discs (129), plates (130) and
springs (131) alternately.
6. No. 7 clutch ring gear 2) Install guide springs (132).
1) Reverse cover assembly (119). a Be sure to install all the springs
2) Install the dowel pin to the carrier and between the plate and disc.
install collar (147).
2 Outside of dowel pin: Molybdenum
disulfide grease (LM-G)
a Support the right and left portions of
the assembly on bocks as shown in
the photo and adjust the heights of
t he fr ont an d r e ar po rt io ns wi th
hydraulic jacks to stabilize the whole
assembly horizontally.
9. Spring and piston plate

Install piston plate (128).
a Check that the springs are fitted to the
spring receiving holes of the piston plate.
3) Install ring gear assembly (134) to the

cover assembly.
52 HD785-7
10. No. 6 ring gear 3) Sling and install housing (118) to No. 6
1) Install bearing (127) to No. 7 gear (121). ring gear and No. 7 gear assembly (121).
2) Install snap ring (126) to No. 7 gear (121).
12. No. 7 sun gear and piston

3) Install No. 7 gear (121) to No. 6 ring gear 1) Install sun gear (120).
(125). a For the installation procedure, see
a For the installation procedure, see "Assembly of No. 4 carrier assembly".
"Assembly of No. 4 carrier assembly". 2 Spline: Molybdenum disulfide
grease (LM-G)
2) Install seal rings (162) and (163) to hous-
ing (118) and piston (161), and then install
the piston to the housing.
a Direct the grooves of the seal rings
toward the pressure receiving side
(inside).
11. Housing
1) Install bearing (124) to the housing.
2) Install snap ring (123).
HD785-7 53
13. No. 6 and 7 housing assembly

1) Using eyebolts, sling and install No. 6 and
7 housing assembly (118).
a Set the marks made when housing
assembly (118) was removed from
cover assembly (119).
a While housing assembly (118) is
reversed, slung and installed, the No.
7 piston is directed down. At this
time, take care that the No. 7 will not
fall.
a If the dowel pin is hard to insert, drive
it in with a plastic hammer.
3) Install No. 6 piston (122).
2) Install seal rings (164) and (165) to hous-

ing (118) and No. 6 piston (122).
a Direct the grooves of the seal rings 14. Guide pin and piston plate
toward the pressure receiving side 1) Install guide pin (117).
(inside). 2) Install plate (116).
3 Mounting bolt:
245.2 – 274.6 Nm {25 – 28 kgm}
54 HD785-7
15. No. 6 clutch disc, plate and spring 3) Install spring guide pin (111).
1) Install discs (112), springs (114) and
plates (113) alternately.
2) Install springs (115).
17. Assembly of No. 5 and No. 6 carrier assem-

bly
1) No. 6 planetary gear
16. No. 5 housing and piston 1] Install bearings (106) to No. 6 plane-
1) Install seal rings (166) and (167) to hous- tary gear (108) and set them to the
ing (109) and piston (110), and then install carrier with thrust washers (107) on
the piston to the housing. their both sides.
a Direct the grooves of the seal rings 2] Install shaft (104) to the carrier.
toward the pressure receiving side a See "Assembly of No. 4 carrier
(inside). and No. 5 ring gear assembly",
2) Using eyebolts, sling and install housing step 1).
(109) and set it to the springs. a Check that the mounting hole of
a If the dowel pin is hard to insert, drive shaft ball (153) is set to the hole
it in with a plastic hammer. of the carrier and install so care-
fully that the bearings and thrust
smoothly.
3] Install snap ring (181) to the carrier.
4] Install inner race (182) to the carrier.
HD785-7 55
2) No. 5 planetary gear 3] Sling and install shaft assembly (96)

1] Reverse the carrier assembly. to the carrier assembly.
2] Install bearings (101) to No. 5 plane-
tary gear (103) and set them to the
carrier with thrust washers (102) on
their both sides.
3] Install shaft (99) to the carrier.
a See "Assembly of No. 4 carrier
and No. 5 ring gear assembly",
step 1).
the shaft ball is set to the hole of
the carrier and install so carefully
that the bear ings and thrust
4) Install sun gear (95) to shaft assembly
smoothly.
(96).
3) Shaft
5) Cover
1] Install inner race (98) to the shaft.
1] Install bearing (93) to cover (92).
2] Install snap ring (97) to the shaft.
2] Install seal ring (94) to cover (92).
56 HD785-7
3] Install cover assembly (92) to carrier 19. Assembly of No. 4 carrier and No. 5 ring
assembly (90). gear assembly
2 Mounting bolt (91): 1) No. 4 carrier assembly
Adhesive (LT-2) 1] Install bearing (88) to the carrier.
3 Mounting bolt (91): 2] Install seal ring (168) to the carrier.
58.3 – 73.5 Nm {6 – 7.5 kgm}
4] Install snap ring (181) to collar (180)
and press fit inner race (182).
5] Install collar (180) to the intermediate
shaft in the direction of (d).
2 Collar (Parts a, b and c):
Molybdenum disulfide grease
(LM-G)
3] Install bearings (85) to No. 5 plane-

tary gear (87) and set them to carrier
(80) with thrust washers (86) on their
both sides.
4] Install ball (84) to shaft (83) and install
them to the carrier.
the shaft ball is set to the hole of
the carrier and install so carefully
that the bearings and thrust
smoothly.
18. No. 5 and No. 6 sun gear and carrier gear

Sling and install No. 5 and No. 6 sun gear and
carrier gear assembly (90).
2 Insertion portion of shaft end:
Molybdenum disulfide grease (LM-G)
HD785-7 57
2) Ring gear 21. No. 4 sun gear

1] Install snap ring (82) to carrier assem- 1) Install No. 4 sun gear assembly (70).
bly (80).
a Apply grease to the snap ring
mounting groove and install the
snap ring evenly.
2] Sling and install No. 4 carrier assem-
bly (80) to ring gear (81).
a Press snap ring (82) inward
evenly to fit.
2) Install snap ring (69) to No. 4 sun gear

assembly (70).
3) Install seal ring (169) to No. 4 sun gear
assembly (70).
20. No. 4 carrier gear

Sling and install No. 4 carrier gear assembly
(79).
22. Tie bolt sleeve

Install tie bolt sleeve (170).
58 HD785-7
23. No. 5 clutch disc, plate and spring 3) Set No. 4 clutch ring gear (73).
1) Install piston plate (78). a Direct the side of the cut inside down.
2) Install disc (74), plate (75) and spring (76). 25. No. 4 clutch disc, plate and spring
3) Install guide spring (77). 1) Install piston plate (68).
24. No. 4 housing and piston 2) Install discs (65), springs (67) and plates
1) Install the seal rings to housing (71) and (66) alternately.
piston (72), and then install the piston to 3) Install spring (64).
the housing.
a Direct the grooves of the seal rings
toward the pressure receiving side
(inside).
2) Using eyebolts, sling and install housing
(71) and set it to the springs.
a If the dowel pin is hard to insert, drive
it in with a plastic hammer.
HD785-7 59
26. No. 4 clutch plate 29. No. 3 clutch drum

Install plate (63). Install drum (171).
27. Tie bolt

3 Tie bolt:
245.2 – 274.6 Nm {25 –28 kgm}
a Tighten each tie bolt to the tap hole end
with the fingers.
a Do not use an impact wrench until the bolt
catches the threads securely.

1) Install disc (172) and spring (173).
28. No. 3 clutch ring gear

1) Install ring gear (59).
3 Mounting bolt:
156.1 – 196.1 Nm {16.0 – 20.0kgm}
2) Install inner race (60).
3) Install seal ring (61).
2) Install plate (174).
a Install the remaining discs, springs,
and plates.
60 HD785-7
31. No. 3 clutch housing assembly 33. Transmission case

1) For assembly of the piston, see "Assem- 1) Install the following parts to the transmis-
bly of No. 2 clutch assembly", (5). sion case.
2) While meshing the external teeth of the 1] Install seal ring (57) to the outside
piston with the internal teeth of drum groove of collar (56) and install them
(171), install housing assembly (175). to the transmission case, setting them
2 Mounting bolt: Adhesive (LT-2) to the dowel pin.
3 Mounting bolt: 2 Seal ring: Grease (G2-LI)
98.1 – 122.6 Nm {10.0 – 12.5 kgm} 2] Install cage (54) to case (53).
3] Install bearings (55) to both sides.
a Press fit the bearing until they
reach the collar. (Ensure that
there is no clearance between
the collar and each bearing.)
32. Check of piston operation

Using tool D1, check the operating condition of
the No. 4, 5, 6 and 7 clutch pistons.
a Air pressure:
0.29 – 0.59 MPa {3 – 6 kg/cm2}
Standard piston stroke:
Piston No Stroke (mm)
No. 4 4.0
No. 5 6.3
No. 6 6.8
No. 7 6.0
a If the pistons do not move smoothly, sup-

ply power train oil.
2) Install O-ring (176) to the cover assembly.
HD785-7 61
3) Using eyebolts, sling and install transmis-

sion case (53).
34. Assembly of No. 2 clutch assembly

1) Carrier assembly
1] Install inner race (177), bearing (52)
and seal ring (178) to carrier assem-
bly (46).
2) Drum
Install carrier assembly (46) to drum (45).
2] Install bearing (50) to gear (49) and

set them to the carrier assembly with
thrust washers (51) on them both
sides.
3] Push in shaft (47), setting it to the
bearing and thrust washers (51).
4] Set ball (48) and install the shaft
securely.
a If the shaft comes out, caulk the
carrier side with a punch.
smoothly.
62 HD785-7
3) Transmission input shaft speed sensor 5) Housing assembly

plate 1] Install bushing (30) and fix it with
Install plate (44) to carrier assembly (46). snap ring (29).
2 Mounting bolt (43): 2] Install inner race (31).
Adhesive (LT-2)
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
3] Reverse housing (34) and install it to

bearing (39).
4] Install seal rings (37) and (38).
4) Disc, plate and spring a Direct the grooves of the seal
1] Reverse the clutch assembly. rings toward the pressure receiv-
ing side (inside) (P).
2] Install 4 discs (40), 4 plates (41) and

5 springs (42).
HD785-7 63
5] Install seal ring (36) to piston (35). 6) Install housing assembly (28) to the clutch
assembly.
Adhesive (LT-2)
3 Mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
6] Install piston (36) to housing (34).

1) Install inner race (176) and spacer (177) to
gear (175).
a Check that there is no clearance in
parts (a) and (b).
7] Install cylinder (33) to housing (34).

2 Mounting bolt:
Adhesive (LT-2)
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2) Using eyebolts, install No. 2 clutch assem-

bly (26).
3) Install sun gear (179).
64 HD785-7
36. Assembly of No. 1 clutch assembly

1) Bearing
Press fit bearing (24) to cage (20) and fix it
with snap ring (25).
4) No. clutch plate, disc and guide pin

1] Install guide pin (18) and install discs
(15), springs (16) and plates (17)
alternately.
2) Sling and install cage assembly (20) to 2] Install guide pin (19) and spring (14).
inner gear (19).
a Press the bearing inner race to press
fit.
5) No. clutch housing, piston and spring

1] Install seal rings (180) and (181) to
piston (13).
3) No. 1 clutch ring gear a Direct the grooves of the seal
1] Reverse cage assembly (20) and rings toward the pressure receiv-
install ring gear (21). ing side (inside).
a Install snap ring (183) to the ring
gear.
2] Install dowel pins (22) and (23).
Adhesive (LT-2)
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
HD785-7 65
2] Install piston (13), setting it to the 6) Input shaft

guide pin. 1] Press fit bearing (9) to the input shaft
and fix it with snap ring (8).
2] Install seal ring (10).
a Before press fitting bearing,
ensure that "6215C3" is stamped
on its outer race end face.
3] Install housing (12).

a Lightly tighten 2 mounting bolts
at diagonal positions from under-
side. (Bolts 11 in 4])
3] Install input shaft assembly (7) to the

clutch assembly.
4] Fix plate (6) with mounting bolts (5).
4] Reverse the No. 1 clutch assembly

and install the rest of bolts (11).
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
Fit the O-ring to the transmission case and
install No. 1 clutch assembly (4), using eye-
bolts.
66 HD785-7
38. Sleeve Assembly of oil pan

Install sleeves (3). 1. Magnet screen and spring
a Install the sleeves to their original posi- 1) Install magnet screen (4) and spring (3) to
tions. the oil pan.
39. Check of piston operation 2) Cover

Using tool D1, check the operating condition of Fit the O-ring and install cover (1) to oil
the No. 1, 2 and 3 clutch pistons. pan (2).
(The operation of the No. 2 and 3 clutch pis-
tons cannot be checked directly, however.
Check it by the movement of the discs or
plates.)
a Standard stroke of No. 1 clutch piston:
6.3 mm
HD785-7 67
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
68 HD785-7
SEN02106-03
HD785-7
SEN02106-02
DUMP TRUCK
Shop Manual
HD785-7

HD785-7 7001 and up

Power train, Part 2
Removal and installation of final drive carrier assembly ............................................................................. 2

Disassembly and assembly of final drive carrier assembly......................................................................... 4
Removal and installation of differential assembly ....................................................................................... 6
Disassembly and assembly of differential assembly................................................................................... 9
HD785-7 1
Removal and installation of final 5. Install a bolt to the drive shaft end and pull out
drive carrier assembly the drive shaft.
Removal
a The outside wheel is removed in the following
procedure. You can work without removing the
outside wheel, however.
1. Remove drain plug (2) of final drive case (1) to

6. Lift off drive shaft assembly (7).
4 Drive shaft assembly: 150 kg
drain the oil. [*1]
6 Final drive case: 64 l
2. Loosen bolts (4) of cover (3). 7. Loosen mounting bolts (8). [*2]
3. Remove nut (5) of the air valve and lock plate

(6).
8. Install guide bolts (9) to carrier assembly [2] and

pull out the assembly toward this side.
4. Install guide bolts [1], pull out cover (3) toward

this side, and lift it off with eyebolts and wires.
4 Cover: 40 kg
2 HD785-7
9. Move the eyebolts to the back side of carrier Installation

assembly (9) and lift off the carrier assembly. q Carry out installation in the reverse order to re-
moval.
a The carrier assembly has its center of gravity
on the back side. a Remove all the rust and dirt from the mating fac-
es.
4 Carrier assembly: 480 kg
[*1]
3 Drain plug (at center of final drive case) :
127.4 – 176.4 Nm {13 – 18 kgm}
3 Drain plug (around final drive case) :
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
[*2]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

HD785-7 3
Disassembly and assembly of 3. Pinion gear assembly

final drive carrier assembly 1) Remove bearing inner races (5) and (6).
Disassembly
1. Using push tool [1], pull out shaft (2) from carrier
(1) with a press.
a When the shaft is pulled out, ball (3) is re-
moved, too. Take care not to lose the ball.
2. Pull out pinion gear assembly (4) from carrier (1).

a When pulling out the pinion gear assembly,
take care not to drop the lower bearing inner
race.
2) Remove bearing outer race and pull out

spacer (8).
3) Remove bearing outer race (9) and snap ring
(10).
4 HD785-7
Assembly 5) Install bearing inner races (6) and (5) to

1. Planetary gear assembly carrier (1).
1) Install snap ring (10) to planetary gear (4).
2) Using push tool [2], press fit bearing outer
race (9) with the press.
2. Push planetary gear assembly (4) into carrier

(1).
3) Reverse planetary gear (4) and install spacer 3. Using push tool [1], press fit shaft (2) to carrier
(8). (1).
4) Using push tool [2], press fit bearing outer a Press fit the shaft until the groove for ball (3)
race (7) with the press. comes near the carrier top and set ball (3) to
the shaft, and then press fit the shaft further
until it reaches the end.
a The planetary gear bearing is an assem-

bly. Assemble the inner races and outer
races of the same product No and identi-
fication marks (A) and (B) and the outer
ring spacers of the same product No. and
identification mark (C).
HD785-7 5
Removal and installation of 5. Install a bolt to the drive shaft end and pull out
differential assembly the drive shaft.
Removal
a Before disconnecting the pipings and wiring har-
nesses, put tags to them and write the mounting
positions.
from leaking.
6. Lift off drive shaft assembly (7).
1. Remove the rear drive shaft assembly. For a Remove the drive shaft assembly on the op-
posite side similarly.
4 Drive shaft assembly: 150 kg
details, see "Removal and installation of rear
drive shaft assembly".
2. Remove drain bolt (2) of differential case (1) to

drain the oil. [*1]
6 Differential case: 137 l
7. Disconnect brake sensor connectors (8) and (9).
3. Remove drain bolt (4) of final drive case (3) to

drain the oil. [*2]
4. Remove bolts (5) and lift off cover (6).

4 Cover: 40 kg
6 HD785-7
8. Remove clamp (10) and brake piping (11). 14. Install guide bolts [1] to 3 places.
9. Remove piping (12). 15. Install forcing screws [18] to 3 places and sepa-
rate differential assembly (16) from differential
10. Disconnect hose (13) case (1). [*4]
11. Remove valve assembly (14) and its bracket

together and move them aside.
16. Lift off differential assembly (16).

4 Differential assembly: 1,150 kg
12. Remove slack adjuster assembly (15).
13. Loosen mounting bolts (17) of differential

assembly (16) . [*3]
HD785-7 7
Installation
q Carry out installation in the reverse order to re-
moval.
a Remove all the rust and dirt from the mating fac-
es.
[*1]
3 Drain plug: 127.4 – 176.4 Nm {13 – 18 kgm}
[*2]
3 Drain plug (at center of final drive case) :
127.4 – 176.4 Nm {13 – 18 kgm}
3 Drain plug (around final drive case) :
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
[*3]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*4]
a If guide bolt [1] and lever block [2] are used, dif-
ferential assembly (16) can be installed to differ-
ential case (1) easily.

5 Differential case: 137 l
8 HD785-7
Disassembly and assembly of 2) Remove mounting bolt (4) and retainer (5).
differential assembly 3) Remove the O-ring and coupling (6)
together.
4) Using forcing screws, remove cover (7).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
3 790-425-1670 Adapter t 1
D
4 792-525-3000 Micrometer t 1
3
792-622-1110 Bracket t 1
H
4 790-425-1660 Wrench t 1
5 792-201-7010 Wrench t 1
Disassembly 5) Remove dust seal (8) from cover (7).

1. Set differential assembly (1) to tool H3.
2. Remove mounting bolts (2).
4. Disassembly of pinion and cage assembly

1) Remove cage (6) and inner bearing (10)
together from pinion gear (11).
3. Cage assembly
1) Remove cage assembly (3).
a Record the thickness and quantity of the
shims.
HD785-7 9
2) Remove inner bearing (13). 5. Differential gear assembly

1) Remove lock (16).
3) Remove bearing (13) from cage (6).

2) Using tool H4, loosen right and left side
bearing adjustment nuts (17) to the degree
that you can rotate them with the fingers.
4) Remove outer races (14) and (15).
3) Loosen mounting bolts (18) and remove caps

(19).
10 HD785-7
4) Lift off differential gear assembly (20). 3) Remove thrust washer (23).
5) Remove right and left side bearing adjust-
ment nuts (17).
4) Remove side gear (24).
q Disassembly of differential gear assembly

1) Remove the mounting bolts and case (21).
a Make positioning marks on the bevel gear
and case in paint.
5) Remove pinion gear assembly (25) and

cross shaft (26) together.
a Take care since the pinion gear assembly
comes off the cross shaft easily.
2) Remove bearing (22).
HD785-7 11
6) Fix pinion gear assembly (25) with a press 9) Remove bearing outer races (32) and (33)
and remove round nut (27) with tool H5. from pinion gear (29).
a Check the match No. of the bearing and
outer races and keep them as a set.
7) Pull out shaft (28) with the press and remove

bearing (30) from pinion gear (29).
10) Remove side gear (34).
8) Remove bearing (31) from shaft (28).

11) Remove thrust washer (35).
12 HD785-7
12) Remove bevel gear (37) from case (36). Assembly

13) Remove bearing (38) from the case. 1. Assembly of differential gear assembly
1) Install bevel gear (37) to differential gear
case (36).
3 Mounting bolt :
921.9 – 1,029.7 Nm {94.0 – 105.0 kgm}
2) Install side bearing (38).
a Heat the bearing to 100°C and install it by
shrink fit
a Check that there is not clearance be-
tween the bearing and case end.
3) Reverse the case and install thrust washer

(35), setting it to the dowel pin.
a Check that the dowel pin head is 0.5
(+0.2/-0) mm lower than the washer sur-
face.
5 Thrust washer: Engine oil (EO30)
HD785-7 13
4) Install side gear (34). 3] Set pinion gear (29) to shaft (28) and
install bearing (30).
5) Pinion gear
a When assembling the bearing and outer 4] Fix pinion gear assembly (25) with the
races, check their match No. press and tighten round nut (27) with tool
1] Press fit outer races (32) and (33) to H5.
pinion gear (29). 3 Round nut:
587.6 – 745.3 Nm {59.0 – 76.0 kgm}
2] Using the push tool, press fit bearing (31)

to shaft (28). 6) Install pinion gear assembly (25) to cross
shaft (26), and then sling and install them to
the case.
a When installing, set the notch of the pin-
ion gear shaft to the dowel pin of the case.
a Move the pinion gear to ensure that the
pinion gear assembly can be rotated light-
ly.
14 HD785-7
7) Install side gear (24). 10) Install case (21).

3 Mounting bolt :
823.8 – 1,029.7 Nm {84.0 – 105.0 kgm}
8) Install thrust washer (23), setting it to the

dowel pin.
a Check that the dowel pin head is 0.5
(+0.2/-0) mm lower than the washer sur- 2. Installation of differential assembly
face. 1) Tighten side bearing adjustment nut (17)
5 Thrust washer: Engine oil (EO30) lightly and place differential gear case
assembly (20) temporarily.
9) Install side bearing (22). 2) Install caps (19) and tighten mounting bolts
a Heat the bearing to 100°C and install it by (18).
shrink fit. 2 Mounting bolt: Adhesive (LT-2)
a Check that there is not clearance be- 3 Mounting bolt:
tween the bearing and case end. 1,520.0 – 1,912.3 Nm {155.0 – 195.0 kgm}
a Set the match marks of the caps.
a Rotate the bevel gear 20 – 30 turns to fit
the bearing, and then tighten the mount-
ing bolts gradually and evenly.
HD785-7 15
3) Adjustment of bearing preload 3] Add 0.4 ± 0.15 mm to the measured

1] Install tools D3 (POLE) to both sides of distance and set the micrometer memory
caps (19). to the obtained value.
a The obtained distance is the deflec-
tion of the case before and after the
preload is given.
4) While taking care of the groove for the lock,
tighten adjustment nut (17) from both sides
with tool H4.
a At this time, lightly hit the bearing caps
and bevel gear with a plastic hammer to fit
the bearing while rotating the bevel gear.
2] Measure the distance between the

adapters with tool D4.
a Hold the micrometer securely with one
hand and apply the probe to tool D3
(POLE) in parallel.
5) Press push-pull scale [2] against the

periphery of the bevel gear and measure the
starting tangential force in the tangential
direction.
Reference starting tangential force:
23.5 – 47 N {2.4 – 4.8 kg}
a If the starting tangential force is below the
reference value, tighten the adjustment
nuts on both sides with tool H4. If the for-
mer exceeds the reference value, loosen
the adjustment nuts on both sides and re-
tighten them to adjust.
16 HD785-7
a Precautions for adjusting preload 2) Press fit bearing inner race (13) and install
If the adjustment nut was tighten too spacer (12).
much and the deflection increase a Shrink fit: 100°C
exceeded the standard dimension, return a When installing, check the match No.
the adjustment nut to the position before a Check that there is not clearance in (C3)
adjustment. Then, while rotating the between the pinion gear and inner bear-
bevel gear, hit the bearing cap and bevel ing end.
gear lightly with a plastic hammer, check
that there is not clearance in (a) and (b),
and adjust again.
3. Assembly of pinion cage assembly

1) Using the push tool, press fit outer races (14)
and (15) to cage (6).
a Check with thickness gauge (Thickness:
Max. 0.05 mm) that there is not clearance
in (C1) and (C2) between the outer race
and cage.
3) Set cage (6) to pinion gear (11) and install

bearing (10).
4) Apply sufficient amount of engine oil (EO30)
to the roller and rolling surfaces of the inner
race and outer race of the bearing.
HD785-7 17
4. Installation of pinion and cage assembly 5. Coupling

1) Fit the O-ring, set the shims, and install 1) Install coupling (4), fit the O-ring and retainer
pinion cage assembly (9) to the differential (3), and tighten bolt (2).
case. a At this time, while rotating the bearing 20
a Set the shims of the quantity and thick- – 30 turns, tighten bolt (2) gradually.
ness checked when disassembled. a If bolt (2) is tightened without rotating the
3 Mounting bolt: bearing, the bearing may be broken.
490 – 608 Nm {50 – 62 kgm} 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt :
1961.4 – 2451.8 Nm {200.0 – 250.0 kgm}
a After tightening bolt (2), rotate the bearing
20 – 30 turns again and check that it ro-
tates smoothly and bolt (2) is tightened to
the specified torque.
2) Install dust seal (8) to cover (5).
Ensure that the bearing is set normally with

either of the following devices.
Insert a bolt in one of the threaded holes of the
pinion cage and measure the starting torque in
the tangential direction with a push-pull gauge
[2] or a spring balance. (Measure before
installing the bevel gear.)
Standard starting torque:
Max. 50.01 Nm {Max. 5.1 kgm}
a If the starting torque is larger than the stan-
3) Install cover (5).
3 Mounting bolt:
dard value, adjust the quantity or thickness of
the shims to set the starting torque within the
490 – 608 Nm {50 – 62 kgm} standard value.
18 HD785-7
6. Adjustment of backlash
1) Apply the probe of dial gauge [3] to a tooth tip
of the bevel gear end perpendicularly.
2) Fix the bevel pinion and move the bevel gear
forward and backward (in the revolving direc-
tions) and read the dial gauge.
q Standard backlash: 0.41 – 0.56 mm
a Measure the backlash at 3 – 4 places and
ensure that the difference between the
measured values is 0.1 mm or less.
3) If the backlash is out of the standard range,

adjust it by moving the bevel gear.
a Move the bevel gear with tool H4 and ad-
justment nuts (17).
a If either adjustment nut is tightened (loos-
ened), loosen (tighten) the other adjust-
ment nut by the same angle so that the
preload applied to bearings (22) and (38)
(in step 3) will not change.
q When the backlash is below standard
value
Loosen adjustment nut (17) on the
bevel gear side and tighten adjust-
ment nut (17) on the right side by the
same angle
(to move the bevel gear in the direc-
tion of (A)).
q When the backlash is above standard
value
Loosen adjustment nut (17) on the
right side and tighten adjustment nut
(17) on the bevel gear side by the
same angle
(to move the bevel gear in the direc-
tion of (B)).
HD785-7 19
7. Testing of tooth contact If bevel pinion is too far from bevel gear
Apply red lead thinly to the surfaces of 7 – 8 a The tooth contact pattern is as follows.
teeth of the bevel gear and turn the bevel gear in 1) Reduce the shim to move the bevel pinion
the forward and reverse directions, then check close to the bevel gear.
the tooth contact pattern on the bevel gear. 2) Move the bevel gear away from the bevel
a The center of the tooth contact must be as pinion.
follows.
q Middle of tooth height
q Point on tooth at distance of (x) from small
end (C)
(X = 55 ± 7 mm) 2
a Width (y) of the tooth contact must be 43 – 88
mm.
q Distance from the tooth tip to tooth contact
part at distance (x)
z = 2.5 – 6 mm
a Check that there is not a strong contact at 1
tooth tip (A), bottom (B), small end (C), or
large end (D). 9J S02972
If bevel pinion is too close to bevel gear

a The tooth contact pattern is as follows.
1) Increase the shim to move the bevel pinion
away from the bevel gear.
2) Move the bevel gear close to the bevel
pinion.
8. Adjustment of tooth contact

If the tooth contact pattern is not proper, adjust
the tooth contact according to the procedure
shown on the following page.
1
a Adjust the toot contact by increasing or de-
creasing shim (6) (to move the bevel pinion) 9J S02973
and rotating the adjustment nuts (to move the
bevel gear: See Adjustment of backlash).
a After adjusting the tooth contact, check the
backlash again.
20 HD785-7
If bevel gear is too close to bevel pinion

1) Reduce the shim to move the bevel pinion
close to the bevel gear.
2) Move the bevel gear away from the bevel
pinion.
9J S02974
If bevel gear is too far from bevel pinion

1) Increase the shim to move the bevel pinion
away from the bevel gear.
2) Move the bevel gear close to the bevel
pinion.
9J S02975
9. Locks
Install locks (16) (right and left) of the adjustment
nuts.
HD785-7 21
HD785-7 Dump truck
©2009 KOMATSU
All Rights Reserved
22
SEN04641-00
HD785-7

HD785-7 7001 and up

Steering system
Removal and installation of steering cylinder assembly ................................................................................. 2
Disassembly and assembly of steering cylinder assembly ............................................................................. 3
Removal and installation of steering valve assembly ..................................................................................... 7
Disassembly and assembly of steering valve assembly ................................................................................. 8
HD785-7 1
Removal and installation of 7. Disconnect grease tube (5).

steering cylinder assembly 1 8. Pull out head pin (6).
q This section shows the removal and installa-
9. Remove the upper and lower rubber boots.
tion procedure for the left steering cylinder
[*2]
assembly. The right steering cylinder assem-
bly is removed and installed similarly to the left
10. Remove steering cylinder assembly (7).
one.
4 Steering cylinder assembly: 45 kg
Removal
1. Support the steering cylinder assembly with
hydraulic jack etc.
2. Disconnect grease tube (1).
3. Pull out bottom pin (2).

a Start the engine, steer to the left, and
retract the piston rod to disconnect the cyl-
inder bottom from the frame.
4. Remove the upper and lower rubber boots.

[*1]
5. Disconnect head hose (3). Installation

6. Disconnect bottom hose (4). removal.
[*1], [*2]
a When connecting the pin, install rubber boot
(8).
2 HD785-7
Disassembly and assembly of 3. Pull cylinder head and piston rod assembly (3)
out of cylinder (4).
steering cylinder assembly 1 a Prepare a container to receive oil which
flows out when the piston rod assembly is
Special tools
pulled out of the cylinder.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1
2 790-102-3802 Wrench assembly t 1
3 790-302-1340 Socket t 1
790-201-1810 • Push tool 1
4
790-101-5021 • Grip 1
U 01010-50816 • Bolt 1 4. Remove cylinder (4) from tool U1.
5. Disassembly of piston rod assembly
790-201-1620 • Push tool 1 1) Set piston rod assembly (3) to tool U1.
5
790-101-5021 • Grip 1 2) Using tool U3, remove nut (5).
a Width across flats of nut: 80 mm
01010-50816 • Bolt 1
6 790-720-1000 Expander t 1
7 796-720-1660 Ring t 1
8 07281-01159 Clamp t 1
Disassembly
1. Set cylinder assembly (1) to tool U1.
2. Raise lock (2) of the cylinder head nut. Using

tool U2, remove cylinder head assembly.
3) Remove piston assembly (6) and cylinder

head assembly (7) from rod (8).
HD785-7 3
6. Disassembly of piston assembly Assembly

1) Remove wear ring (9) from piston (10). a Apply engine oil to the sliding surfaces of each
2) Remove piston ring (11) from piston (10). part. When assembling, take care not damage
the packing, dust seal and O-ring.
1. Assembly of cylinder head assembly

1) Using tool U4, press fit bushing (15) to cyl-
inder head (16).
a When press fitting the bushing, take
extreme care not to deform it.
2) Install rod packing (14).
a Install the rod packing as shown in
the following figure.
3) Install backup ring (18) and O-ring (17) in
order.
a Do not install the backup ring forcibly.
7. Disassembly of cylinder head assembly Warm it in water at 50 – 60 °C before
1) Remove snap ring (12) and dust seal (13). installing it.
2) Remove rod packing (14). 4) Using tool U5, install dust seal (13) to cyl-
3) Remove bushing (15) from cylinder head inder head (16), and then install snap ring
(16). (12).
4) Remove O-ring (17) and backup ring (18).
2. Assembly of piston assembly

1) Using tool U6, expand piston ring (11).
a Set the piston ring to the tool and
rotate the handle 8 – 10 turns to
expand the piston ring.
2) Remove the piston ring from tool U6 and
install it to piston (10).
4 HD785-7
3) Set tool U7. Using tool U8, shrink the pis- 2) Using tool U3, tighten nut (5).
ton ring. 2 Nut: Adhesive (LOCTITE No. 262)
3 Nut:
3.97 ± 0.40 kNm {405 ± 40.5 kgm}
a Width across flats: 80 mm
3) Remove piston rod assembly (3) from tool
U1.
4) Install wear ring (9).
4. Set cylinder (4) to tool U1.
5. Install cylinder head and piston rod assembly

(3) to cylinder (4).
3. Assembly of piston rod assembly

1) Install cylinder head assembly (7) and pis-
ton assembly (6) to piston rod (8).
HD785-7 5
6. Using tool U2, tighten cylinder head nut (2).

3 Cylinder head nut:
931 ± 93.1 Nm {95 ± 9.5 kgm}
7. Tighten lock (2) of cylinder head nut.
6 HD785-7
Removal and installation of Installation

steering valve assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k loosen the oil filler cap gradually to release a When installing, rotate the steering wheel 1
the pressure inside the hydraulic tank. turn to increase the dimensions marked with *
a Pass a rope etc. through yoke (5) and sling the between yoke path (a) and floor (7) and
yoke so that the yoke will not come off the between column support (8) and hole (b) to at
spline of column shaft (4) . least 5 mm.
1. Loosen yoke fixing bolt (1).

a Since the fixing bolt has fine threads and
is a special one, take care not to apply
excessive force to it to damage its threads
or lose it.
a Ensure that yoke (5) can be moved up and
down lightly along spline (6) of the input
shaft and can be pulled out easily.
a If the input shaft of the steering valve is
hitted strongly, it may become eccentric
and that can cause a trouble.
2. Disconnect 5 hoses (2).
3. Remove steering valve assembly (3).

a Lift off the steering valve assembly with a
rope and take care not to drop it.
HD785-7 7
Disassembly and assembly of steering valve assembly 1
8 HD785-7
Special tools Disassembly

1. Remove 7 mounting bolts (1). Insert a flat-
New/Remodel
head screwdriver between end cover assem-
Necessity
Sym- bly (2) and sleeve (3) to remove end cover
Part No. Part name
Sketch
bol assembly (2).
Q'ty
a After removing the end cover assembly,
1 790-452-1200 Pilot ring tool t 1 check the edges of the end cover hole for
T breakage.
2 790-452-1100 Installer set t 1
a Cleanliness is essential to maintenance of the

power steering system. The hydraulic circuit
must be isolated from dirt and other foreign
matter.
a When disassembling any part of the unit, pre-
pare a clean worktable.
a Before disconnecting a pipe, wipe off the exter-
nal dirt from it.
a Before placing the unit on the worktable, be
sure to wipe off the external dirt from it.
a After disassembling the unit, clean the parts in
kerosene-based solvent containing no impurity
and dry them by blowing dry compressed air 2. Remove commutator (5) and washer (6) from
containing no impurity against them. end cover assembly (2).
a If any solvent other than the above is used, it a Do not remove pin (4).
can deteriorate the rubber seals. Never wipe
the parts with cloths or blow steam against the
unit.
a Since the solvent is combustible material, han-
dle it carefully and keep it off fire.
Preparation work
1) Install plugs to the 5 ports of housing
assembly (11) and clean the outside of the
housing, and then remove the plugs.
2) Install tube nut [1] to one of the ports.
3) Install the housing assembly to vise [2]
with end cover assembly (2) up.
a Do not hold housing assembly (11)
directly with the vise. If it is held so,
the unit may be broken.
HD785-7 9
3. Insert a flat-head screwdriver between sleeve 10. Remove upper cover assembly (19) from input
(3) and housing assembly (11) to remove shaft (18) and valve spool assembly (23).
sleeve (3).
4. Remove commutator ring (7) and manifold (8).
5. Remove roller assembly (9) and wear plate

(10).
6. Remove drive link (12) from housing assembly

(11).
7. Remove the spring and ball (13).
11. Remove shim (24) and spacer (25).
12. Remove snap ring (31), thrust washer (32),

thrust bearing (33), thrust washer (34) and
race (35) from input shaft (18).
8. Install housing assembly (11) to the vise with

input shaft (18) up and make match marks (A)
on upper cover (19) and housing assembly
(11) with a punch.
9. Remove 4 mounting bolts (20) and hold and

raise input shaft (18) to remove input shaft
(18), upper cover (19) and valve spool assem-
bly (23).
a Valve spool assembly (23) is fitted to
housing assembly (11) with very narrow
clearance between them. Accordingly, if it
is pressed sideway, it cannot be pulled out
completely. Take care.
a When removing the valve spool from the
housing, never apply an excessive force
to it.
10 HD785-7
13. Remove seal (26) and snap ring (27) and 16. Direct valve spool assembly (23) down and
remove seal kit (30) from upper cover (19). rotate input shaft (18) until drive ring (40)
comes off.
17. Direct valve spool assembly (23) down and

rotate input shaft (18) clockwise until ball (41)
comes off.
a Since ball (41) may come off by itself, take
care not to lose it.
14. Using pin punch [3] (ø 3.0 mm, l = Min. 16

mm), remove needle roller (36) from input shaft
(18).
a Perform this work on a wood block so that
the input shaft will not be damaged.
a Remove ball retaining spring (42) only

when replacing it.
a When removing ball retaining spring (42),
hold its flat end with pliers and raise it until
it is removed from valve spool assembly
(23).
a Take care not to damage the periphery of
valve spool assembly (23) and control
edge.
15. Direct valve spool assembly (23) down and

remove torsion bar assembly (37) and spacer
(38) from valve spool assembly (23).
a Do not remove needle roller (39) from tor-
sion bar assembly (37).
HD785-7 11
Assembly 4. Set thrust washer (34), thrust bearing (33) and

a Before assembling, wash all the parts in clean thrust washer (32) to input shaft (18) in this
based-based solvent and dry them by blowing order, and then install snap ring (31).
dry compressed against them. Never wipe a Thrust washer (32) is larger than thrust
them with cloths. washer (34).
a Check the edges of the lapped surface for
paint and dirt.
a Do not apply oil to the parts to be installed,
unless otherwise specified.
a Replace all the seals with new ones according
to this manual.
1. Install race (35) to input shaft (18).
2. Install ball (41) to the inside of valve spool

assembly (23).
5. Set the intermediate part of torsion bar assem-

bly (37) between thrust washer (34) and valve
spool assembly (23).
a If torsion bar assembly (37) is set as
above, valve spool assembly (23) and
input shaft (18) are positioned.
3. Insert input shaft (18) in valve spool assembly

(23) while rotating it counterclockwise so that
the ball will be fitted to its groove.
a Keep valve spool assembly (23) horizon-
tally during this work.
12 HD785-7
6. Check the splines of drive ring (40) and input 7. Measure diameter l of needle roller (39) of tor-
shaft (18), and then install drive ring (40), set- sion bar assembly (37) at several points.
ting it to the spline of valve spool assembly Check that the difference between measured
(23). diameters does not exceed 0.025 mm.
a If the splines of the drive ring and input
shaft (18) are not meshed with each other, 8. Set spacer (38) to torsion bar assembly (37)
rotate the input shaft (18) a little to mesh and insert them in the valve spool and input
them, and then insert the drive ring. shaft assembly (23).
a Set torsion bar assembly (37) securely.
9. Using pin punch [3] (ø 3.0 mm, l = Min. 16

a Rotate the input shaft (18) in the direction mm), align the pin holes of torsion bar (37) and
to project valve spool (23) (clockwise) until input shaft (18).
it stops. If the drive ring is installed cor-
rectly, a clearance of 8 – 9 mm is made 10. Using pin punch [3], drive needle roller (36) to
between thrust washer (34) and valve a depth of 0.8 mm from the end of input shaft
spool (23) at this time. (18)
a If drive ring (40) is not installed correctly, a Check that needle roller (39) is not pro-
the steering system does not work nor- jected from input shaft (18).
mally.
HD785-7 13
11. Install spacer (25) to valve spool assembly 15. Set tool T1 so that housing assembly (11) will
(23). be aligned with the upper cover.
a When installing spacer (25), direct lip sur-
face (C) at the end of inside of spacer (25) 16. Tighten the upper cover mounting bolts and
toward race (35). remove tool T1.
3 Mounting bolt:
12. Install the input shaft and valve spool assembly 27.0 ± 2.5 Nm {2.75 ± 0.25 kgm}
(23) to housing assembly (11). a Install the housing assembly to a vise with
a Valve spool assembly (23) is fitted to input shaft (18) down.
housing assembly (11) with very narrow
clearance between them. Accordingly, if it
is pressed sideway when installed, it may
not operate normally.
13. Set shim (24) on thrust washer (32). Apply

grease to new seal (21) and fix it to the groove
of upper cover (19).
14. Install upper cover (19), setting it to match

marks (A) made when it was removed, and
tighten mounting bolts (20) lightly.
17. Measure groove width l of drive ring (40) at

several points over the length and check that
the difference between the obtained values
does not exceed 0.025 mm.
18. Pull down and fix drive link (12) and mesh
drive ring (40) with the spline of the valve
spool, and then revolve the valve spool so that
its end will be flush with housing assembly
(11).
14 HD785-7
19. Remove drive link (12) and adjust its position 21. Before installing the rotor, check it according to
so that needle roller (36) of the torsion bar will the following procedure.
be in its groove. Then, insert drive link (12) in 1) Set end cover assembly (2) with the pin
valve spool (23). side up and set rotor assembly (9) with the
rotor spline side down.
2) Check that the rotor rotates freely in the
stator.
20. Using depth gauge [6], measure installed

height (h) of valve spool (23) above housing
assembly (11).
a If installed height (h) is 0.063 mm or less, 3) Measure thickness of rotor (16) and that of
do not adjust the shim. stator (9) and check that the difference
If installed height (h) is 0.064 mm or between them is 0.18 mm or less.
larger, disassemble and assemble again 4) Using thickness gauge [7], check that the
and adjust the shim so that (h) will be clearance between stator (9) and rotor
0.063 mm or less. (16) is 0.18 mm or less.
22. Lubricate a new seal and the seal groove with

grease and install ring (11A) and seal (11B) to
housing assembly (11) in order.
HD785-7 15
23. Install ball (13) and the spring. 28. Install washer (6) and commutator (5) to end
cover assembly (2).
24. Using guide pin [8], install wear plate (10), a Apply grease to commutator (5) so that it
rotor assembly (9), manifold (8) and commuta- will not fall even if is set down.
tor ring (7).
25. Lubricate the inside of both ends of sleeve (3)

and the seal installed to housing assembly (11)
with grease.
26. Install sleeve (3) to housing assembly (11).

a Install end cover assembly (2) to the end
of the sleeve, insert the sleeve vertically,
and tighten the mounting bolts.
a Install commutator (5) so that its hollow (e)

will be on the end cover assembly side.
a Position commutator (5) so that its oval

hole (f) and one of the bolt holes (g) of the
end cover assembly will be in line.
27. Remove end cover (2) and lubricate a new

seal and the seal groove with grease, and then
install ring (2A) and seal (2B) to end cover
assembly (2) in order.
16 HD785-7
29. Rotate the input shaft so that the end of drive 32. Direct the input side up and wind tapes onto
link (12) can be inserted in the oval hole of the serrated part of input shaft to protect the
commutator (5). seal kit (30). (Remove the tapes when install-
a Lubricate the seal in end cover assembly ing snap ring (27).)
(2) with grease.
33. Apply grease to the inside and outside of seal
30. Set end cover assembly (2) on sleeve (3) and kit (30) and install its parts in the order shown
tighten 5 mounting bolts (1) evenly. in the figure with the lip side on the inside of
3 Mounting bolt: the valve.
68.6 ± 5.9 Nm {7.0 ± 0.6 kgm}
a Tighten the mounting bolts in the diagonal
order so that the sleeve and end cover will
not slant while they are being installed.
31. Remove the guide pin and tighten the remain-

ing 2 bolts evenly.
3 Mounting bolt:
68.6 ± 5.9 Nm {7.0 ± 0.6 kgm}
HD785-7 17
a Use tool T2 to install spacer (28).

a Install snap ring (27) with the edged side
out.
18 HD785-7
HD785-7 19
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
20 HD785-7
SEN04642-01
HD785-7

HD785-7 7001 and up

Brake system
Removal and installation of front wheel hub and brake assembly .................................................................. 2
Disassembly and assembly of front wheel hub and brake assembly.............................................................. 6
Removal and installation of final drive and rear brake assembly .................................................................. 14
Disassembly and assembly of final drive and rear brake assembly ............................................................. 16
HD785-7 1
Removal and installation of front 3. Install tools J1 to 3 places equally spaced.

a Install tools J1 to protect the internal float-
wheel hub and brake assembly 1 ing seal.
Special tools
4. Remove plug (5) to drain the oil . [*1]
New/Remodel
5. Remove bolts (6) to remove cap (7). [*2]
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
01011-61670 Bolt t 2 N
1
01643-31645 Washer t 2 N
J
Coupler assem-
2 792-101-1430 t 1
bly
391-40-11560 Nipple t 1
Removal
a Before disconnecting the pipings and wiring
harnesses, put tags to them and write the
mounting positions.
a Prepare an oil receiver to receive oil flowing
out of the disconnected hoses and tubes.
from leaking.
1. Remove the front wheel assembly. For details,

see "Removal and installation of front wheel
assembly".
2. Install tool J2 to parking brake release oil

adapter (1) and apply oil pressure of 8.5 – 10
MPa {8.68 – 101.97 kg/cm²} to release the
parking brake.
a Never apply oil pressure higher than 10
MPa {10.97 kg/cm²}.
2 HD785-7
6. Remove clamp (9) of hose (8). 12. Loosen and remove mounting bolts (18a) of
hub bearing fixing plate (18), leaving 2 of them
at diagonal positions. [*3]
7. Remove clamp (10) and disconnect wiring har-

ness (11).
13. Sling wheel hub assembly (19).
8. Remove U-clamp (12) and tube (13).
a Hang tube (14) on the frame. 14. Insert a bar in the hole of bolt (18a), remove
the remaining 2 bolts, and remove hub bearing
fixing plate (18) toward this side, taking care
not to dropping it.
9. Disconnect tube (15) and hang it on the frame.
10. Remove slack adjuster (16).

15. Remove hub bearing assembly (20).
11. Remove wheel hub assembly mounting bolts
(17), leaving some of them. [*3]
HD785-7 3
16. Remove all the wheel hub mounting bolts left Installation
in step (13) and lift off wheel hub assembly q Carry out installation in the reverse order to
(21). removal.
4 Wheel hub assembly: 750 kg a Remove all the rust and dirt from the mating
faces.
[*1]
3 Drain plug: 58.8 – 78.4 Nm {6 – 8 kgm}
[*2]
3 Cap mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*3]
3 Hub mounting bolt:
490 – 608 Nm {50 – 62 kgm}
[*4]
3
17. Remove inside hub bearing (22).
Hub bearing fixing plate mounting bolt:
824 – 1,030 Nm {84 – 105kgm}
q Adjustment of hub bearing preload

1) Install retainer (18) with 3 mounting bolts
without setting the shim.
At this time, while rotating the hub 20 – 30
turns, tighten the mounting bolts gradually
and evenly to the specified torque.
3 Bolt (Specified value 1):
93.2 – 10.3 Nm {9.5 – 10.5 kgm}
2) Using depth gauge (C), measure distance
(B) from the retainer end face to the axle
end face.
a Set the retainer thickness as (A).
3) Calculate the shim thickness by the follow-
ing formula and insert shims of that thick-
ness.
q Shim thickness (T) mm: (B) – (A) +
0.2
4) Tighten the bolts to specified value 2.
3 Bolt (Specified value 2):
824 – 1,030 Nm {84 – 105 kgm}
5) Rotate the hub 20 – 30 turns and measure
the tightening torque.
a Repeat the above procedure until
specified value 2 is obtained.
4 HD785-7
a After tightening the bolts, rotate the

hub and ensure that it is free from
abnormality.

Add oil to the specified level. Run the engine
to circulate the oil. Then, check the oil level
again.
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from brake circuit".
HD785-7 5
Disassembly and assembly of 3. Remove front wheel hub assembly (2).

front wheel hub and brake a Make positioning marks on front wheel
hub assembly (2) and service brake
assembly 1 assembly (3) in paint.
4 Front wheel hub assembly: 160 kg
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
01011-61670 Bolt t 3
1
01643-31645 Washer t 3
J 01017-51620 Bolt t 8
2 01580-31613 Nut t 8
01643-31645 Washer t 8
Disassembly 4. Disassembly of front wheel hub assembly

1. Place front wheel hub and brake assembly (1) 1) Remove outer race (4).
with front wheel hub assembly (2) side up.
4 Brake assembly: 760 kg
2. Remove tools J1.

a Tool J1 was installed to protect the floating
seal when front wheel hub and brake
assembly (1) was removed from the
machine.
2) Reverse front wheel hub assembly (2).

3) Remove outer race (5).
4) Remove floating seal (6).
5) emove retainer (7).
6 HD785-7
5. Brake assembly
1) Remove oil seal (8).
2) Remove floating seal (9).
8) Remove 8 parking brake cover mounting

bolts (16).
9) Loosen the nuts of tools J2 gradually and
3) Reverse brake assembly (10). evenly to remove the bolts.
a Make positioning marks (a) on park- a If the nuts are not loosened gradually,
ing brake cover (11), parking brake the piston and cylinder may interfere
assembly (12) and service brake with each other.
assembly (13) in paint. 10) Remove parking brake cover (11).
4 Parking brake and service brake 4 Parking brake cover: 190 kg
assembly: 560 kg
4) Remove plug (14) and install tools J2
(bolt, nut and washer for releasing parking
brake manually) to eight places (in the
peripheral direction).
5) Tighten all the nuts of tools J2 gradually
and evenly to compress the parking brake
spring.
a Tightening length: Approx. 10 mm
a If the nuts are not tightened gradually,
the piston and cylinder may interfere
with each other.
3 Bolt and nut:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
11) Remove parking brake spring (17).
6) Remove 38 parking brake mounting bolts
(15).
a Do not remove parking brake cover
mounting bolts (16). (Their diameter
is smaller than that of the washers of
the parking brake mounting bolts.)
7) Remove parking brake assembly (12)
from service brake assembly (13).
4 Parking brake assembly: 400 kg
HD785-7 7
12) Remove parking brake piston (18) from 7. Plate and disc
parking brake housing (19). 1) Remove 2 lock plates (29).
4 Parking brake piston: 70 kg 2) Remove plate stuck with cork (30).
a Cork is stuck to one side of this plate.
13) Remove seal rings (20) and (21) and

backup rings (22) and (23) from parking 3) Remove disc (31).
brake piston (18).

6. Service brake assembly a There are 7 discs and 7 plates
1) Remove service brake piston (24). installed.
4 Service brake piston: 55 kg
backup rings (27) and (28) from the ser-
vice brake piston.
8 HD785-7
5) Remove plate (33). Assembly

a Both sides of this plate are polished. 1. Front wheel hub
Record its installed direction. 1) Place the inner gear.
4 Inner gear: 160 kg
2) Install outer race (5).
3) Install retainer (7).

3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
4) Install floating seal (6).
HD785-7 9
2. Service brake 5) Install 3 tools J1 from underside.

1) Place the outer gear. a Tighten until the inner gear assembly
4 Outer gear: 160 kg is fitted to the outer gear assembly.
2) Install floating seal (9) to the outer gear. Tightening distance: Approx. 3 mm
a Wipe off the oil from the mounting a Do not remove tools J1 until installed
portion. (If oil is sticking to the mount- to the machine.
ing portion, the floating seal may fall
when the outer gear assembly is
reversed.)
3) Install oil seal (8).
6) Disc and plate

1] Install plate (33).
a Install the plate in the direction
when removed.
4) Reverse outer gear assembly (34) and
install it to inner gear assembly (2).
a Take care that the floating seal will
not fall.
2] Install disc (31) and plate (32).
10 HD785-7
3] Install plate stuck with cork (30). 2) Install seal rings (20) and (21) and backup
a Install this plate with the cork rings (22) and (23) to piston (18).
side up. a Install seal ring (20) to the pressure
receiving side (inside).
4] Install lock plate (29).

3) Install piston (18) to housing (19).
4 Piston: 70 kg
3. Parking brake
1) Install housing (19).
4 Housing: 80 kg 4) Install spring (17).
HD785-7 11
5) Fit the O-ring to parking brake cover (11) 4. Service brake piston
and install them to the piston housing 1) Install seal rings (25) and (26) and backup
assembly. rings (27) and (28) to service brake piston
4 Cover: 190 kg (24).
a Install the seal rings to the pressure
6) Install tools J2 to 8 places (in the periph-

eral direction).
7) Tighten all the nuts of tools J2 gradually 2) Sling and place service brake piston (24)
and evenly to pull up the parking brake on the service brake assembly.
piston. 4 Service brake piston: 55 kg
with each other.
3 Bolt and nut:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
8) Install parking brake cover mounting bolts
(16).
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
5. Sling and install parking brake assembly (12)

to service brake assembly (13).
12 HD785-7
6. Install parking brake mounting bolts (15).

3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
7. Loosen the nuts of tools J2 gradually and

evenly and remove tools J2.
a If the nuts are not loosened gradually, the
piston and cylinder may interfere with
each other.
8. Install plug (14) to the mounting hole.

3 Plug: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
9. Adjustment of preload
Adjust the preload on bearing (35) after install-
ing to the machine.
(See "Removal and installation of front wheel
hub and brake assembly".)
HD785-7 13
Removal and installation of final 4. Remove clamps (5) and (6).

drive and rear brake assembly 1 5. Disconnect brake tube (7), lubrication hose (8)
and sensor wiring harness (9).
Removal
mounting positions.
from leaking.
1. Remove the rear wheel. For details, see

"Removal and installation of rear wheel". 6. Make positioning marks on the final drive case
and axle housing in paint. [*2]
2. Remove drain plug (2) of final drive carrier
case (1) to drain the oil. [*1] 7. Remove mounting nuts (11), leaving several of
6 Drive case: 64 l them. [*3]
3. Remove the drive shaft assembly. For details,

see "Removal and installation of final drive car-
rier assembly".
a Install cover (3) temporarily to prevent
dust from entering.
8. Sling final drive and rear brake assembly (4)

with a lift truck.
a Sling the assembly by 2 points at the front
and rear and balance it.
14 HD785-7
9. Remove the nuts left in step 7 and push out Installation

stud bolts (12) evenly with hydraulic puller [1]. q Carry out installation in the reverse order to
removal.
a Remove all the rust and dirt from the mating
faces.
[*1]
3 Drain plug (at center of final drive case):
127.4 – 176.4 Nm {13 – 18 kgm}
3 Drain plug (around final drive case):
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
[*2]
a Since there are escape holes for bolts (14) on
the brake side. Take care of the mounting
10. Move the lift truck slowly in reverse to remove position.
final drive and rear brake assembly (13).
4 Final drive and rear brake assembly:
3,800 kg
[*3]
3 Mounting nut:
1,180 – 1,470 Nm {120 – 150 kgm}

q Bleeding air from brake circuit

Bleed air from the brake circuit. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
HD785-7 15

final drive and rear brake
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
01011-61670 Bolt t 3
1
01643-31645 Washer t 3
J 01017-51620 Bolt t 9 5) Remove retainer (5).
2 01580-31613 Nut t 9
01643-31645 Washer t 9
Disassembly
1. Final drive carrier assembly and ring gear
1) Place rear axle assembly (3) with final
drive carrier assembly (51) up.
a Place support stands under the shaft,
too.
k Place the rear axle assembly verti-
cally and stably so that the final
drive and rear brake assembly will
not fall down. 6) Remove shims (6).
4 Final drive and rear brake assem- a Record the thickness and quantity of
bly: 2,900 kg the shims.
2) Remove the cover.
4 Cover: 40 kg
3) Remove carrier assembly mounting bolts
(52).
4) Remove final drive carrier assembly (51).
16 HD785-7
7) Lift off ring gear assembly (4). 4) Remove outer races (11) and (12).
4 Ring gear assembly: 350 kg
4 Bearing: 50 kg
3. Shaft
1) Install tools J1 to 3 places equally spaced.
a Install tools J1 to protect the internal
floating seal.
2) Sling rear brake and shaft assembly (13)
and remove the support stands under the
shaft.
4 Rear brake and shaft assembly:
1,900 kg
3) Lift off shaft (1).
4 Shaft: 750 kg
2. Rear axle case

1) Sling rear axle case (8).
a Make positioning marks on rear axle
case (8) and brake assembly (9) in
paint.
2) Remove rear axle case mounting bolts
(10).
3) Lift off rear axle case (8).
k When slinging, take care that the 4) Make positioning marks on service brake
shaft will not overturn. assembly (15), parking brake cylinder (16)
4 Rear axle case: 1,000 kg and parking brake cover (17) in paint.
4 Rear brake assembly: 1,150 kg
HD785-7 17
4. Parking brake 5) Remove plug (20).

4 Bearing: 50 kg
6) Install tools J2 to 9 places equally spaced

(in the peripheral direction).
2) Remove floating seal (19). 7) Tighten all the nuts of tools J2 gradually
and evenly to compress the parking brake
spring.
with each other.
3 Bolt and nut:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
8) Remove 45 parking brake mounting bolts
(21).
a Leave parking brake cover mounting
bolts (22) which have the washers of
a smaller diameter.
3) Reverse brake assembly (9).

4 Brake assembly: 1,100 kg
4) Remove stud bolts (53).
18 HD785-7
9) Lift off parking brake assembly (23). 14) Remove parking brake piston and parking
4 Parking brake assembly: 495 kg brake cylinder assembly (25) and service
brake piston (26).
4 Parking brake piston and parking
brake cylinder assembly: 310 kg
4 Service brake piston: 80 kg
10) Remove parking brake cover mounting

bolts (22).
evenly to remove tool J2.
a If the nuts are not loosened gradually, 15) Remove parking brake piston (27).
4 Parking brake piston: 95 kg
with each other.
12) Remove parking brake cover (17).
4 Parking brake cover: 210 kg

backup rings (30) and (31) from parking
brake piston (27).
13) Remove parking brake spring (24).
HD785-7 19
5. Service brake 5) Remove plate (39).

1) Remove seal rings (32) and (33) and a There are 9 discs and 8 plates
backup rings (34) and (35) from the ser- installed.
vice brake piston (26).

2) Remove fixing plates (36). a The spacer side of plate (40) is pol-
3) Remove plate stuck with cork (37). ished. Record its installed direction.
4) Remove disc (38). 7) Remove spacer (41).

4 Spacer: 20 kg
20 HD785-7
8) Remove mounting bolts (42) and inner 12) Remove floating seal (47) from cage (46).
gear (43). 13) Reverse the cage.
4 Inner gear: 60 kg 4 Cage: 130 kg
14) Remove floating seal (48) from cage (46).
9) Sling outer gear (44) and remove tools J1.

10) Remove outer gear (44).
4 Outer gear: 200 kg
11) Reverse outer gear (44) and remove float-

ing seal (45).
HD785-7 21
Assembly 5) Install inner gear (43) and mounting bolts

1. Service brake (42).
1) Install floating seals (47) and (48) to cage 4 Inner gear: 60 kg
(46). 3 Mounting bolt:
1,529 – 1,910 Nm {155 – 195 kg}
2) Install floating seal (45) to outer gear (44).

6) Install spacer (41).
4 Spacer: 20 kg
3) Install outer gear (44) to cage (46).

4 Outer gear: 200 kg
4) Fix outer gear (44) and cage (46) with 7) Install plate (40).
tools J1. a Install the plate in the direction when
a Tighten until the inner gear assembly removed.
is fitted to the outer gear assembly.
q Tightening distance:
Approx. 3 mm
a Do not remove tools J1 until the shaft
i s i ns tal l ed or t he ou t er g ea r i s
installed to the machine.
22 HD785-7
8) Install disc (38). 12) Install seal rings (32) and (33) and backup
rings (34) and (35) to service brake piston
(26).
9) Install plate (39).

a Install the 9 discs and 8 plates alter-
nately.
13) Install service brake piston (26).
10) Install plate stuck with cork (37).

a Direct the cork side toward the piston.
11) Install fixing plate (36). 2. Parking brake
1) Install seal rings (28) and (29) and backup
rings (30) and (31) to piston (27).
HD785-7 23
2) Install piston (27) to parking brake cylinder 5) Install tools J2 to 9 places equally spaced
(16). (in the peripheral direction).
a If the piston is installed to the cylinder 6) Tighten all the nuts of tools J2 gradually
diagonally, their sliding surfaces will and evenly to compress the parking brake
be scratched. Take care. spring.
4 Piston: 95 kg a If the nuts are not tightened gradually,
with each other.
3 Bolt and nut:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
7) Install cover mounting bolts (22).
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
3) Install springs (24).
8) Install parking brake assembly (23) to ser-

vice brake assembly (15).
4) Install parking brake cover (23) to service

brake assembly (15).
4 Cover: 210 kg
24 HD785-7
9) Install 45 parking brake mounting bolts 13) Reverse the brake assembly.
(21). 14) Install floating seal (19).
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
evenly to remove tool J2.
a If the nuts are not loosened gradually,
with each other.
15) Install bearing (18).

4 Bearing: 50 kg
11) Install plug (20).

3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3. Shaft
1) Place shaft (1) with the flange down.
4 Shaft: 750 kg
12) Install stud bolts (53).
HD785-7 25
2) Sling brake assembly (9). 2) Reverse rear axle case (8), sling it, and
4 Brake assembly: 1,100 kg install it to brake assembly (9).
a Place blocks about 400 mm high 4 Rear axle case:1,000 kg
under the brake assembly. Rear axle case mounting bolt:
490 – 608 Nm {50 – 62 kgm}
3) Sling shaft (1) and install it to the brake

assembly. 3) Install outer race (11).
4. Case 5. Ring gear

1) Install outer race (12). 1) Install bearing (7) to ring gear (4).
(Install outer race (11) later.) 4 Bearing: 50 kg
26 HD785-7
2) Install ring gear assembly (4) to rear axle 3) Measure the distance (depth Dt) from the
case (8). end of spacer (5) to the end of shaft (14).
4 Ring gear assembly: 350 kg 4) Remove the 4 mounting bolts and retainer.
5) Measure the thickness of the retainer at 3
places and set the average as (Pt).
6) Adjust the quantity of the shims so that
their total thickness (St) = (Dt) – (Pt) + 0.3,
and install them as shim (6).
6. Adjustment of bearing preload

1) Install retainer (5) and tighten 4 mounting
bolts (49) without setting the shim.
3 Bolt: 58 – 68 Nm {5.9 – 6.9 kgm}
2) While rotating ring gear (4) 20 – 30 turns,
tighten the 4 mounting bolts gradually and
evenly to the specified torque.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
HD785-7 27
7) Install retainer (5) and tighten the mount-

ing bolts.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
7. Install final drive carrier assembly (51).

1) Tighten carrier assembly mounting bolts
(52).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
2) Install the cover.
4 Cover: 40 kg
28 HD785-7
HD785-7 29
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
30 HD785-7
SEN04643-01
HD785-7

HD785-7 7001 and up

Undercarriage and frame
Removal and installation of front wheel assembly .......................................................................................... 2
Removal and installation of rear wheel assembly ........................................................................................... 4
Removal and installation of front suspension cylinder assembly .................................................................... 6
Disassembly and assembly of front suspension cylinder assembly (cylinder with buffer ring) ....................... 8
Removal and installation of king pin ..............................................................................................................11
Removal and installation of rear suspension cylinder assembly................................................................... 13
Disassembly and assembly of rear suspension cylinder assembly .............................................................. 14
HD785-7 1
Removal and installation of front 2. Insert the fork of a lift truck under wheel
assembly (2).
wheel assembly 1
3. Secure wheel assembly (2) with wires, chain
Removal
k
block [3], etc.
Stop the machine on a level ground, set the
4. Remove wheel nuts (3). [*1]
1. Set hydraulic jack [1] (50 t) under frame (1)

and raise the machine to float front wheel
assembly (2).
5. Move the lift truck slowly in reverse to remove

wheel assembly (2).
4 Wheel assembly (2): 1,200 kg
a Set blocks [2] under the right and left of the

frame to support.
k The removed wheel assembly should

be placed flat on its side in a safe
place. When resting it against some-
thing, put chocks under it to prevent it
from falling down.
2 HD785-7
Reference: Procedure for jacking up either front Installation

wheel q Carry out installation in the reverse order to
q The figure shows the left side. removal.
1) Set hydraulic jack [1] (50 t) to holder (4) under
the king pin. [*1]
q Put steel plate [2] etc. between holder (4) a Remove all the rust and dirt from the mating
and jack [1] to disperse the surface pres- faces of the wheel assembly and hub.
sure. a Tighten the wheel nuts evenly in the numerical
Caution: q Set steel plate [2] so that order shown in the following figure.
it will not contact bolt (5). 3 Wheel nut:
q Do not set the hydraulic 1,519 – 1,852 Nm {155 – 189 kgm}

jack to A-frame (6). If it is
set so, the A-frame will be
deformed or damaged by
the load.
2) Set stand [3] under frame (7) to stabilize the
machine.
a After installing the wheel assembly, travel

about 5 km and check that the wheel nuts are
tightened to the specified torque.
3) While checking stability, jack up carefully to

raise the wheel.
HD785-7 3
Removal and installation of rear 3. Remove air valve locknut (4) and plate (5).
wheel assembly 1 4. Insert the fork of a lift truck under wheel
assembly (6).
Removal
5. Secure wheel assembly (6) with wires, chain
block [3], etc.
k
6. Remove wheel nuts (7). [*1]
Disconnect the cable from the negative (–)
1. Fix poke ejector (2) to body (1) with the

attached pin.
2. Set hydraulic jack [1] (50 t) under axle (3) and

raise the rear wheel.

wheel assembly (6).
4 Wheel assembly: 1,200 kg
a Set blocks [2] under the right and left of the

body (1) to support.
k The removed wheel assembly should

be placed flat on its side in a safe
place. When resting it against some-
thing, put chocks under it to prevent it
from falling down.
4 HD785-7
8. Similarly to the outside wheel, secure wheel Reference: Procedure for jacking up either rear
assembly (8) with wires, chain block [3], etc. wheel
q The figure shows the left side. (Condition after
9. Remove wheel nuts (9). [*2] the wheel is removed is shown.)
1) Seat the body.
2) Set hydraulic jack [1] (50 t) to rear axle (3).
q Put steel plate [2] etc. rear axle (3) and
jack [1] to disperse the surface pressure.
3) Set stand [3] under the frame to stabilize the
machine.
4) While checking stability, jack up carefully to

raise the wheel.
Installation
removal.
wheel assembly (8). [*1], [*2]
4 Wheel assembly: 1,200 kg a Remove all the rust and dirt from the mating
faces of the wheel assembly and hub.
a Tighten the wheel nuts evenly in the numerical
order shown in the following figure.
3 Wheel nut:
1,519 – 1,852 Nm {155 – 189 kgm}
a After installing the wheel assembly, travel

about 5 km and check that the wheel nuts are
tightened to the specified torque.
HD785-7 5
Removal and installation of front 4. Disconnect hoses (4) (yellow), (5) (red), (6)
(black) and (7) (green) going to the auto sus-
suspension cylinder assembly 1 pension cylinders.
Removal
mounting positions.
from leaking.
1. Remove the front wheel hub and brake assem- 5. Using a lift truck, sling the front suspension cyl-
bly. For details, see "Removal and installation inder assembly with wires, lever blocks, etc.
of front wheel hub and brake assembly".
a When removing brake tube (1), remove 6. Set hydraulic jack [1] (50 t) under knuckle arm
stay (2), too. (8).
2. Release the nitrogen gas. 7. Remove 8 lower bolts (9) of knuckle arm (8).
a See Testing and adjusting, "Testing and [*1]
adjusting front suspension cylinder",
Releasing nitrogen gas.
3. Disconnect pressure sensor connector (3).
6 HD785-7
8. Disconnect grease supply hose (10) at the cyl- Installation

inder top. q Carry out installation in the reverse order to
removal.
9. Remove bolt (11) and pull out pin (12). [*2] k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
[*1]
3 Mounting bolt:
2,450 – 3,040 Nm {250 – 310 kgm}
[*2]
3 Pin fixing bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Before operating the steering system after
installing the front suspension cylinder assem-
bly, be sure to charge the front suspension cyl-
inder with nitrogen gas and adjust it, referring
10. Move the lift truck slowly in reverse to remove to Testing and adjusting, "Testing and adjusting
front suspension cylinder assembly (13). front suspension cylinder".
a
4 Front suspension cylinder assembly:
Bleed air from the brake circuit. For details,
see Testing and adjusting, "Bleeding air from
750 kg
brake circuit".
HD785-7 7
Disassembly and assembly of 2. Drain the cylinder oil.

front suspension cylinder 6 Cylinder: 29.8 l
assembly (cylinder with buffer

3. Remove air intake valve (1) and oil level valve
ring) 1 (2).
Special tools 4. Removal of cylinder rod assembly
1) Remove flange mounting bolts (3) and air
New/Remodel
bleeding valve (4).
Necessity
Sym-
Part No. Part name 2) Sling cylinder rod assembly (5), plate (6),
Sketch
bol
retainer (7) and flange (8) together.
Q'ty
792T-650-1110 Push tool t 1 5. Disassembly of flange
1 790-101-5421 Grip t 1 1) Remove plate (6), retainer (7) and flange
(8) from rod assembly (5).
01010-51240 Bolt t 1
2) Remove dust seal (9) and bushing (10)
Q 790-610-1000 Suspension tool t 1 from retainer (7).
• Pump assem- 3) Remove U-packing (11), buffer ring (14)
2 790-610-1100 1
bly and bushing (12) from flange (8).
6. Remove wear ring (13) from cylinder rod (5).
Disassembly
q Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
8 HD785-7
Assembly k Buffer ring (14) is divided into 2 pieces. Set

(See the figure for disassembly, too.) the round side of [2] (black) into [1] (blue).
q The arrow indicates the direction of the pres-
1. Installation of wear ring sure.
Install wear ring (13) to cylinder rod (5).
2 Outside of wear ring: Engine oil (EO10)
2. Assembly of flange
1) Using tool Q1, press fit bushing (12) to
flange (8) and install U-packing (11) and
buffer ring (14)
2 Inside of bushing:
Engine oil (EO10)
a When installing the U-packing, check
that there are 4 projections on the top
of the inside lip.
2) Press fit bushing (10) to retainer (7) and

install dust seal (9).
a When press fitting the bushing, take
care not to deform it.
2 Periphery of seal: Adhesive (LT-2)
3. Assembly of cylinder rod assembly

1) Install flange (8), retainer (7) and plate (6)
to the cylinder rod.
2 Mating faces of flange and retainer:
a Apply the gasket sealant evenly to
a Apply rust-preventive oil to part (A) hatched part (B) and apply it thinly to
indicated with 2-dot chain lines on the U-packing (C) so that it will not be
periphery of the U-packing (NISSEKI projected.
P1300 or equivalent).
HD785-7 9
2) Using a block, erect the cylinder. 5. Cover

a Fill the cylinder with engine oil. Install the dust cover.
5 Cylinder: 29.8 l (EO10) a The dust cover consists of 2 pieces.
3) Sling cylinder rod assembly (5) and install Reduce the clearance between them to
it to the cylinder. 0.5 mm or less.
a If the rod assembly is inserted too
deep, the oil spouts out. Stop it to a
position where the oil does not spout
out.
a Charge the front suspension cylinder
with nitrogen gas and adjust it. For
details, see Testing and adjusting,
"Testing and adjusting front suspen-
sion cylinder".
4) Install flange (8), retainer (7) and plate (6)
to the cylinder with bolts (3).
3 Mounting bolt:
157 – 196 Nm {16.0 – 20.0 kgm}
5) Install air bleeding valve (4).
3 Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install oil level valve (2) and air intake valve

(1).
3 Oil level valve:
39.2 – 49.0 Nm {4 – 5 kgm}
3 Air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
10 HD785-7
Removal and installation of king 7. While looking at A-frame (13) from below,
straighten lock plate (7) of the king pin mount-
pin 1 ing bolt.
Removal
k
8. Remove the king pin (11) mounting bolt (7) and
holder (10). [*3]
1. Loosen bolt (9) of knuckle arm (8). [*1]
2. Disconnect grease tube (1).
3. Disconnect bolt (2), pull out pin (3), and dis-

connect tie rod (4).
4. Pull out pin (5) and disconnect steering cylin-

der (6). [*2]
9. Lower the jack under the A-frame gradually.
5. Support wheel hub assembly (12) with a fork-
lift. 10. Support knuckle arm (8) with an engine jack
a Fix wheel hub assembly (12) securely to etc., remove mounting bolt (9) which has been
the fork of the forklift with a chain block loosened, and lower and remove knuckle arm
etc. (8) gradually.
4 Knuckle arm: 170 kg
6. Support A-frame (13) with an engine jack etc.
11. Using a press, remove the king pin (11) from
knuckle arm (8).
HD785-7 11
Installation
removal.
[*1]
3 Mounting bolt:
2,450 – 3,040 Nm {250 – 310 kgm}
[*2]
a Install the rubber boot. For details, see
"Removal and installation of steering cylinder".
[*3]
a Tighten all the bolts evenly to the specified
torque in several times.
a Bend the lock plate to lock.
k Bend each lock plate securely so that it will
be fitted to a side of the bolt head.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
12 HD785-7
Removal and installation of rear Installation

suspension cylinder assembly 1 q Carry out installation in the reverse order to
removal.
Removal k When aligning the pin holes, use a bar.
k Stop the machine on a level ground, set the Never insert your fingers in the pin holes.
tion, and lock the tires with chocks. [*1]
3
k Raise the body and fix it with the lock pin. Oil level valve: 39 – 49 Nm {4 – 5 kgm}
terminal of the battery. [*2]
3 Mounting band:
1. Release nitrogen gas. [*1] 6.8 ± 0.49 Nm {0.7 ± 0.05 kgm}
a For details, see Testing and adjusting,
"Testing and adjusting rear suspension [*3]
3 Bolt: 245 – 309 Nm {25 – 31.5 kgm}
cylinder".
a Charge the rear suspension cylinder with nitro-
2. Disconnect pressure sensor connector DT2 gen gas and adjust it. For details, see Testing
(1). and adjusting, "Testing and adjusting rear sus-
pension cylinder".
3. Remove guard (2). [*2]
4. Remove pin (3) on the rear suspension cylin-

der head side.
5. Sling rear suspension cylinder assembly (7)

with a lift truck
6. Remove bolt (5) and pin (6) on the rear sus-

pension cylinder rod side. [*3]
7. Disconnect grease supply hose (4).
8. Sling and remove rear suspension cylinder

assembly (7) with the lift truck.
4 Rear suspension cylinder assembly:
250 kg
HD785-7 13

rear suspension cylinder
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-650-1110 Push tool t 1
1 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Q 790-610-1000 Suspension tool t 1
• Pump assem-
2 790-610-1100 1
bly
Disassembly
1. Guard
Sling the cylinder assembly, loosen clamp (1),
undo buttons (2), and remove guard (3).
2. Air intake valve and oil level valve

See "Removal and installation of rear suspen- 4. Cylinder rod assembly
sion cylinder assembly". 1) Erect the cylinder assembly upside down.
Remove cover (4), air intake valve (5a), and oil 2) Remove the mounting bolt of retainer (6).
level valve (5b). 3) Slowly sling and remove cylinder rod
assembly (7), retainer (6) and flange (8)
3. Drain the cylinder oil. together from cylinder (9).
6 Cylinder: 16.5 l
14 HD785-7
5. Flange and retainer Assembly

1) Remove retainer (6) and flange (8) from 1. Wear ring
cylinder rod assembly (7). Install wear ring (15) to rod (16).
2) Remove U-packing (10), buffer ring (17),
backup ring and O-ring (11) from flange
(8).
3) Remove bushing (12) from flange (8).
4) Remove seal (13) and bushing (14) from
retainer (6).
2. Flange
1) Using tool Q1, install bushing (12) to
flange (8).
2) Install U-packing (10) and buffer ring (17)
to flange (8).
a Apply rust-preventive oil to part "A" on
6. Wear ring the periphery of the U-packing (NIS-
Remove wear ring (15) from rod (16). SEKI P1300 or equivalent).
k Buffer ring (17) is divided into 2
pieces. Set the round side of [2]
(black) into [1] (blue).
3) Install backup ring and O-ring (11) to
flange (8).
HD785-7 15
3. Retainer 4) Install retainer (6) and flange (8) together

1) Install seal (13) to retainer (6). to cylinder (9) with the mounting bolts.
2 Periphery of seal: Adhesive (LT-2) 3 Mounting bolt:
2) Using tool Q1, install bushing (14) to 157 – 196 Nm {16.0 – 20.0 kgm}
retainer (6).
5. Air intake valve and oil level valve

4. Cylinder rod assembly 1) Set the cylinder assembly upside down
1) Using a block, erect cylinder (9). (Set the rod side down).
2) Sling cylinder rod assembly (7) and install 2) Sling the cylinder until dimension (D) on
it to cylinder (9). the rod side becomes as follow.
3) Install flange (8) and retainer (6) to cylin- Without buffer ring: 140 ± 3 mm
der rod assembly (7). With buffer ring: 124 ± 3 mm
2 Mating faces of flange and retainer:
a Apply the gasket sealant evenly to hatched
part (B) and apply it thinly to U-packing (C) so
that it will not be projected.
16 HD785-7
3) Supply oil through the oil level port with

the oil level pump and spout oil from the
air intake port until bubbles do not come
out any more.
4) After supplying oil, install oil level (5) and
air intake valve (4).
3 Air intake valve:
39 – 49 Nm {4 – 5 kgm}
3 Oil level valve:
39 – 49 Nm {4 – 5 kgm}
5) Install cover (3).
6. Guard
1) Install guard (3) and fix button (2) to
tighten clamp (1).
3 Clamp:
6.8 ± 0.49 Nm {0.7 ± 0.05 kgm}
HD785-7 17
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
18 HD785-7
SEN04644-00
HD785-7

HD785-7 7001 and up

Hydraulic system
Removal and installation of hoist valve assembly........................................................................................... 2
Disassembly and assembly of hoist valve assembly ...................................................................................... 3
Disassembly and assembly of hoist cylinder assembly .................................................................................. 5
HD785-7 1
Removal and installation of hoist 5. Remove clamp (7) and tank return tube (8).
valve assembly 1 6. Remove U-clamp (9) and tube (10) coming
from the steering control valve.
Removal
a Remove the U-clamp at the lower part of
tube (10), too.
k Disconnect the cable from the negative (-)
mounting positions.
from leaking.
a Prepare an oil receiver to receive oil flowing
out of the disconnected hoses and tubes.
a Loosen the hydraulic tank cap to release the
pressure inside the tank.
7. Remove mounting bolts (11) and lift off hoist
1. Disconnect tube (1). valve assembly (12).
4 Hoist valve assembly: 65 kg
2. Disconnect tube (2) going to the hoist cylinder

bottom.
a Loosen the mounting bolt gradually to Installation
release the pressure inside the tube. q Carry out installation in the reverse order to
removal.
3. Remove clamp (3) and disconnect hoses (4) q Clean the mating faces of the tube and hoses
and (5). when installing.
4. Remove tube (6) going to the hoist cylinder

head.
2 HD785-7
Disassembly and assembly of hoist valve assembly 1

Disassembly
1. Housing assembly 2. Spring case assembly

1) Remove housing (2) from body (1). 1) Remove spring case (18) from body (1)
2) Loosen nut (3). and then remove springs (19) and (20)
3) Remove screw (4), spacer (5), spring (6) and retainer (21).
and poppet (7). 2) Remove spring case (22) from body (1)
4) Remove plug (8). and then remove retainer (23).
5) Loosen sleeve (9) and remove spring (10), 3) Remove plug (24).
seat (11), piston (12), spring (13), seal 4) Remove flange (25) from spring case (22),
(14), poppet (15), sleeve (16) and orifice t hen r emov e sp ri ngs ( 26) and ( 27) ,
(17). retainer (28) and spring (29).
3. Body assembly
1) Remove spool (30) and plug (31) from
body (1).
2) Remove seat (32), spring (33) and valve
(34) from body (1).
HD785-7 3
Assembly
a Clean all the parts carefully and remove burrs. 3. Housing assembly
a Apply engine oil to the sliding parts before 1) Install orifice (17), sleeve (16), poppet
installing. (15), seal (14), spring (13), piston (12),
seat (11) and spring (10) to housing (2)
1. Body assembly and tighten sleeve (9).
1) Install valve (34), spring (33) and seat (32) 2) Tighten plug (8).
to body (1). 3) Install poppet (7), spring (6) and spacer
2) Install plug (31) and spool (30) to body (1). (5) and tighten screw (4) and nut (3).
4) Install housing (2) to body (1).
2. Spring case assembly 2 Mating faces of housing and body:
1) Install spring (29), retainer (28) and Sealant (LOCTITE #572 or 575 or
springs (27) and (26) to spring case (22) Sealend #242)
and then install flange (25). 3 Housing:
2) Install plug (24). Thread 12 mm in diameter:
3) Install retainer (23) to body (1) and then 98 – 123 Nm {10 – 12.5 kgm}
install spring case (22). Thread 14 mm in diameter:
4) Install retainer (21) and springs (20) and 157 – 196 Nm {16 – 20 kgm}
(19) to body (1) and then install spring a After installing the hoist valve assembly to the
case (18). machine, test the hoist oil pressure. For
details, see Testing and adjusting, "Steering
and hoist circuit oil pressure".
4 HD785-7

hoist cylinder assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
9
10 790-720-1000 Expander t 1
Ring 4. Remove piston mounting nut (5) and lift off rod
11 796-720-1690 t 1
(for cylinder ) (7) from cylinder (6).
Clamp
12 07281-02059 t 1
(for cylinder )
5. Remove cylinder head assembly (1).
Push tool
792-630-1300 t 1
(for cylinder )
U Grip
790-101-5421 t 1
(for cylinder )
Bolt
01010-51240 t 1
(for cylinder )
13
Push tool
790-445-4210 t 1
(for cylinder )
• Grip
790-101-5421 1
(for cylinder )
• Bolt
01010-51240 1
(for cylinder )
Disassembly 6. Remove dust seal (8), rod packing (9), bushing

a When disassembling, take care not to damage (12), O-ring (11) and backup ring (10) from cyl-
the rod packing, dust seal, piston ring, wear inder head assembly (1).
ring, etc.
7. Remove wear ring (13).
1. Set the cylinder assembly to tool U9.
8. Remove snap ring (14) and pull out piston
2. Remove mounting bolts (2) of cylinder head assembly (15).
assembly (1).
9. Remove piston ring (16) and wear ring (17)
3. Remove cylinder and rod assembly (4) from from piston assembly (15).
cylinder (3).
HD785-7 5
10. Remove snap ring (18) from cylinder (6) and Assembly
then remove dust seal (19), rod packing (20) a Clean all the parts and check them for dirt or
and bushing (21). damage. Coat their sliding surfaces with
engine oil before installing.
1. Using tool U13, press fit bushing (21).
2. Fit rod packing (20) and dust seal (19) and

install snap ring (18).
3. Assembly of piston assembly

1) Using tool U10, expand piston ring (16)
and install it to piston (15).
a Set the piston ring to tool U10 and
rotate the handle 8 – 10 turns to
expand the piston ring.
2) Set tool U11. Using tool U12, shrink pis-
ton ring (16).
3) Install wear ring (17).
6 HD785-7
4. Install piston assembly (15) to cylinder (6), 8. Install cylinder head assembly (1) to cylinder
and then install snap ring (14). (6).
9. Sling and install rod (7) to cylinder (6).

a When installing the rod, align the stud bolt
hole.
10. Tighten piston mounting nut (5).

2 Threaded part of piston rod:
Adhesive (LOCTITE 262)
3 Mounting nut:
324 ± 32.5 Nm {33.0 ± 3.3 kgm}
5. Install wear ring (13) to cylinder (6).
11. Install cylinder and rod assembly (4) to cylin-

der (3).
6. Using tool U13, press fit bushing (12) to the

cylinder head.
7. Install rod packing (9), dust seal (8), backup

ring (10) and O-ring (11) to cylinder head (1).
12. Install cylinder assembly (1) with mounting

bolts (2).
3 Mounting bolt:
530 ± 78.5 Nm {54.0 ± 8.0 kgm}
HD785-7 7
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
8 HD785-7
SEN04645-00
HD785-7

HD785-7 7001 and up

Body
Removal and installation of body assembly .................................................................................................... 2
HD785-7 1
Removal and installation of body

assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
V 1 792T-674-1010 Body sling pin t 4 N Q
Removal
k Stop the machine on a level ground, set the 5. Disconnect body potentiometer rod (8) from
parking brake switch in the "PARK" posi- the body side. [*2]
k Raise the poke ejector and fix it to the body 6. Remove right and left body hinge pins (9). [*3]
with the pin. a Record the thickness, quantity and posi-
tions of the inserted shims. [*4]
1. Remove bolt (1) to remove mudguard rubber
(2) and plate (3).
2. Remove bolt (4) to remove mudguard (5).
7. Lift off body assembly (10). [*5]

4 Body assembly: 15,400 kg
3. Using tool V1, sling the body assembly (10) by

4 parts.
a If chain slings are not available, use wires
ø 28 mm in diameter.
4. Remove hoist cylinder bottom pin (6). [*1]

a Fix hoist cylinder (7) with a lever block etc.
so that it will not fall down when pin (6) is
removed.
a Remove the pin on the opposite side simi-
larly.
2 HD785-7
Installation
removal.
[*1]
kWhen aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
3 Lock plate mounting bolt:
157 – 196 Nm {16 – 20 kgm}
[*2]
a Adjust the body positioner sensor. For details,
see Testing and adjusting, "Adjusting body
positioner sensor". [*5]
a Set tool V1 (body sling pin) from outside of the
[*3] body side.
kWhen aligning the pin holes, use a bar. a Connect the slings with shackles (for 10 t)
Never insert your fingers in the pin holes. inside the body.
a Insert the shims as recorded when removed.
3 Lock plate mounting bolt:
a Adjustment of body mount shim
245 – 309 Nm {25 – 31.5 kgm} 1. Adjust the bottom mount shim.
1) Insert 43-mm thick spacer [1] in the end of
[*4] body (10). (1 place each on right and left
a After installing the body, check that difference sides)
(Z) between the levels of the body assembly 2) Measure clearance (X) between the cen-
and cab assembly is in the following range. ter of the mounting portion of bottom
q Standard value of difference (Z): mount (12) and the top of rear frame (13)
59 ± 30 mm q Shim thickness = ((X) – 35) mm
a Measure clearance at each of the 8
places of (A), (B), (C) and (D) on the
right and left sides.
3) Calculate the shim thickness at each of
the 8 places of (A), (B), (C) and (D) on the
right and left sides.
4) Set shim (14) calculated in 3) above to
bottom mount (12).
q Standard shim thickness at (A), (B),
(C) and (D): 3 mm
q Kinds of shim thickness: 1 mm, 3.2
mm
5) Remove spacer [1], lower the body, and
a If difference (Z) is out of the standard, adjust it check that all of 8 bottom mounts (A), (B),
with spacers (11) of the right and left body (C) and (D) are in contact with rear frame
hinge pins. top (13).
q Kinds of spacer thickness: 1 mm, 6 mm 3 Mounting bolt (9):
a Clearance (Y) must be 1 mm or less. 245 – 309 Nm {25 – 31.5 kgm}
HD785-7 3
2. Adjust the front mount shim.

a After adjusting the bottom mount shim,
adjust the right and left front mount shims.
1) Lower the body and measure thickness
(Y) of rubber pad (15).
2) If thickness (Y) of rubber pad (15) is larger
than the standard value or there is a clear-
ance between the body and rubber pad,
adjust shim (16) to set thickness (Y) to the
standard value.
q Standard thickness (Y): 50 mm
4 HD785-7
HD785-7 5
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
6 HD785-7
SEN04646-00
HD785-7

HD785-7 7001 and up

Cab and its attachments
Disassembly and assembly of operator's seat assembly................................................................................ 2
Removal and installation of air conditioner unit assembly ............................................................................ 12
HD785-7 1
Disassembly and assembly of operator's seat assembly 1

a The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manu-
factured by ISRING HAUSEN is optional.)] is shown below.
A: Headrest D: Left-hand armrest

B: Back seat E: Suspension cover
C: Cushion seat F: Rails
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of 2 clips (2) of headrest stay (1) on both
sides.
2 HD785-7
2) Apply force (b) to part (a) of each clip (2) 2. Back seat
in the direction of the arrow to turn the clip 1) Disconnect 3 air hoses (5) from the rear
and release it from part (d) of headrest left of back seat (4).
stay (1), and then pull out up headrest (3). a Before disconnecting the air hoses, check
their types.
2) Remove back seat hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring back seat (4) down forward.
HD785-7 3
4) Apply force (E) to the right side of back 3. Cushion seat

seat (4) in the direction of the arrow. 1) Push cushion adjuster lever (7) inward
5) Applying the force to back seat (4), pull its and slide cushion seat (8) to the front end.
right side up.
6) Slide back seat (4) sideway and remove it.
2) Push cushion slide stopper wire (9) down

with screwdriver [1], etc.
3) Keeping the state in 2), pull out cushion
seat (8) forward and remove it.
4 HD785-7
4. Armrest 4) Turn left-hand armrest (10) up by 180°.

The procedure for disassembling left-hand a If the armrest is not turned, you can-
armrest (10) is shown below. not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B).
1) Remove plastic cap (12) from the armrest

hinge.
a Use a flat-head screwdriver, etc. to
remove the cap. 6) Remove left-hand armrest (10).
2) Loosen armrest hinge mounting bolt (13). a There are 2 position adjustment
washers (16) installed to each bolt
between the armrest and back seat.
Take care not to lose them.
3) Remove plastic cap (14), and then remove

lower mounting bolt (15A) (M8 bolt) of left-
hand armrest (10).
HD785-7 5
5. Suspension cover 4) Remove 4 mounting bolts (20), cushion

1) Remove right-hand hinge cover (17). rear fixing plate (21), 2 cushion rails (22),
2) Remove plastic plate (18) from the rear and 4 bushings (23).
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
5) Remove 3 metallic suspension cover clips

(24).
3) Remove 4 suspension cover fixing rings

(19).
6 HD785-7
6) Remove 6 plastic suspension cover clips 2) Slide rails (28) to the rear end.
(small) (25) and 2 plastic suspension 3) Remove 1 hexagon socket head bolt (29)
cover clips (large) (26). and 1 lock washer (30) from the front part
a Clips (small) (25): of each rail.
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part
of each rail, and then remove rails (28).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
HD785-7 7
Assembly 2. Suspension cover

1. Rails 1) Set suspension cover (27) in position and
1) Put height adjustment washers (31) between install 6 plastic suspension cover clips
rails (28) and suspension, and then set rails (small) (25) and 2 plastic suspension
(28) in position. cover clips (large) (26).
a Clips (small):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large):
Front lower part; 2 places
2) Set rails (28) to the front end and install 1

lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
2) Install 3 metallic suspension cover clips

(24).
3) Set rails (28) to the rear end and install 1

lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
8 HD785-7
3) Set 4 bushings (23) and 2 cushion rails 3. Armrest

(22), and then install cushion rear fixing The procedure for assembling left-hand arm-
plate (21) and 4 mounting bolts (20). rest (10) is shown below.
3 Cushion rail mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
1) Install 2 position adjustment washers (16)

for each bolt and set left-hand armrest
4) Install 4 suspension cover fixing rings (10) in position.
(19).
2) Tighten lower mounting bolt (15A) lightly

5) Install plastic plate (18) to the rear. and turn armrest (10) by 180°.
6) Install right-hand hinge cover (17). 3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
HD785-7 9
6) Tighten armrest hinge mounting bolt (13). 5. Back seat

a Tighten the bolt so that the arm will 1) Insert the left side of back seat (4), and
move smoothly. then lower and set the right side.
q Operating effort at armrest end:
49.0 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
4. Cushion seat
1) Slide in the cushion seat from the front of
the fitting position.
a If cushion seat (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Install back seat hinge mounting bolt (6).

3 Back seat hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
10 HD785-7
3) Connect 3 air hoses (5) to the rear left of

back seat (4).
6. Headrest
1) Insert headrest (3) in back seat (4).
a Check that 2 clips (2) on both sides
are locked securely.
HD785-7 11
Removal and installation of air 3 Disconnect hose (5).

conditioner unit assembly 1 4. Remove ducts (6) – (8). [*1]
Removal
k
5. Remove glove box (9).
7. Move floor mat (11) toward the operator seat.
k If the coolant temperature is high, wait until

it decreases to avoid scalding yourself with
the hot coolant, and then disconnect the
heater hose and drain the coolant.
k Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
k If the refrigerant (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
Accordingly, you must put on safety glasses
while you are collecting the refrigerant or
charging the air conditioner with the refrig-
erant.
8. Remove the filter and then remove air cleaner
q Precautions for handling refrigerant box assembly (12).
a Ask a "refrigerant collection" contrac-
tor who is registered in the local gov-
ernment. (Only the registered
contractors can collect the refrigerant.)
a Discharging the refrigerant (air condi-
tioner gas: R134a) into the atmosphere
is violation of the law.
1. Drain the coolant

6 Coolant: 283 l
2. Remove bolts (1) and remove covers (2), (3)

and (4).
9. Remove dashboard cover (13).
12 HD785-7
10. Disconnect air conditioner hoses and tubes Installation

(14) – (17). q Carry out installation in the reverse order to
removal.
q Charging with refrigerant (air conditioner

gas: R134a)
Charge the air conditioner circuit with refriger-
ant (air conditioner gas: R134a).
[*1]
Assembly procedure for air ducts
1. Install vent duct (24) and foot duct (25) to the
dashboard bracket temporarily.
2. Install each duct to air conditioner unit (23).

11. Disconnect connectors (18), CG1 (19), TCHET a Ensure that vent duct (24) and foot duct
(20), AC1 (21) and AS1 (22). (25) are installed to the air outlets cor-
rectly, and then install face duct (26).
12. Remove air conditioner unit assembly (23). a Be sure to check that insertion portion (a)
is installed correctly.
a If the ducts are installed while their inser-
tion portions are floated, the air outlets will
be deformed.

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
HD785-7 13
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
14 HD785-7
SEN04647-01
HD785-7

HD785-7 7001 and up

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 2
Removal and installation of retarder controller assembly ............................................................................... 3
Removal and installation of ABS controller assembly..................................................................................... 3
Removal and installation of VHMS controller assembly ................................................................................. 4
HD785-7 1
Removal and installation of Removal and installation of

engine controller assembly 1 transmission controller assembly1
Removal Removal
k Stop the machine on a level ground, set the k Stop the machine on a level ground, set the
parking brake switch in the "PARK" posi- parking brake switch in the "PARK" posi-
tion, and lock the tires with chocks. tion, and lock the tires with chocks.
k Raise the body and fix it with the lock pin. k Disconnect the cable from the negative (–)
k Disconnect the cable from the negative (–) terminal of the battery.
1. Remove seat rear cover (1).
1. Remove engine controller covers (1).
a The cover mounting bolts are used to
secure the controller, too. Take care not
drop them.
2. Disconnect connectors CN1 (3), CN2 (4) and

CN3 (5) from the transmission controller (2).
3. Remove transmission controller (2).

2. Disconnect connectors J2P (2), J3P (3), J3C
(4) and J2C (5) and (6).
3. Remove engine controller.
Installation
removal.
Installation
removal.
2 HD785-7
Removal and installation of Removal and installation of ABS

retarder controller assembly 1 controller assembly 1
Removal Removal
k Stop the machine on a level ground, set the k Stop the machine on a level ground, set the
parking brake switch in the "PARK" posi- parking brake switch in the "PARK" posi-
tion, and lock the tires with chocks. tion, and lock the tires with chocks.
k Disconnect the cable from the negative (–) k Disconnect the cable from the negative (–)
terminal of the battery. terminal of the battery.
1. Remove seat rear cover (1). 1. Remove seat rear cover (1).
2. Disconnect connectors CN1 (3), CN2 (4) and 2. Disconnect connectors CN1 (3), CN2 (4) and
CN3 (5) from the retarder controller (2). CN3 (5) from the ABS controller (2).
3. Remove retarder controller (2). 3. Remove ABS controller (2).
Installation Installation
q Carry out installation in the reverse order to q Carry out installation in the reverse order to
removal. removal.
HD785-7 3
Removal and installation of VHMS Installation

controller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove seat rear cover (1).
2. Disconnect connector (3) from the VHMS con-

troller (2).
3. Remove VHMS controller (2).
q For the connector position, see the figure (bot-

tom view).
4 HD785-7
HD785-7 5
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
6 HD785-7
SEN01298-03
DUMP TRUCK
HD785-7

HD785-7 7001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Steering and hoist hydraulic circuit diagram ................................................................................................... 5
Brake hydraulic circuit diagram....................................................................................................................... 7
Brake hydraulic circuit diagram (ASR specification) ....................................................................................... 9
Brake hydraulic circuit diagram (ABS specification) ......................................................................................11
Brake hydraulic circuit diagram (ASR and ABS specification) ...................................................................... 13
HD785-7 1
SEN01298-03 90 Diagrams and drawings
2 HD785-7
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
HD785-7
HD785-7 3
Steering and hoist hydraulic circuit diagram Steering and hoist hydraulic circuit diagram
HD785-7
(Auto-suspension and exhaust brake are optional)
HD785-7 5
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HD785-7
HD785-7 7

HD785-7
(ASR specification)
(If equipped)
HD785-7 9

HD785-7
(ABS specification)
(If equipped)
HD785-7 11

HD785-7
(ASR and ABS specification)
(If equipped)
HD785-7 13
HD785-7 15
HD785-7 Dump truck

© 2008 KOMATSU
All Rights Reserved
16 HD785-7
SEN01299-07
DUMP TRUCK
HD785-7

HD785-7 7001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram for outside cab (1/3) ................................................................................................ 3
Electrical circuit diagram for inside cab (1/3) .................................................................................................. 9
Electrical circuit diagram for inside cab (2/3) .................................................................................................11
Electrical circuit diagram for inside cab (3/3) ................................................................................................ 13
Electrical circuit diagram for VHMS (If equipped) ......................................................................................... 15
Electrical circuit diagram for ABS (Outside cab) (If equipped) ...................................................................... 17
Electrical circuit diagram for ABS (Inside cab) (If equipped)......................................................................... 19
Electrical circuit diagram for ASR (If equipped) ............................................................................................ 21
Air conditioner electrical circuit diagram (If equipped) .................................................................................. 23
Electrical circuit diagram for auto greasing (If equipped).............................................................................. 25
Electrical circuit diagram of external power supply heater............................................................................ 26
Connectors table and arrangement drawing ................................................................................................. 27
HD785-7 1
2 HD785-7
Electrical circuit diagram for outside cab (1/3) Electrical circuit diagram for outside cab (1/3) 1
HD785-7
SEN01299-07
HD785-7 3
HD785-7
SEN01299-07
HD785-7 5
HD785-7
SEN01299-07
HD785-7 7
Electrical circuit diagram for inside cab (1/3) Electrical circuit diagram for inside cab (1/3) 1
HD785-7
SEN01299-07
HD785-7 9
HD785-7
SEN01299-07
HD785-7 11
HD785-7
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HD785-7 13
Electrical circuit diagram for VHMS Electrical circuit diagram for VHMS 1
(If equipped) HD785-7
SEN01299-07
HD785-7 15
Electrical circuit diagram for ABS Electrical circuit diagram for ABS
HD785-7
(Outside cab)
(If equipped)
SEN01299-07
HD785-7 17
Electrical circuit diagram for ABS Electrical circuit diagram for ABS
HD785-7
(Inside cab)
(If equipped)
SEN01299-07
HD785-7 19
Electrical circuit diagram for ASR Electrical circuit diagram for ASR
SEN01299-07
HD785-7 21
Air conditioner electrical circuit diagram Air conditioner electrical circuit diagram
HD785-7 23
Electrical circuit diagram for auto greasing 1

(If equipped)
HD785-7 25
Electrical circuit diagram of external power supply heater 1
26 HD785-7
Connectors table and arrangement drawing HD785-7 Connectors table and arrangement drawing
HD785-7
The address column in the following table shows the addresses in the connector arrangement drawing (3D drawing).
Connector No. Connector Number Location Address in Connector No. Connector Number Location Address in Connector No. Connector Number Location Address in Connector No. Connector Number Location Address in
type of pins 3D drawing type of pins 3D drawing type of pins 3D drawing type of pins 3D drawing
250 2 Resistor (male) R-2 JCC SWP 16 Joint connector U-1 55 Terminal 1 Emergency steering relay C-8 HEPC DT2 2 Hoist EPC valve N-5
1020 2 Resistor (male) S-1 JCD SWP 16 Joint connector V-1 56 Terminal 1 Emergency steering relay C-8 HM12 DT2 3 Blow-by sensor AL-6
A1_F 1 Emergency escape switch AE-3 JCE SWP 8 Joint connector 58 Terminal 1 Battery relay B-8 HM25 Plug 1 Battery isolator (if equipped) VHMS indicator C-3
A1_M 1 Emergency escape switch AE-3 JCF SWP 16 Joint connector 59 Terminal 1 Battery relay B-8 HM26 Plug 1 Battery isolator (if equipped) VHMS indicator C-3
ABS M 6 ABS system switch Q-7 JRE DT2 8 Joint connector 60 Terminal 1 Battery relay B-7 HN1 DT2 2 Horn valve C-3
ABS1 DRC 24 ABS controller LKO DT2 2 Lever kick-out solenoid Y-3 61 Terminal 1 Battery relay B-7 HN2 DT2 2 Horn valve C-3
ABS2 DRC 40 ABS controller LKO DT2 2 Intermediate connector X-2 62 Terminal 1 Circuit breaker (80 A) A-7 HSOL DT2 2 Hoist selector valve N-5
ABS3 DRC 40 ABS controller LS 3 Rheostat W-1 63 Terminal 1 Circuit breaker (80 A) A-7 J07 DT2B 12 Intermediate connector M-8
ABS6 4 Intermediate connector MON AMP 4 Intermediate connector P-9 64 Terminal 1 Circuit breaker (80 A) B-6 J08 DT2A 12 Intermediate connector M-8
ABS7 DT2C 12 Intermediate connector AC-2 OP7 1 Connector V-1 65 Terminal 1 Circuit breaker (80 A) A-6 LM1 Plug 1 Download box
ABS8 DT2B 12 Intermediate connector AC-2 OPS DT2 2 Operator's seat heater 66 Terminal 1 Circuit breaker (60 A) B-7 LM2 Plug 1 Download box
ABS9 DT2A 12 Intermediate connector AC-2 ORB-A 14 ORBCOMM controller (if equipped) 67 Terminal 1 Circuit breaker (60 A) B-7 LP1 DT2 6 Intermediate connector J-2
AC1 M 6 Intermediate connector Q-2 ORB-B 10 ORBCOMM controller (if equipped) 68 Terminal 1 Circuit breaker (30 A) B-7 LP2 DT2C 12 Intermediate connector K-2
ACC Terminal 1 Starting switch ACC terminal O-8 PLM 5 Intermediate connector 69 Terminal 1 Circuit breaker (30 A) B-7 LP3 DT2 6 Intermediate connector F-1
AISS M 6 AISS switch (if equipped) P-9 PM1 MIC 21 Intermediate connector V-9 70 Terminal 1 Emergency steering relay C-9 M Terminal 1 Emergency steering motor J-2
ARC M 3 ARSC set switch R-2 PM11 MIC 20 Intermediate connector 71 Terminal 1 Emergency steering relay C-9 PDL 4 Download box
ARSC M 6 ARSC system switch P-7 PM3 DT2 3 Pitch angle sensor AH-1 72 Terminal 1 Emergency steering relay B-9 PL01 M 2 Headlamp (high) (left) F-1
AS1 DT2 6 Acceleration sensor Q-4 PM4 S 16 Intermediate connector V-9 73 Terminal 1 Emergency steering relay B-9 PL02 M 2 Headlamp (low) (left) G-1
AS2 DT2 2 Intermediate connector (Serial No.: 7079 and up) Q-3 PM5 13 Payload meter controller (if equipped) 74 Terminal 1 Battery relay B-8 PL03 M 3 Front combination lamp (left) H-1
AS3 DT2 3 Pitch angle sensor AG-2 PM6 12 Payload meter controller (if equipped) 75 Terminal 1 Battery relay B-8 PL04 Plug 1 Beacon lamp (left) (if equipped) G-1
ASR M 6 ASR system switch Q-8 PM7 9 Payload meter controller (if equipped) 76 Terminal 1 Battery relay B-9 PL06 M 2 Fog lamp (left) (if equipped) G-1
ASS DT2 2 Pneumatic suspension seat X-2 PM8 5 Intermediate connector 77 Terminal 1 Battery relay B-9 PL07 Terminal 1 Ground G-1
ATC1 DRC 24 Transmission controller AF-2 PWL_F 1 Power window motor (left) I-1 ACCF DT2 3 ACC oil pressure sensor (front) PMLA DT2A 12 Intermediate connector K-3
ATC2 DRC 40 Transmission controller AE-2 PWL_M 1 Power window motor (left) J-2 ACCR DT2 3 ACC oil pressure sensor (rear) PMRA DT2 6 Intermediate connector D-7
ATC3 DRC 40 Transmission controller AE-2 PWM M 6 Power mode switch P-9 B01 DT2 6 Intermediate connector K-9 PR01 M 2 Headlamp (low) (right) C-5
ATC6 X 4 Intermediate connector AF-1 PWR_F 1 Power window motor (right) I-1 B02 DT2 6 Intermediate connector J-9 PR02 M 2 Headlamp (high) (right) C-5
B Terminal 1 Starting switch B terminal P-7 PWR_M 1 Power window motor (right) H-1 B03 DT2 6 Winker tail stop lamp L-8 PR03 M 3 Front combination lamp (right) C-6
BLS M 6 Rotary lamp switch AA-1 R01 Relay 5 Engine starting relay AF-4 B04 M 2 Backup lamp (70 W) L-8 PR04 Plug 1 Beacon lamp (right) (if equipped) C-5
BR Terminal 1 Starting switch BR terminal O-7 R02 Relay 5 Transmission neutral relay AF-4 B05 Terminal 1 Backup alarm buzzer K-9 PR06 M 2 Fog lamp (right) (if equipped) C-5
BRC1 DRC 24 Retarder controller AD-3 R03 Relay 5 Parking brake relay AF-4 B06 Terminal 1 Backup alarm buzzer K-9 PR07 Terminal 1 Ground C-5
BRC2 DRC 40 Retarder controller AD-3 R04 Relay 5 Stop lamp relay AF-3 B07 DT2 3 Body position sensor J-9 PSOLF DT2 2 Parking brake solenoid (front) H-9
BRC3 DRC 40 Retarder controller AD-3 R05 Relay 5 Backup lamp/buzzer relay AF-3 B08 M 2 ADD backup lamp (if equipped) J-9 PSOLR DT2 2 Parking brake solenoid (rear) I-9
BRC6 X 4 Intermediate connector AF-1 R06 Relay 5 Fog lamp relay AF-4 B1 DT2 2 Lamp G (right) (for payload meter) (if equipped) D-7 PSWF DT2 2 Parking brake switch (front) H-9
BT1 Fuse box AH-3 R08 Relay 5 Stop lamp relay AF-4 81 Terminal 1 Fuse D-9 PSWR DT2 2 Parking brake switch (rear) I-9
BT2 Fuse box AH-3 R11 Relay 5 Horn relay AF-3 B10 Terminal 1 Ground M-7 RESWF DT2 2 Retarder switch (front) D-2
BT3 Fuse box AG-3 R14 Relay 5 BCV relay AF-3 B1L DT2 2 Lamp G (left) (for payload meter) (if equipped) M-4 RESWR DT2 2 Retarder switch (rear) E-2
BT4 Fuse box AH-3 R16 Relay 5 Hazard relay 1 AF-4 B2 DT2 2 Lamp A (right) (for payload meter) (if equipped) C-7 REVF DT2 2 Retarder valve (front) D-2
BZ2 M 2 Buzzer V-1 R17 Relay 5 Hazard relay 2 AF-4 82 Terminal 1 Fuse D-9 REVR DT2 2 Retarder valve (rear) D-2
C Terminal 1 Starting switch C terminal P-7 R19 Relay 5 Parking brake safety relay AF-3 B2L DT2 2 Lamp A (left) (for payload meter) (if equipped) N-4 RP DT2 8 Intermediate connector C-4
CAB1 DT2A 8 Intermediate connector U-9 R21 Relay 5 Side lamp relay AF-2 B3 DT2 2 Lamp R (right) (for payload meter) (if equipped) C-7 RTF DT2 2 Retarder oil temperature sensor (front) E-2
CAB2 DT2B 8 Intermediate connector V-9 R22 Relay 5 Rotary lamp relay AF-2 83 Terminal 1 Fuse C-9 RTR DT2 2 Retarder oil temperature sensor (rear) H-9
CAN1 DT2 3 Intermediate connector R25 11 Power window relay X-9 B3L DT2 2 Lamp R (left) (for payload meter) (if equipped) N-5 S01 DT2 2 Service brake switch
CAN2 DT2 3 Resistor U-1 R29 Relay 5 Headlamp relay (Hi) (PASS) AF-4 84 Terminal 1 Fuse D-9 S04 DT2 2 Auto suspension solenoid 1 (if equipped) E-2
CG1 2 Cigarette lighter Q-6 R30 Relay 5 Headlamp relay (Hi) AF-4 BCVR X 2 BCV solenoid (right) N-6 S05 DT2 2 Auto suspension solenoid 2 (if equipped) E-1
CH1 M 8 Mode selector switch 1 Z-2 R31 Relay 5 Headlamp relay (Lo) AG-4 BT DT2B 8 Intermediate connector C-8 SLL M 2 Side lamp (left) (if equipped) L-3
CH2 M 8 Mode selector switch 2 Z-2 R32 Relay 5 Dust indicator relay AF-2 BT-1A Terminal 1 Battery 1 (+) E-8 SLR M 2 Side lamp (right) (if equipped) E-8
CHECK M 6 ABS check switch AA-3 R33 M 6 Parking brake manual switch T-8 BT-1B Terminal 1 Battery 1 (-) E-8 STR DT2 2 Steering oil temperature sensor (if equipped) N-4
CK1 M 6 Bulb breakage check switch AA-3 R34 M 7 Power window switch (right) U-9 BT-2A Terminal 1 Battery 2 (-) E-8 SUFL DT2 3 Suspension oil pressure sensor (front, left) (if equipped) H-1
CM DT2C 8 Lighting switch, passing switch, turn switch U-1 R35 M 7 Power window switch (left) U-9 BT-2B Terminal 1 Battery 2 (+) F-8 SUFR DT2 3 Suspension oil pressure sensor (front, right) (if equipped) C-4
CNS1 DT2D 12 Intermediate connector U-8 R37 Relay 5 Auto pre-heater relay AF-2 BT-3A Terminal 1 Battery 1 (+) F-8 SURL DT2 3 Suspension oil pressure sensor (rear, left) M-7
CNS2 DT2C 12 Intermediate connector U-8 R40 Relay 5 Payload meter relay (if equipped) AG-4 BT-3B Terminal 1 Battery 1 (-) F-9 SURR DT2 3 Suspension oil pressure sensor (rear, right) J-9
CNS3 DT2B 12 Intermediate connector T-8 R43 Relay 5 Payload meter external indicator lamp blue relay AG-4 BT-4A Terminal 1 Battery 2 (-) F-9 T05 Terminal 1 Ground N-5
CUTF 5 ABS cut valve relay (front) R44 Relay 5 Payload meter external indicator lamp yellow relay AG-4 BT-4B Terminal 1 Battery 2 (+) F-9 TMF1 DT2 2 Transmission oil filter switch L-3
CUTR 5 ABS cut valve relay (rear) R45 Relay 5 Payload meter external indicator lamp red relay AG-2 BTL DT2 2 Battery electrolyte level switch (if equipped) B-7 TMF2 DT2 2 Transmission oil filter switch L-3
D01 AMP 2 Diode AC-3 R46 5 Small lamp relay AG-2 CJA DT2 6 Joint connector C-7 VDL 4 Download box
D02 AMP 2 Diode RAD 9 Cassette stereo AM/FM radio O-8 CJB DT2 6 Joint connector C-6 CAN3 3 Terminal resistor (120z) AJ-1
D03 AMP 2 Diode RE1 2 Resistor AF-2 CJC DT2 6 Joint connector C-6 CAN4 3 Connector AJ-2
D04 AMP 2 Diode AC-1 RE3 2 Resistor (female) R-2 CJD DT2 6 Joint connector C-6 CJE4 DT2B 8 Joint connector AI-2
D05 AMP 2 Diode AC-1 RE4 2 Resistor (female) S-1 CJE2 DT2 8 Joint connector AI-2 CJE5 DT2B 8 Joint connector AI-2
D06 AMP 2 Diode AC-3 RL M 2 Room lamp E-8 CJE3 DT2B 8 Joint connector AM-7 GS Terminal 1 Ground AM-2
D07 AMP 2 Diode T-1 RL2 2 Room lamp 2 G-9 CJG DT2 6 Joint connector M-4 J2C DRC 50 Engine controller AK-1
D08 AMP 2 Diode AC-3 RTL DT2 6 Retarder lever potentiometer S-1 CJH1 DT2B 8 Joint connector J2P DRC 50 Engine controller AI-3
D09 AMP 2 Diode AC-3 SBS DT2 2 Seat belt switch Y-3 CJK DT2 6 Joint connector C-7 J3C DT06 4 Engine controller AJ-1
D10 AMP 2 Diode AC-2 SDE M 6 Side lamp switch (if equipped) AB-2 CJL DT2 6 Joint connector N-6 J3P DT06 4 Engine controller AI-3
D11 AMP 2 Diode AC-1 SF1 DT2 12 Gearshift lever T-8 CJN DT2 6 Joint connector N-6 CM850.L Terminal 1 Ground AI-3
DL DT2A 12 Intermediate connector AF-2 SF2 DT2 2 Gearshift lever T-8 CJP DT2 6 Joint connector N-7 CM850.R Terminal 1 Ground AK-1
DPC1 AMP070 20 Monitor panel S-8 SPARE X 4 Intermediate connector AD-3 CJP1 DT2 6 Joint connector L-3 ENG DRC 60 Engine controller (R bank) AI-3
DPC2A AMP070 18 Monitor panel S-7 SPL 2 Speaker (left) G-9 CJP2 DT2 6 Joint connector M-4 ENG DRC 60 Engine controller (L bank) AJ-1
DPC2B AMP070 12 Monitor panel S-7 SPR 2 Speaker (right) G-9 CJPR DT2 6 Intermediate connector D-8 HM21A 2 Exhaust temperature sensor (left front) AL-9
DPC3A AMP070 18 Monitor panel R-7 SR3 X 3 Steering speed sensor T-1 CJR DT2 6 Joint connector K-8 HM21B 2 Exhaust temperature sensor (left rear) AM-9
DPC4 AMP070 12 Monitor panel S-7 ST1 Terminal 1 Emergency steering switch R-9 CJS DT2 6 Joint connector H-9 HM21C 2 Exhaust temperature sensor (right front) AL-9
DPC6 AMP070 8 Monitor panel R-7 ST2 Terminal 1 Emergency steering switch R-8 CJSL DT2 6 Joint connector HM21D 2 Exhaust temperature sensor (right rear) AM-9
DPC7 X 4 Monitor panel S-1 ST3 Terminal 1 Emergency steering switch R-8 CJT DT2 6 Joint connector H-9 G DT2 3 G sensor AK-5
DSL 1 Door switch (left) I-1 ST4 Terminal 1 Emergency steering switch S-8 CJV DT2 6 Joint connector L-8 G SUMITOMO 3 G sensor AM-2
DSR 1 Door switch (right) D-7 TCHET X 4 Intermediate connector Q-5 CJX DT2 6 Joint connector L-8 GND Terminal 1 Ground AL-6
DT7 DT2 12 Intermediate connector X-2 TEST_F 1 ASR test switch AE-3 CJY DT2 6 Joint connector M-3 GND.L Terminal 1 Ground AL-6
DT8 DT2 4 Intermediate connector W-2 TEST_M 1 ASR test switch AE-2 D12 DT2 2 Diode I-9 GND.R Terminal 1 Ground AL-1
EG4 DT2D 12 Intermediate connector VHMS 5 Intermediate connector E Terminal 1 Emergency steering motor K-2 JC01 6 Joint connector AM-7
EM 6 Emergency steering timer AH-2 WFM 6 Wiper motor (front) T-1 E01 Terminal 1 Alternator R terminal AN-5 JC01 8 Joint connector AL-1
ER Terminal 1 Ground WFR 6 Wiper relay (front) V-1 E02A DT2 2 Intermediate connector AM-6 JC02 6 Joint connector AM-8
ER1 Terminal 1 Ground X-9 WPS DT2B 12 Wiper switch S-1 E02B DT2 2 Intermediate connector AM-7 JC02 6 Joint connector AL-1
ER3 Terminal 1 Ground CN10 DT2 2 3rd clutch ECMV AF-9 E04 DT2 2 Engine oil level switch AK-5 JC03 9 Joint connector AM-8
EXH M 6 Exhaust brake switch CN11 DT2 2 3rd fill switch AF-9 E05 Terminal 1 Oil filter switch AN-4 L..S 14 Intermediate connector AJ-4
FLS 4 Flusher W-2 CN12 DT2 2 R clutch ECMV AE-9 E06 Terminal 1 Alternator E terminal AN-5 NE FRAMATOME 3 Ne sensor AK-1
FOG M 6 Fog lamp switch (if equipped) Z-1 CN13 DT2 2 R fill switch AE-9 E07 X 2 Air compressor AN-4 NE J1939 DT2 8 Intermediate connector AJ-2
HAZ M 6 Hazard switch Q-9 CN14 DT2 2 4th clutch ECMV AE-9 E09 Terminal 1 Alternator B terminal AN-5 PAMB AMP 3 Ambient pressure sensor AI-4
HM2130 2 Connector CN15 DT2 2 4th fill switch AE-9 E10 Terminal 1 Ground AN-4 PCV1 SUMITOMO 2 Supply pump control valve AK-5
HM2140 2 Connector CN16 DT2 2 Torque converter lockup solenoid AE-9 E11A Terminal 1 Heater relay AL-9 PCV1 SUMITOMO 2 Supply pump control valve AN-2
HM-22A 2 Exhaust temperature sensor amplifier CN17 DT2 2 Low clutch ECMV AD-9 E11B Terminal 1 Heater relay AK-5 PCV2 SUMITOMO 2 Supply pump control valve AJ-5
HM-22B 2 Exhaust temperature sensor amplifier CN18 DT2 2 Low fill switch AD-9 E12A Terminal 1 Heater relay AL-9 PCV2 SUMITOMO 2 Supply pump control valve AN-2
HM-23A 2 Exhaust temperature sensor amplifier CN19 DT2 2 High clutch ECMV AD-8 E12B Terminal 1 Heater relay AK-5 PFUEL AMP 3 Common rail pressure sensor AL-6
HM-23B 2 Exhaust temperature sensor amplifier CN20 DT2 2 High fill switch AD-8 E14 Terminal 1 Starting motor B terminal AM-7 PFUEL AMP 3 Common rail pressure sensor AL-1
HM-50 3 Connector CN21 DT2 2 Torque converter intermediate pressure sensor AE-5 E15 Terminal 1 Ground AN-3 PIM SUMITOMO 3 Boost pressure sensor AJ-4
HM-55 3 Intermediate connector CN22 DT2 2 Torque converter oil temperature sensor AC-7 E16A Terminal 1 Ground AL-9 POIL FRAMATOME 3 Engine oil pressure sensor AL-6
HM-81 8 Intermediate connector CN23 DT2 2 Transmission oil temperature sensor AH-6 E16B Terminal 1 Ground AM-2 R.P 14 Intermediate connector AK-1
HM-CN1 20 VHMS and payload meter controller CN24 DT2 2 Lubricating oil flow variable valve switch AG-5 E17A DT2 2 Diode AM-8 RES DT2 2 Resistor AL-1
HM-CN2A 18 VHMS and payload meter controller CN25 DT2 2 Lubricating oil flow variable valve AF-5 E17B DT2 2 Diode AM-1 RES L DT2 3 Resistor AM-8
HM-CN2B 12 VHMS and payload meter controller CN26 DT2 2 Main pressure switch AC-8 EMPR 2 Emergency steering fuse C-9 RES R DT2 3 Resistor AK-1
HM-CN3A 18 VHMS and payload meter controller CN27 DT2 2 Main pressure variable valve AC-8 ENG DT2B 12 Engine controller AI-2 RES1 DT2 2 Resistor AM-7
HM-CN3B 12 VHMS and payload meter controller CN28 DT2 2 Flow selector valve AC-8 ER Terminal 1 Ground E-8 TAMB PACKARD 2 Connector AJ-9
HM-CN4A 14 VHMS and payload meter controller CN29 DT2 2 Flow variable valve switch AC-7 EXSOL DT2 2 Exhaust brake solenoid (if equipped) G-9 TFUEL PACKARD 2 Fuel temperature sensor AJ-5
HM-CN4B 10 VHMS and payload meter controller CN3 DT2 2 Input shaft speed sensor AD-5 EXSW DT2 2 Exhaust brake switch (if equipped) G-9 TFUEL PACKARD 2 Fuel temperature sensor AN-3
HN 1 Horn switch Q-6 CN4 DT2 2 Intermediate shaft speed sensor AE-5 FR02 DT2 2 Radiator coolant level sensor D-2 TIM PACKARD 2 Boost temperature sensor AJ-4
HSL DT2 4 Hoist lever potentiometer Y-3 CN5 DT2 2 Output shaft speed sensor AH-8 FL04 2 Washer motor TOIL PACKARD 2 Engine oil temperature sensor AM-6
HSL DT2 4 Intermediate connector X-2 CN6 DT2 2 1st clutch ECMV AF-9 FL06 DT2 3 Ambient temperature sensor TWTR PACKARD 2 Engine coolant temperature sensor AI-6
J01 HD 9 Intermediate connector AA-4 CN7 DT2 2 1st fill switch AF-9 FR01 DT2 2 Air cleaner clogging sensor C-4 Details of colored connectors
J02 DRC 70 Intermediate connector AA-4 CN8 DT2 2 2nd clutch ECMV AG-9 FUA1 Circuit breaker (60 A) B-6 DT2A : Gr (Gray), DT2B : B (Black), DT2C : G (Green), DT2D : Br (Brown)
J03 DRC 70 Intermediate connector Z-3 CN9 DT2 2 2nd fill switch AG-9 FUA2 Circuit breaker (30 A) B-7
J04 DRC 70 Intermediate connector AA-4 T1 Terminal 1 Ground AC-6 FUB1 Circuit breaker (80 A) A-6
J05 DRC 70 Intermediate connector Z-3 TM2 HD 23 Intermediate connector AH-7 FUB2 Circuit breaker (80 A) A-6
J06 DT06 4 Intermediate connector Z-4 TM3 HD 31 Intermediate connector AH-7 FUEL DT2 2 Fuel level gauge sensor F-9
JCA SWP 16 Joint connector AF-1 53 Terminal 1 Emergency steering relay D-8 GDL DT2B 12 Intermediate connector C-3
JCB SWP 8 Joint connector AF-1 54 Terminal 1 Emergency steering relay D-8 H01 DT2 3 Steering pressure switch J-2
SEN01299-07
HD785-7 27
HD785-7 29
HD785-7 Dump truck

© 2010 KOMATSU
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30 HD785-7

Shop Manual HD 785-7

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SEN01274-15

DUMP TRUCK HD785 -7

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01274-15

00 Index and foreword SEN01275-15

10 Structure, function and maintenance standard SEN01280-09

20 Standard value table SEN01293-01

30 Testing and adjusting SEN01294-06

General information on troubleshooting SEN01937-03

50 Disassembly and assembly SEN01296-04

90 Diagrams and drawings SEN01297-07

Foreword and general information SEN01277-04

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Testing and adjusting tools list..................................................................................................... 3

Failure code [B@BFZK] Lowering of fuel level............................................................................ 42

Troubleshooting by failure code, Part 6 SEN01943-03

Failure code [DDD9KA] ABS system switch system: Disconnection .......................................... 86

Failure code [DUM7KZ] Pre-lubrication operation lamp output abnormality:

H-5 Transmission does not shift up............................................................................................. 8

50 Disassembly and assembly

Power train, Part 2 SEN02106-03

90 Diagrams and drawings

HD785-7 Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-