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SEBM013912
MACHINE MODEL
SERIAL NUMBER
HD785-5
4001 and up
HD985-5
1021 and up
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This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
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HD785-5 and HD985-5 mount the SA12V140-1 engine. For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2002 1 All Rights Reserved Printed in Japan 10-02(02)
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CONTENTS No. of page
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GENERAL ............................................................................................................ 01-1
10
STRUCTURE AND FUNCTION
20
TESTING AND ADJUSTING
30
DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40
MAINTENANCE STANDARD ............................................................... 40-1
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OTHERS
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........................................................... 10-1
................................................................ 20-1
............................................................................................................... 90-1
HD785-5
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HD785-5
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
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To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
¤
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ ¤
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
27 30 33 36 39
41 46 50 55 60
Thread diameter of bolt
Width across flats
mm
mm
Nm
6 8 10 12
10 13 14 27
7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85
Nm
kgm
0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 3.2 6.7 11.5 18
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 6.8 112 9.8 279 29
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14 20 24 33 42
Varies depending on type of connector.
34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3
Norminal No.
02 03, 04 05, 06 10, 12 14
kgm
0 0 0 0 0
0 0.5 01 02 06 0 13.5
3.5 9.5 14.5 43 89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1
0 0 0 0 0 0 0 0 0 0 0 0 0
0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3 1 8 2 12 2 15 2 24 4 36 5 60 9
kgm
0 0 0 0 0 0 0
0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per Root diameter (mm) (mm) (Reference) inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
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
3 1 – - 12UNF 16
30.3
(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
–
–
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
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
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
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
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
Accelerator sensor ..................................... 10-223 Suspension pressure sensor ..................... 10-224 Sensors, switches ....................................... 10-225 Engine oil level sensor .............................. 10-225 Brake oil level sensor ................................. 10-225 Hydraulic oil level sensor .......................... 10-226 Retarder oil level sensor ............................ 10-226 Air cleaner clogging sensor ....................... 10-226 Retarder brake wear sensor ..................... 10-227 Hydraulic filter sensor ............................... 10-227 Retarder oil filter sensor ............................ 10-227 Full-flow filter sensor ................................ 10-228 Battery electrolyte level sensor ................. 10-228 Maintenance monitor system ................ 10-228-1 System diagram .................................... 10-228-1 Monitor panel ........................................ 10-228-2 Monitor display, functions .................... 10-228-3 Functions of switches ........................... 10-228-5 Sensors, switches ................................. 10-228-7 Engine oil level sensor ....................... 10-228-7 Radiator water level sensor ............... 10-228-7 Transmission oil level sensor ............. 10-228-7 Hydraulic oil level sensor ................... 10-228-8 Retarder oil level sensor ..................... 10-228-8 Air filter clogging sensor .................... 10-228-8 Retarder brake wear sensor ............... 10-228-9 Hydraulic filter sensor ........................ 10-228-9 Retarder oil filter sensor ..................... 10-228-9 Transmission oil filter sensor ............. 10-228-9 Battery electrolyte level sensor ....... 10-228-10 Torque converter oil temperature switch ................................................ 10-228-10 Retarder oil temperature switch ...... 10-228-10 ABS/ASR system ........................................ 10-229 System circuit diagram ............................ 10-229 Principle of operation .............................. 10-231 When ABS is actuated ............................. 10-232 When ASR is actuated ............................. 10-233 System structure diagram ....................... 10-234 ABS/ASR electrical circuit diagram ........ 10-236 ABS/ASR controller (ECU) ......................... 10-238 ABS pressure control valve ....................... 10-240 ASR control valve ....................................... 10-243 Wheel speed sensor ................................... 10-245 Relay ............................................................ 10-245 ASR-II system (If equipped) ....................... 10-247 System diagram ....................................... 10-247 Basic operation ......................................... 10-248 System configuration .............................. 10-248 Controller of automatic spin regulator ... 10-251 Hydraulic tank pressurizing system (High altitude specification) ..................... 10-252 Electrical circuit diagram of hydraulic tank pressurizing system ....................... 10-254
HD785-5
10-3 B
STRUCTURE AND FUNCTION
REAR AXLE
REAR AXLE HD785-5 Serial No.: 4001 – 4253
1. 2. 3. 4. 5.
Parking brake Differential Axle housing Brake Final drive
10-30 B
SPECIFICATIONS Reducation ratio Differential: 3.467 Final drive: 6.500 Oil Differential: EO30-CD (130 liters) Final drive: EO30-CD (64 liters each side) Tire size: 27.00 R49 Rim size: 19.50-49
HD785-5
STRUCTURE AND FUNCTION
REAR AXLE
HD785-5 Serial No.: 4254 and up
1. 2. 3. 4. 5.
Parking brake Differential Axle housing Brake Final drive
HD785-5
SPECIFICATIONS Reducation ratio Differential: 3.467 Final drive: 6.500 Oil Differential: EO30-CD (130 liters) Final drive: EO30-CD (64 liters each side) Tire size: 27.00 R49 Rim size: 19.50-49
10-30-1 B
STRUCTURE AND FUNCTION
REAR AXLE
HD985-5 Serial No.: 1021 and up
1. 2. 3. 4. 5.
Parking brake Differential Axle housing Brake Final drive
10-30-2 B
SPECIFICATIONS Reducation ratio Differential: 3.467 Final drive: 6.500 Oil Differential: EO30-CD (130 liters) Final drive: EO30-CD (64 liters each side) Tire size: 30.00 R51flfl Rim size: 22.00 × 51
HD785-5
STRUCTURE AND FUNCTION
FINAL DRIVE
HD785-5 Serial No.: 4254 and up
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Carrier Planet gear shaft Planet gear (No. of teeth: 39) Sun gear (No. of teeth: 18) Button Cover Ring gear (No. of teeth: 99) Spacer Holder Inner hub Tube Wheel hub Drive shaft
10-37-1 B
SPECIFICATIONS Type: Planetary gear, splash-type lubrication Reduction tatio: 6.50 Oil: EO30-CD (64 liters each side)
HD785-5
STRUCTURE AND FUNCTION
REAR BRAKE
HD785-5 Serial No.: 4254 and up
1. 2. 3. 4. 5. 6. 7. 8. 9.
Inner gear Floating seal Floating seal Hub Plate Disc Outer gear Piston Cylinder
10-40 B
SPECIFICATIONS Type: Air over hydraulic, oil-cooled, multipledisc brake (acts also as retarder) Oil: Brake oil EO10-CD Cooling oil EO10-CD
HD785-5
STRUCTURE AND FUNCTION
REAR BRAKE
HD785-5 Serial No.: 4254 and up
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Spacer Sensor Retainer Inner gear Floating seal Floating seal Hub Plate Disc Outer gear Piston Cylinder
10-40-2 B
SPECIFICATIONS Model: Air-over-hydraulic oil-cooled multiple disc brake (acting also as retarder) Oil: Brake oil EO10-CD Cooling oil EO10-CD
HD785-5
STRUCTURE AND FUNCTION
AXLE SUPPORT
AXLE SUPPORT HD785-5 Serial No.: 4001 – 4253
1. 2. 3. 4.
Rod Rod Axle Suspension cylinder
10-42-2 B
HD785-5
STRUCTURE AND FUNCTION
AUTOMATIC SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
1. 2. 3. 4. 5.
Self-diagnostic display window Connector Case Printboard Model selection switch (rotary switch 1) 6. Network connection switch (rotary switch 2)
OUTLINE • This transmission controller is designed to control the system, so it has a built-in computer. It has the following features and functions. 1. It has a high-power mode and economy mode and it changes the shift pattern. (Machines not equipped with an electronic governor have only the high-power mode.) 2. The braking mode is the mode when the brake is used. The gear shifting point is raised and the brake cooling pump speed is also increased to improve the cooling effect for the retarder. At the same time it also enables the braking force of the engine to be used effectively. 3. It drives and controls the torque converter lock-up solenoid valve, overrun prevention solenoid valve, exhaust brake solenoid valve, and BCV solenoid valve. 4. Speed sensors are located at three points (transmission input shaft, intermediate shaft, and output shaft) to make it possible to detect any slipping of the transmission clutches. It also acts to protect the transmission when there is any abnormality in the hydraulic system. 5. It is connected to the network and makes various data common with other controllers.
HD785-5
6. It receives the input of model selection data (what machine the controller is mounted on) and network data (what controller is connected to the network), and contacts the other controllers through the network. (For details of the method of setting, see TESTING, ADJUSTING, AND TROUBLESHOOTING.) 7. It has finely divided self-diagnostic functions for both the input and output systems. 8. The content of the self-diagnostic display is shown with 2-digit numbers. 9. When any failure is detected, it sends details to the network, and displays this on the other display panels. 10. The content of the self-diagnosis is recorded in memory, so even when the main switch is turned off it is possible to check details of failures. 11. It sends the trouble data to the network, and displays this on the other display panels. 12. The location of any existing failure is displayed on the monitor panel. 13. It has an emergency travel function for use if there is any failure in the electrical system. 14. It is located separately from the gearshift lever.
10-125 B
AUTOMATIC SHIFT CONTROL SYSTEM
STRUCTURE AND FUNCTION
CONNECTOR SIGNALS ATC1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
L/C SOL — — Overrun SOL (+) Exhaust brake SOL (+) AISS relay Battery direct power source GND Power source 24 V — BCV — Overrun SOL (–) Exhaust brake SOL (–) Transmission cut relay GND Power source 24 V
ATC2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Proportional SOL power source 24 V ECMV 1st (+) ECMV 3rd (+) ECMV 2nd(+) ECMV R (+) — ECMV L (+) ECMV 4th (+) ECMV H (+) — — Proportional SOL power source 24 V ECMV 1st, 3rd (–) Sensor power source 12 V ECMV 2nd, R (–) — ECMV L (–) ECMV 4th (–) ECMV H (–) — GND
10-126
ATC3A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Connector check Transmission input shaft speed Transmission output shaft speed — Throttle correction Potentiometer power source 5V — — — Emergency escape switch Steering oil temperature Transmission intermediate shaft speed Engine speed GND (pulse) — GND (analog) — — — —
ATC3A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Alternator terminal R Brake air pressure — Fuel level Engine water temperature — Torque converter oil temperature Retarder oil temperature Transmission valve inlet port oil temperature — Accelerator angle Engine oil pressure — — Differential lock switch —
ATC4 1 2 3 4 5 6 7 8 9 10 11 12
RS422 TX (+) RS422 RX (+) RS232C TX RS232C RX RS485 (+) S-NET (+) RS422 TX (–) FLASH switch RS422 RX (–) GND (serial) RS485 (–) S-NET (–)
ATC5A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Connector check Rear brake signal Body FLOAT signal Body seated signal Machine tilt angle Transmission filter clogging — Brake stroke signal — Fill switch L Fill switch 4th Fill switch H Fill switch 1st Fill switch 2nd Fill switch 3rd Fill switch R — Start signal Emergency steering Heater relay ON/OFF
ATC5B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Exhaust brake ON/OFF Shift lever R signal Shift lever N signal Shift lever D signal Shift lever 5 signal Shift lever 4 signal Shift lever 3 signal Shift lever L signal Shift limit switch Model selection 1 Model selection 2 Model selection 3 Model selection 4 Parking brake ON/OFF Cooling water level Mode switch
HD785-5
STRUCTURE AND FUNCTION
ASR-II SYSTEM (OP)
ASR-II SYSTEM (IF EQUIPPED) [Automatic Spin Regulator (ASR-II)] SYSTEM DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
ASR caution lamp ASR working lamp ASR controller Pressure control valve (R.H.) Pressure switching valve Pressure control valve (L.H.) Wheel speed sensor (L.H.) Wheel speed sensor (R.H.) System switch Steering angle sensor
HD785-5
Automatic Spin Regulator (ASR) is a system that is used to prevent spin of the drive wheels caused by excessive torque. The ASR system will aid the vehicle so that it can start and travel more easily and safely on rough roads and frozen roads. If excessive torque is applied to the tires when the vehicle starts on a road covered with snow or a split road (a road having different conditions on its both sides, e.g. a road either side of which is coverd with snow and the other side of with is dry), both or either of the tires will spin and the vehicle cannot move. If the vehicle is equipped with ASR, the spinning tire (s) is (are) braked automatically in order to control the torque that is applied to the tire (s) and the vehicle can start to move. Since the ASR-II controller has the automatic retarder (ARSC) function, a combination system of ASR and ARSC, which could not be made up in the past, can be made up.
10-247 B
STRUCTURE AND FUNCTION
BASIC OPERATION 1) Transmission control If the rear tires slip on soft ground and their speeds are different from each other, then the tire turning faster is braked and the drive force of the tire turning is transmitted. The transmission control is turned on only while the travel speed is 0 – 30 km/h and the accelerator pedal is depressed. If the accelerator pedal is released or the foot brake or retarder is operated while ASR is working, the ASR system will shut down. 2) Turning correcting function A potentionmeter is installed to the center steering arm lever. The condition for starting and finishing the transmission control is changed according to the center lever angle. The potentiometer is used in order to avoid mistaking the speed difference between the inner and outer tires for slip. of the tires. It also helps to secure normal turning when the vehicle is steered while ASR is in operation. 3) Self-diagnosis function and saving of error code The controller monitors the system. If the system has a failure, the controller alerts the operator by turning on the trouble and buzzer. An error code is displayed and saved according to the contents of the failure. The controller then turns off the system.
ASR-II SYSTEM (OP)
4) ASR working lamp The ASR working lamp notifies that ASR is working. 5) Wheel speed sensors Each wheel speed sensor generates pulse voltage with the gear installed on the periphery of each pulse wheel and sends it to the sends it to the controller. 6) Steering angle sensor The steering angle sensor is installed to the center steering arm lever. The sensor sends the voltage signal of the center lever angle to the controller. 7) Pressure supply valve The pressure supply valve supplies air to the pressure control valve. If the system has a failure, the pressure supply valve will stop supplying air to the pressure control valve (upon receiving a command from the controller). 8) Pressure control valve The pressure control valve controls the brake according to the command from the controller.
SYSTEM CONFIGURATION The basic ASR system consists of electric parts such as the controller, switches, relays, lamps, wheel speed sensors, steering angle sensor, pressure control valve, and pressure supply valve. 1) ASR controller The ASR controller receives various signals and calculates them. The ASR controller will then output various signals for the above basic functions. 2) ASR system switch The ASR system works only while the ASR system switch is turned on. 3) ASR caution lamp If a system failure is detected while the ASR system switch is turned on, the ASR caution lamp will flash. The ASR caution lamp will also be utilized by the Automatic Retarder Speed Control ARSC if the ARSC is installed.
10-248 8
HD785-5
ASR • II SYSTEM (OP)
STRUCTURE AND FUNCTION
CONTROLLER OF AUTOMATIC SPIN REGULATOR
1. 2. 3. 4. 5. 6.
Self-diagnosis display window Printed circuit board Connector Connector Connector Case
HD785-5
FUNCTION This controller senses the speeds of both rear wheels with the wheel speed sensors. If the speed difference between both wheels increases, this controller applies the brake to the slipping wheel so that the speeds of both wheels will be the same.
10-251 8
STRUCTURE AND FUNCTION
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION) HD785-5
10-252 A
HD785-5
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8.
Air tank (wet) Regulator valve Hand valve Quick release valve Muffler Pressure switch Pressure caution lamp Hydraulic tank
A. To regulator valve B. From air tank (wet)
HD785-5
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)
OUTLINE • The machine with high altitude specification prevents cavitation in the hydraulic pumps by pressurizing hydraulic tank (8). • The pressure in the air tank (wet) (1) is reduced (78.4 kPa {0.8 kg/cm2}) by regulator valve (2) and applied through hand valve (3) and quick release valve (4) to the hydraulic tank. • If the pressure in the tank lowers below 34.3 kPa {0.35 kg/cm2}, pressure caution lamp (7) lights up.
10-253 A
STRUCTURE AND FUNCTION
HYDRAULIC TANK PRESSURIZING SYSTEM (HIGH ALTITUDE SPECIFICATION)
ELECTRICAL CIRCUIT DIAGRAM OF HYDRAULIC TANK PRESSURIZING SYSTEM
10-254 A
HD785-5
TESTING AND ADJUSTING Tools for testing, adjusting and troubleshooting ................................................................................ 20-102 Adjusting valve clearance ...................................................................................................................... 20-104 Measuring compression pressure ........................................................................................................ 20-105 Measuring blowby pressure .................................................................................................................. 20-106 Measuring boost pressure ..................................................................................................................... 20-107 Measuring exhaust temperature ........................................................................................................... 20-108 Testing and adjusting fuel injection timing .......................................................................................... 20-109 Adjusting alternator belt tension .......................................................................................................... 20-112 Adjusting engine speed sensor ............................................................................................................. 20-113 Adjusting transmission speed sensor .................................................................................................. 20-113 Adjusting accelerator pedal ................................................................................................................... 20-114 Testing hydtaulic pressure of torque converter valve ......................................................................... 20-115 Testing ECMV hydraulic pressure ...................................................................................................... 20-115-2 Testing transmission lubrication pressure ........................................................................................... 20-118 Testing torque converter stall speed .................................................................................................... 20-119 Testing brake pressure ........................................................................................................................... 20-121 Bleeding air from brake circuit .............................................................................................................. 20-122 Testing wear of front brake pad ............................................................................................................ 20-122 Testing wear of rear brake disc ............................................................................................................. 20-123 Adjusting parking brake ......................................................................................................................... 20-124 Testing brake performance .................................................................................................................... 20-125 Testing and adjusting front suspension cylinder (with variable damping force selector valve) ..... 20-126 Testing and adjusting inverted type rear suspension cylinder ........................................................... 20-130 Testing and adjusting suspension air cylinder .................................................................................... 20-134 Testing and adjusting air pressure in air circuit ................................................................................... 20-135 Adjusting hoist lever linkage ................................................................................................................. 20-136 Adjusting body positioner ..................................................................................................................... 20-137 Testing and adjusting hydraulic pressure in steering, hoist circuit ................................................... 20-138 Air bleeding from steering cylinder ...................................................................................................... 20-140 Adjusting electronic monitor (speedometer, tachometer module) .................................................... 20-141 Adjusting Q [fuel injection amount] when replacing engine controller ............................................ 20-142 Setting rotary switch (model data, network data) when replacing transmission controller ........... 20-143 Method of deleting data from engine controller, transmission controller and PMC memory (control from monitor panel) .............................................................................................................. 20-144 Method for emergency escape when there is failure in electrical system ........................................ 20-147 Procedure for operating modulation checker ...................................................................................... 20-153 Adjusting hydraulic tank pressure (High altitude specification) ........................................................ 20-158 Performing Pm clinic using manual snapshot (= quick PM) ............................................................... 20-159 Pm-clinic service ..................................................................................................................................... 20-163
HD785-5
20-101 B
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING Measurement item
Symbol
Engine speed
Oil pressure
Compression pressure
Blow-by pressure
6215-81-3500
Thermometer drive
6210-81-4111
Gear box
799-101-1502
Digital temperature gauge
–99.9 – 1,299˚C
799-101-5002
Hydraulic tester
Pressure gauge 2.4,5.9,39.2,58,8 MPa {25,60,400,600kg/cm2}
790-261-1203
Digital hydraulic tester
Pressure gauge 49.0MPa{500 kg/cm2}
2
799-401-2320
Hydraulic gauge
1.0 MPa{10 kg/cm2}
1
795-502-1590
Gauge assembly
2
795-502-1500
0 – 0.69 MPa {0 – 70 kg/cm2} Kit Part No. 795-502-1205
Adapter assembly
1
799-201-1511
Nozzle
2
799-201-1450
Adapter
3
799-201-1571
Tube
5
799-201-1590
Gauge
F
795-125-1210 or commercially available
Feeler gauge
V
799-201-2202
Boost gauge KIT
–760 – 1,500 mHg
R
795-471-1200
Gauge assembly
Dial gauge as commercially available
799-201-9000
Handy smoke checker
Commercially available
Smoke meter
79A-264-0091
Push-pull scale
0 – 490 N {0 – 50 kg}
79A-264-0021
Push-pull scale
0 – 294 N {0 – 30 kg}
1
C
D
Exhaust color
G
Operating effort
—
Kit Part No. 799-201-1504
Measurement range: 0 – 9.80 kPa {0 – 1,000 mmH2O} —
Discoloration 0 – 70% (with standard color) (Discoloration % × 1/10 • =• Bosch index)
H
Stroke, hydraulic drift
I
Work equipment speed
J
Sensors, wiring harnesses
L:60 – 2,000rpm Digital display H:60 –19,999rpm
E
Air supply pressure (boost pressure) Fuel injection timing adjustment
Voltage, resistance
Remarks
Multi-tachometer
B
Valve clearance
Disc wear
Part Name
799-203-8001 A
Water, exhaust, and oil temperatures
Part No.
Commercially available Commercially available
Scale
—
Stopwatch
—
1
561-98-61120
Disc gauge
For brake (ª1)
2
561-98-61122
Disc gauge
For brake (ª2)
79A-261-0211
Tester
K
L
M
799-601-7400
T-adapter kit
This includes all the T-adapters used on this machine. Depending on the attachments and specifications, the following part numbers are also available. • 799-601-2900 • 799-601-7300 799-601-7000 799-601-7200 For details of the above, see Service Mate SMP-405.
ª1. HD785-5 Serial No.: 4001 – 4253, HD985-5 Serial No.: 1021 and up ª2. HD785-5 Serial No.: 4254 and up
20-102 B
HD785-5
TESTING AND ADJUSTING
TESTING WEAR OF REAR BRAKE DISC
HD785-5 Serial No.: 4254 and up
¤
Stop the machine on level ground, apply the parking brake, and put blocks under the tires. ¤ Install and remove plugs and gauges with the brake cooling oil temperature below 60˚C and with the retarder brake control lever at the OFF position. ¤ If the disc is near the wear limit, check the wear frequently, regardless of the maintenance interval. In addition, check the performance of the retarder carefully. 1. Remove plug (1) of the rear brake, then install disc wear measurement gauge K. When installing, tighten nipple [2] completely and pull rod [1] of disc wear measurement gauge K fully. fl Pull rod [1] of gauge K fully before operating the retarder brake. 2. Turn the starting switch ON, and check that the air pressure gauge is in the green range. 3. If the air pressure is low, start the engine and run it at 2000 rpm until the air pressure gauge enters the green range. When it enters the green range, turn the starting switch OFF. 4. Pull rod [1] of disc wear measurement gauge K fully, then operate the retarder brake control lever slowly (take approx. 10 sec.) to apply the brake. 5. In this condition, push in rod [1] of disc wear measurement gauge K until it contacts the piston. 6. If mark a on disc wear measurement gauge K goes in beyond the end face (portion b) of the case, the disc has reached the wear limit. 7. After checking the brake wear, pull back rod [1] of wear measurement gauge K fully, then release the retarder brake. ¤ After checking the wear, if the retarder brake control lever is pulled suddenly, there is seious danger that the rod of the disc wear measurement gauge may fly out suddenly. for this reason, when the rod is fully pulled, release it, then pull the retarder control lever slowly over a period of approx. 10 seconds. (Release the retarder brake.) 8. After measuring the brake wear, install the plug, and bleed the air. For details, see Bleeding air from brake circuit.
20-123-1 B
HD785-5
SETTING ROTARY SWITCH WHEN REPLACING TRANSMISSION CONTROLLER
TESTING AND ADJUSTING
SETTING ROTARY SWITCH (MODEL DATA, NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER fl If the transmission controller is replaced with a new controller or the controller is used on another machine, set the model data and network connection data to match the model and specification of the machine. 1. Remove left and right grommets (1) on the top face of the old controller (controller being replaced) and check the settings of built-in rotary switch (2). 2. Remove left and right grommets (1) on the top face of the new (replacement) controller and use a screwdriver to turn built-in rotary switch (2) to set the controller settings to the settings of the old controller (settings before replacement). 3. Put left and right rubber grommets (1) back in their original positions on the top face. (Reference) The model data are set with the right rotary switch (switch 1) and the network connection data are set with the left rotary switch (switch 2). The relationship of the settings and the model data and network connection data is as shown in the table below. Rotary switch combination table Rotary switch (switch 1, 2) combinations (Switch 1 setting) – (Switch 2 setting)
HD785-5
8–0 8–1 8–2 8–3 9–1 9–2 9–3 9–4 A–1 A–2 A–3 A–4 B–0 B–1 B–2 B–3
HD985-5
8-8 8-9 8-A 8-B 9-8 9-9 9-A
9-B A-8 A-9 A-A A-B B-8 B-9 8-A B-B
ABS system
No No No No Yes Yes Yes Yes No
Engine controller (Komatsu engine)
No No No No No No
PMC controller
Yes No Yes No Yes No Yes
No Yes No Yes No Yes No Yes
No
Suspension controller (SUS)
Yes Yes No No Yes Yes No
No Yes Yes No No Yes Yes No
No
HD785-5
No
No No No Yes Yes Yes Yes
No Yes Yes Yes Yes Yes Yes Yes Yes
20-143 7
TESTING AND ADJUSTING
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL)
METHOD OF DELETING DATA FROM ENGINE CONTROLLER, TRANSMISSION CONTROLLER AND PMC MEMORY (CONTROL FROM MONITOR PANEL) fl For details, see MONITOR PANEL USER CODE AND SERVICE MODE FUNCTION in the Foreword of the Troubleshooting Section. 1. Outline fl If the transmission controller is going to be used on another machine, delete the trouble data and other data related to the current machine from the memory of the engine controller, transmission controller and PMC as follows. fl For the method of deleting the trouble data after troubleshooting or for another common reason, see MONITOR PANEL USER CODE AND SERVICE MODE FUNCTION, 3.3 Method of Operating Service Mode, (6) Method of Deleting Trouble Data from Memory in the Troubleshooting Section. fl If this function is used, the machine information saved in the controller is also deleted. Take care, especially when the machine is equipped with VHMS. 1) This function is used to delete data from the memory of the engine controller, transmission controller and PMC. 2) This function is effected by operating bulb check switch (1) and mode change switches (2) (the red switch at the front of the machine) and (3) (the black switch at the rear of the machine) {there are numbers on switch box (4), so check the numbers}, and using the SNET to send the command from the monitor panel to each controller to delete the data from memory. 3) The monitor panel accepts the operation for this function only when the starting switch is ON and the engine is stopped. In addition, each controller also accepts the operation for this function only when the starting switch is ON and the engine is stopped. 4) To prevent the data from being deleted from the memory of the wrong controller, mechatronics caution display (5) lights up to make it possible to confirm the controller from which the data is being deleted.
20-144 B
HD785-5
TESTING AND ADJUSTING
PROCEDURE FOR OPERATING MODULATION CHECKER
5. Procedure for manual operation of lock-up
¤
Check that the indicator of the machine air pressure gauge is in the green range. Turn the parking brake ON. Check that the surrounding area is safe, then start the engine. Turn the modulation checker power ON. Press 4th switch F on the keyboard. Press LOCK-UP switch C on the keyboard. fl Do this with the engine running at a midrange speed and check that the lock-up has been engaged by listening to the change in the engine sound. After this operation, press LOCK-UP switch C to turn the lock-up OFF. Press 4th switch F and check that the clutch signal has changed to N. After completing the measurement, stop the engine.
1) 2) 3) 4) 5)
6) 7) 8)
6. Measuring torque converter stall speed
¤
3) 4) 5)
6)
7) 8)
HD785-5
1) 2)
Check that the indicator of the machine air pressure gauge is in the green range. Turn the parking brake ON. Check that the surrounding area is safe, then start the engine. Turn the modulation checker power ON. Depress the brake pedal and actuate the emergency brake. Press SHIFT UP switch 9 on the key board three times to set the speed range to F3. fl When pressing SHIFT UP switch 9 the 2nd and 3rd times, press within 1 – 3 seconds each time. Depress the brake pedal with your left foot, then depress the accelerator pedal slowly with your right foot as far as it will go. Measure the engine speed. After completing the measurement, run the engine at low idling, then stop the engine.
20-157 5
TESTING AND ADJUSTING
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION)R
ADJUSTING HYDRAULIC TANK PRESSURE (HIGH ALTITUDE SPECIFICATION) HD785-5 Installation of pressure gauge 1. Before starting the engine, turn hand valve (1) to the CLOSE position and turn regulator valve knob (2) fully counterclockwise to close it (to prevent application of high pressure to the hydraulic tank). 2. Open the drain valve to discharge the all air from the air tank. 3. After discharging the air, remove plug (3) of the regulator valve and install a pressure gauge which can measure pressure of 9.8 – 98 kPa {0.1 – 1.0 kg/cm2}. Adjustment of pressure 1. Start the engine and accumulate air in the air tank. 2. Set regulator valve knob (2) to 49 kPa {0.5 kg/cm2} (to prevent application of high pressure to the hydraulic tank). 3. Turn hand valve (1) to the OPEN position to apply pressure to the hydraulic tank. 4. Raise the body slowly. At this time, the pressure gauge pointer lowers. 5. Lower the body slowly in the "FLOAT" mode. At this time, the pressure gauge pointer rises. When the body lowers halfway, the air is discharged through the quick release valve and the oil pressure stops rising. 6. Repeat the above operation of the body 2 to 3 times and seat the body. At this time, the pressure gauge pointer indicates the set pressure. 7. Set the pressure to the specified pressure by turning regulator valve knob (2). fl Specified pressure: 78.4 kPa {0.8 kg/cm2} 8. Repeat above steps 4 to 7 to set the pressure precisely to the specified pressure. Removal of pressure gauge 1. Stop the engine and release the air from the air tank. 2. Remove the pressure gauge and install plug (3).
20-158 A
HD785-5
TESTING AND ADJUSTING
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT (= QUICK PM)
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT (= QUICK PM) WHAT IS QUICK PM? If a serious error occurs, the VHMS snapshot function saves all the data for a period of 5 minutes 30 seconds before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds). This snapshot function can be started by pressing the manual switch. After the button is pressed, all data is automatically saved for seven minutes 30 seconds. All data can be automatically collected in cases such as torque converter stall, so it is possible to reduce the time taken for measurements in the Pm clinic. However, the data sampling frequency is one time every 10 seconds for the first 5 minutes and one time every second for the next 2 minutes 30 seconds. To raise the precision of the data, it is necessary to create the conditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.
NECESSARY TOOLS • Personal computer • VHMS technical analysis toolbox (software) 799-608-3211 • Download cable 799-608-3220 • Stopwatch
¤
To ensure safety, stop the machine on flat ground and put blocks under the tires to prevent the machine from moving.
1. Start the engine. 2. Keep the manual snapshot switch (green push button) pressed for approx. 5 sec.
HD785-5
20-159 B
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT (= QUICK PM)
TESTING AND ADJUSTING
3. Run the engine at low idling for 2 minutes to stabilize it. fl Check that the coolant temperature and torque converter oil temperature gauge are within the green range. 4. After starting, operate the machine as shown in Table 1. Table 1 Measurement conditions AISS SW
Power mode Gear shift lever selection
120 sec. Low idling(Low)
Auto
Economy
120 sec. Low idling(High)
Auto
Low idling 60 sec. (Economy mode)
5:30
High idling 30 sec. (Economy mode)
5:30
6:00
30 sec. (ª)
6
6:00
6:30
7
6:30
8
7:00
Start
Finish
1
0:00
2:00
2
2:00
3:00
3
4:00
5:00
4
5:00
5
Time
Engine speed
Parking brake
Retarder
Dump lever
N
ON
ON
Hold
Economy
N
OFF
OFF
Hold
Auto
Economy
N
ON
ON
Hold
Auto
Economy
N
ON
ON
Hold
Auto
Economy
D
OFF
ON
Hold
High idling 30 sec. (Power mode)
Auto
Power
N
ON
ON
Hold
7:00
30 sec. (ª)
Auto
Power
D
OFF
ON
Hold
7:30
High idling 30 sec. (Power mode)
Auto
Power
N
ON
ON
Hold
Torque converter stall (Economy mode)
Torque converter stall (Power mode)
Remarks
Note 1
Note 2, 3
Note 2, 3
Note 1: Press the foot brake. Note 2: When performing the torque converter stall {portion (ª)}, do not overheat the torque converter. [The 30 seconds for torque converter stall is only a reference value. If the torque converter oil temperature gauge enters the top level of the green range during the torque converter stall operation, return the transmission (gearshift lever) immediately to the N position.] Note 3: Reduce the speed to low idling before shifting to position D (to prevent the machine from starting suddenly).
20-160 B
HD785-5
TESTING AND ADJUSTING
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT (= QUICK PM)
5. After completing the measurement, reduce the engine speed to cool down the engine, then stop the engine. (End of snapshot) 6. Download the snapshot data to the personal computer. For details, see Procedure for downloading VHMS data to personal computer. NOTICE The quick PM data is only recorded once. If the operation is carried out again, the data is overwritten, so after performing the quick PM, always download the data to the personal computer. 7. Use the technical analysis toolbox to read the quick PM data. fl For details of the method of using the technical analysis toolbox, see the instruction manual. • Open the quick PM data and make a graph For the X-axis, select Time and for the Y-axis select the following: 1) Engine Speed 2) Blowby Press (Blow-by pressure) 3) Exhaust Temp RB (Right bank) 4) Exhaust Temp LB (Left bank) 5) Engine Oil Press (Engine oil pressure) and put a check mark against Graph value display at the click position (marked by ).
HD785-5
20-161 B
PERFORMING Pm CLINIC USING MANUAL SNAPSHOT (= QUICK PM)
TESTING AND ADJUSTING
•
If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph. (Example of graph display)
•
Enter these values on the Pm Clinic check sheet. The relationship between the measurement conditions and the necessary data in the Pm Clinic is as shown below. Conditions Engine speed
Mode
1
Low idling
Low
2
Low idling
High
3
Low idling
Economy mode
4
High idling
Economy mode
5
Torque converter stall Economy mode
6
High idling
7
Torque converter stall Power mode
8
High idling
20-162 B
Measurement items Lublicating oil Engine speed Blow-By pressure pressure
Exhaust temperature
Power mode Power mode
HD785-5
TESTING AND ADJUSTING
Pm-CLINIC SERVICE
Pm-CLINIC SERVICE
HD785-5
20-163 B
TESTING AND ADJUSTING
20-164 B
Pm-CLINIC SERVICE
HD785-5
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors 1 Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. fl If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the 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. fl If there is any damage or breakage, replace the connector. 2 Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3 Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. fl If the connector cannot be corrected easily, remove the clamp and adjust the position. 4 If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole heavy duty type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female conector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
HD785-5
20-207 A
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in 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 follows. 1 Disconnect the connector and wipe off the water with a dry cloth. fl 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 oil and water from the compressed 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. fl Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. fl After completely drying the connector, blow it with contact restorer and reassemble.
20-208 A
HD785-5
TROUBLESHOOTING
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
3.5 Monitoring items in machine data monitoring mode Monitoring item values are useful when-cheking or troubleshooting the machine. For details of the method for going on to the next monitor item (or going back to the previous monitor item) in the machine data monitoring mode, see 3.3 Method of operating service mode. Control- Monitor Item Display unit Remarks ler code item code
fl
Monitor panel 1 Standard service meter 2 Switch check 1) KPH/MPH selector signal 2) Exhaust brake switch 3) AISS switch 4) Mode selector switch 1 5) Mode selector switch 2 3 Rotary switch setting Transmission controller 1 Model recognition 2 Service meter A
3 Switch check 1) Body seated switch 2) Spare 3) Spare 4) Spare 5) Spare 6) Spare 7) AISS relay signal 8) Spare 9) BCV solenoid 10) Model selection signal 1 11) Model selection signal 2 12) Model selection signal 3 13) Model selection signal 4 14) Connector check 1 15) Connector check 2 16) Emergency escape switch 17) Starting switch 4 Fill signal switch
b 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
HD785-5
1) L clutch 2) Spare 3) H clutch 4) 1st clutch 5) 2nd clutch 6) 3rd clutch 7) 4th clutch 8) R clutch Engine speed Transmission input shaft speed Transmission intermediate shaft speed Transmission output shaft speed Accelerator sensor Brake air pressure Spare Spare Rear brake cooling oil temperature Engine water temperature Torque converter outlet port oil temperature Fuel level Spare ECMV oil temperature Spare Spare Spare Engine oil pressure
10h ª1 ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 0–F ª2 10h ª1 ON/OFF — — — — — ON/OFF — ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ª1
ON/OFF — ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 10rpm 10rpm 10rpm 10rpm 0.02 V ª3 — — 1˚C 1˚C 1˚C 1Ω — 1˚C — — — 9.81kPa {0.1kg/cm2} Max. speed range 4–7 Max. speed range (when body is raised) 0–3 Caution setting (when body is raised) 1 or 2 Spare — Solenoid H output 4 mmA Solenoid L output 4 mmA Solenoid 1 output 4 mmA Solenoid 2 output 4 mmA Solenoid 3 output 4 mmA Solenoid 4 output 4 mmA Spare — Spare —
After 10000h, shows units of 100h, and left turn signal lamp lights up The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number lights up, See Table 1-a (ª1-a) ON: MPH displayed Only when exhaust brake is installed
Applicable item in Table 1-b lights up (ª1-b) See Table 2 (ª2) For details, see Item 3) Service meter for each controller (ª5) After 10000h, shows units of 100h, and left turn signal lamp lights up The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number lights up. See Table 1-a (ª1-a) ON: When not seated
HD785 mechanical governor specification machine only HD465 – HD785 ON: When retarder lever or brake pedal is ON OFF : OPEN (HD785), ON : GND (HD985) OFF : OPEN (HD785, HD985) ON : GND (HD785, HD985) ON : GND (HD785, HD985) OFF : OPEN ON : GND ON: When cranking (START position) The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number lights up. See Table 1-a (ª1-a) For details of the relationship between the speed range and the clutches, see ECMV Clutch Actuation Table in the section on the transmission valve.
When at Li : 180–200, when at Hi : 50–70 See Table 3 (ª3)
Lo display when less than 60˚C, see Table 4 (ª4) Lo display when less than 60˚C (mechanical governor specification machine only), see Table 4 (ª4)
Lo display when less than 60˚C, see Table 4 (ª4) 4 – 100 (FULL: Less than 13; EMPTY: More than 75) Lo display when less than 60˚C, see Table 4 (ª4)
Mechanical governor specification machine only. For details, see “Pressure display value” in Item 4) (ª6) 4 – 7: F4 – F7 (no limit) 1 – 3: F1 – F3, 0: default (F2 only when lever is at D, F1 only when lever is at position other than D)
1: OFF, 2: ON, When actuated : 133–138 When actuated : 150–156 When actuated : 211–220 When actuated : 211–220 When actuated : 154–160 When actuated : 202–211
20-255 7
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
TROUBLESHOOTING
Control- Monitor ler code item code Engine controller 1 Service meter 2
3 4 5 6 7 8 9 10 11 12
c
Item
Switch check
1) Governor cut relay signal (Left) 2) Governor cut relay signal (Right) 3) Connector check 1 4) Connector check 2 5) Idling varidation signal 2 6) Idling varidation signal 3 7) Start switch Set value rotary switch1 Set value rotary switch2 Axcel sensor Rack sensor (Left) Rack sensor (Right) Pre-stroke solenoid (Left) Pre-stroke solenoid (Right) Governor solenoid (Left) Governor solenoid (Right) Engine oil pressure
13 Engine water temperature 14 Spare 15 Spare 16 Spare 17 Spare 18 Spare 19 Spare 20 Spare 21 Spare 22 Spare 23 Spare 24 Spare 25 Spare 26 Spare 27 Spare 28 Engine 29 Spare Suspension controller 1 Service meter 2
d 3 4 5 6 7 8 9 10 11
20-256 B
Switch check
Remarks
Display unit 10h 1ª
ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 0-F 0-F 0.02 V 0.1 mm 0.1 mm 10 mmA 10 mmA 10 mmA 10 mmA 9.81kPa {0.1kg/cm2} 1°C — — — — — — — — — — — — — — 10rpm — 10h ª1
1) Auto suspension solenoid 1 output ON/OFF 2) Auto suspension solenoid 2 output ON/OFF 3) Auto suspension solenoid 3 output ON/OFF 4) Rear brake ON/OFF 5) Body FLOAT switch ON/OFF 6) Body selection switch ON/OFF Suspension pressure (left) 0.098MPa{1kg/cm2} Suspension pressure (right) 0.098MPa{1kg/cm2} Steering angle speed 1 rpm Spare — Spare — Spare — Spare — Spare — Transmission output shaft speed 10 rpm
See item 3). After 10000h, shows units of 100h, and left turn signal lamp lights up The 1), 2), etc. in the item corresponds to the bit number, When ON, applicable bit ummber lights up. See Table 1-a (ª1-a) HD785 (V engine only) OFF: OPEN ON : GND ON : GND (at accelater pedal OFF) ON : GND (at accelater pedal ON) ON : When cranking (START position) Applicable item in Table 1-b lights up (ª1-b) Applicable item in Table 1-b lights up (ª1-b) When at Li : 15–27, when at Hi : 175–225 HD785 (V engine only) When at Li : 60–80 When at Li : 60–80 HD785 (V engine only) When at Li : 55–60, when at Hi : 63–80 When at Li : 55–60, when at Hi : 63–80 HD785 (V engine only) When at Li : 49–52, when at Hi : 47–53 When at Li : 49–52, when at Hi : 47–53 When at Li : 10–20, when at Hi : 30–40 For details, see “Pressure display value” in Item 4) (ª6) Lo display wheb less than 60°C, ª4: See Table 4
For details, see Item 3) Service meter for each controller (ª5) After 10000h, shows units of 100h, and left turn signal lamp lights up The 1), 2), etc. in the item corresponds to the bit number. When ON, applicable bit number lights up, See Table 1-a (ª1-a) ON : When at M mode or H mode ON : When at M mode ON : When at S mode or H mode ON : GND (when not at FLOAT position) ON : GND (HD465) OFF : OPEN (other than HD465) For details, see “Pressure display value” in Item 4) (ª6) For details, see “Pressure display value” in Item 4) (ª6)
HD785-5
TROUBLESHOOTING
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
Table 1-a Bit number (ª1-a) Of the machine data monitoring mode items, with the displays for the switch checks (monitor panel item code 2, transmission controller 3, 4, engine controller 2, suspension controller 2), the values 1), 2), 3)... with each signal in the item corrspond to the number of each pin in the chart below.
Table 1-b Rotary switch set (ª1-b)
HD785-5
20-257 7
TROUBLESHOOTING
MONITOR PANEL USER CODES AND SERVICE MODE FUNCTION
fl When it is difficult to judge which bit number is lighted up (in particular, numbers 3 and 8 or 5 and 14), it is possible to press the burned-out bulb check switch (1) to light up all the segments and check the bit position.
Table 2 Controller model recognition (ª2) Model display value for machine data monitoring mode
Machine specification
Model display value for machine data monitoring mode
325
HD325/405 mechanical governor
785
HD785 mechanical governor
32b
HD325/405 electronic governor
78b
HD785 electronic governor
465
HD465/605 electronic governor
985
HD985 mechanical governor
98b
HD985 electronic governor
Machine specification
Table 3 Pressure display of brake air pressure sensor (ª3) The brake air pressure sensor is not an analog output but a level output, so the value for the pressure display corresponding to the air pressure level display is the fixed value in the table below.
20-258 B
Pressure display value in machine data monitoring mode MPa {kg/cm2} When pressure is rising and at When pressure is rising and at present level present level 0.932 {9.5}
Caution level
Gauge level
Red
7
Green
6
0.814 {8.3}
0.912 {9.3}
Green
5
0.716 {7.3}
0.794 {8.1}
Green
4
0.618 {6.3}
0.696 {7.1}
Green
3
0.510 {5.2}
0.598 {6.1}
Red
2
0.245 {2.5}
0.510 {5.2}
Red
1
0 {0}
0.226 {2.3}
HD785-5
TROUBLESHOOTING
TABLE OF SERVICE CODES AND USER CODES
Monitor panel display
Details of failure
No.
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
Abnormality 1 in pressure control valve system for 1st clutch Abnormality 1 in pressure control valve system for 2nd clutch Abnormality 1 in pressure control valve system for 3rd clutch Abnormality 1 in pressure control valve system for 4th clutch Abnormality 1 in pressure control valve system for R clutch Abnormality 2 in pressure control valve system for H clutch Abnormality 2 in pressure control valve system for L clutch Abnormality 2 in pressure control valve system for 1st clutch Abnormality 2 in pressure control valve system for 2nd clutch Abnormality 2 in pressure control valve system for 3rd clutch Abnormality 2 in pressure control valve system for 4th clutch Abnormality 2 in pressure control valve system for R clutch Abnormality in oil flow detection valve system for H clutch Abnormality in oil flow detection valve system for L clutch Abnormality in oil flow detection valve system for 1st clutch Abnormality in oil flow detection valve system for 2nd clutch Abnormality in oil flow detection valve system for 3rd clutch Abnormality in oil flow detection valve system for 4th clutch Abnormality in oil flow detection valve system for R clutch Abnormality in engine speed sensor system Abnormality in transmission input shaft speed sensor system Abnormality in transmission intermediate shaft speed sensor system Abnormality in transmission output shaft speed sensor system Short circuit in lock-up clutch solenoid system Short circuit in H clutch solenoid Short circuit in L clutch solenoid Short circuit in 1st clutch solenoid Short circuit in 2nd clutch solenoid Short circuit in 3rd clutch solenoid Short circuit in 4th clutch solenoid Short circuit in R clutch solenoid Disconnection in lock-up clutch solenoid system Disconnection in H clutch solenoid Disconnection in L clutch solenoid Disconnection in 1st clutch solenoid Disconnection in 2nd clutch solenoid Disconnection in 3rd clutch solenoid Disconnection in 4th clutch solenoid Disconnection in R clutch solenoid Abnormality in model selection system rotary switch Abnormality in torque converter oil temperature sensor system Abnormality in fuel sensor system Abnormality in coolant temperature sensor system (✩) Abnormality in air pressure sensor system Abnormality in retarder brake oil level sensor (right) system Abnormality in connector connection Short circuit with ground in BCV solenoid system Disconnection in BCV solenoid system Short circuit in BCV solenoid system Transmission filter clogging warning
HD785-5
Service code
User code
Automatic gearshifting Central mechatronics warning lamp caution lamp
(Existing, reset) (Existing) (Existing) (Existing) b034 02 ON FLASHES b035 02 ON FLASHES b036 02 ON FLASHES b037 02 ON FLASHES b038 02 ON FLASHES b042 02 ON FLASHES b043 02 ON FLASHES b044 02 ON FLASHES b045 02 ON FLASHES b046 02 ON FLASHES b047 02 ON FLASHES b048 02 ON FLASHES b052 02 ON FLASHES b053 02 ON FLASHES b054 02 ON FLASHES b055 02 ON FLASHES b056 02 ON FLASHES b057 02 ON FLASHES b058 02 ON FLASHES b060 02 ON FLASHES b061 02 ON FLASHES b062 02 ON FLASHES b063 02 ON FLASHES b071 02 ON FLASHES b072 02 ON FLASHES b073 02 ON FLASHES b074 02 ON FLASHES b075 02 ON FLASHES b076 02 ON FLASHES b077 02 ON FLASHES b078 02 ON FLASHES b091 02 ON FLASHES b092 02 ON FLASHES b093 02 ON FLASHES b094 02 ON FLASHES b095 02 ON FLASHES b096 02 ON FLASHES b097 02 ON FLASHES b098 02 ON FLASHES b0A1 04 ON FLASHES b0A2 02 ON FLASHES b0A3 02 ON FLASHES b0b2 02 ON FLASHES b0b3 02 ON FLASHES b0b4 02 ON FLASHES b0C1 04 ON FLASHES b0C4 02 ON FLASHES b0C6 02 ON FLASHES b0C8 02 ON FLASHES b0d1 01 OFF FLASHES(ª)
Controller LED display Transmission oil temperature 15˚ or above (Existing) E. ↔ 3.4 E. ↔ 3.5 E. ↔ 3.6 E. ↔ 3.7 E. ↔ 3.8 E. ↔ 4.2 E. ↔ 4.3 E. ↔ 4.4 E. ↔ 4.5 E. ↔ 4.6 E. ↔ 4.7 E. ↔ 4.8 E. ↔ 5.2 E. ↔ 5.3 E. ↔ 5.4 E. ↔ 5.5 E. ↔ 5.6 E. ↔ 5.7 E. ↔ 5.8 E. ↔ 6.0 E. ↔ 6.1 E. ↔ 6.2 E. ↔ 6.3 E. ↔ 7.1 E. ↔ 7.2 E. ↔ 7.3 E. ↔ 7.4 E. ↔ 7.5 E. ↔ 7.6 E. ↔ 7.7 E. ↔ 7.8 E. ↔ 9.1 E. ↔ 9.2 E. ↔ 9.3 E. ↔ 9.4 E. ↔ 9.5 E. ↔ 9.6 E. ↔ 9.7 E. ↔ 9.8 E. ↔ A.1 E. ↔ A.2 E. ↔ A.3 E. ↔ b.2 E. ↔ b.3 E. ↔ b.4 E. ↔ C.1 E. ↔ C.4 E. ↔ C.6 E. ↔ C.8 E. ↔ d.1
Below 15˚ (Existing) (Reset) E.C ↔ 3.4 3.4 E.C ↔ 3.5 3.5 E.C ↔ 3.6 3.6 E.C ↔ 3.7 3.7 E.C ↔ 3.8 3.8 E.C ↔ 4.2 4.2 E.C ↔ 4.3 4.3 E.C ↔ 4.4 4.4 E.C ↔ 4.5 4.5 E.C ↔ 4.6 4.6 E.C ↔ 4.7 4.7 E.C ↔ 4.8 4.8 E.C ↔ 5.2 5.2 E.C ↔ 5.3 5.3 E.C ↔ 5.4 5.4 E.C ↔ 5.5 5.5 E.C ↔ 5.6 5.6 E.C ↔ 5.7 5.7 E.C ↔ 5.8 5.8 E.C ↔ 6.0 6.0 E.C ↔ 6.1 6.1 E.C ↔ 6.2 6.2 E.C ↔ 6.3 6.3 E.C ↔ 7.1 7.1 E.C ↔ 7.2 7.2 E.C ↔ 7.3 7.3 E.C ↔ 7.4 7.4 E.C ↔ 7.5 7.5 E.C ↔ 7.6 7.6 E.C ↔ 7.7 7.7 E.C ↔ 7.8 7.8 E.C ↔ 9.1 9.1 E.C ↔ 9.2 9.2 E.C ↔ 9.3 9.3 E.C ↔ 9.4 9.4 E.C ↔ 9.5 9.5 E.C ↔ 9.6 9.6 E.C ↔ 9.7 9.7 E.C ↔ 9.8 9.8 E.C ↔ A.1 A.1 E.C ↔ A.2 A.2 E.C ↔ A.3 A.3 E.C ↔ b.2 b.2 E.C ↔ b.3 b.3 E.C ↔ b.4 b.4 E.C ↔ C.1 C.1 E.C ↔ C.4 C.4 E.C ↔ C.6 C.6 E.C ↔ C.8 C.8 E.C ↔ d.1 d.1
20-267 7
TROUBLESHOOTING
TABLE OF SERVICE CODES AND USER CODES
Monitor panel display
Details of failure
No.
77 78 79 80 81 82 83 84 85 86 87 88 89 90
Torque converter oil temperature overheat warning Engine water temperature overheat warning (✩) Tilt warning Radiator water level drop warning Abnormality in charging circuit system Engine overrun prevention brake actuated Engine overshoot Drop in battery direct power source voltage Drop in main power source voltage Steering oil temperature overheat warning Drop in air pressure Retarder overheat warning Drop in engine oil pressure Abnormality in brake circuit system
Service code
User code
Controller LED display
Automatic gearshifting Central mechatronics warning lamp caution lamp
(Existing, reset) (Existing) (Existing) (Existing) b0d2 05 OFF FLASHES b0d3 05 OFF FLASHES b0d5 07 OFF FLASHES b0d6 01 OFF FLASHES b0d7 01 ON FLASHES(ª) b0d8 03 OFF FLASHES b0d9 02 ON FLASHES b0dA 04 ON FLASHES b0db 04 ON FLASHES b0E5 05 OFF FLASHES b0E9 05 OFF FLASHES b0F3 05 OFF FLASHES b0F5 04 OFF OFF b0F6 04 OFF FLASHES
Transmission oil temperature 15˚ or above (Existing) E. ↔ d.2 E. ↔ d.3 E. ↔ d.5 E. ↔ d.6 E. ↔ d.7 E. ↔ d.8 E. ↔ d.9 E. ↔ d.A E. ↔ d.b E. ↔ E.5 E. ↔ E.9 E. ↔ F.3 E. ↔ F.5 E. ↔ F.6
Below 15˚ (Existing) (Reset) E.C ↔ d.2 d.2 E.C ↔ d.3 d.3 E.C ↔ d.5 d.5 E.C ↔ d.6 d.6 E.C ↔ d.7 d.7 E.C ↔ d.8 d.8 E.C ↔ d.9 d.9 E.C ↔ d.A d.A E.C ↔ d.b d.b E.C ↔ E.5 E.5 E.C ↔ E.9 E.9 E.C ↔ F.3 F.3 E.C ↔ F.5 F.5 E.C ↔ F.6 F.6
Note 1: “Existing” means that the problem is still occurring; “Reset” means that the problem occurred in the past. Note 2: If the problem is still existing, the alarm buzzer will also sound. (When the central warning lamp is FLASHES.) For items marked ª, the alarm buzzer does not sound. Note 3: Reset failures are kept as existing failures for 5 minutes by the transmission controller only; after that, they are saved as a service code for past failures. Note 4: For details of the method of display of the service code for reset failures on the monitor panel, see MONITOR PANEL USER CODE AND SERVICE MODE FUNCTION, Section 3.2 SERVICE CODE AND TROUBLE DATA DISPLAY MODE in the Foreword to the Troubleshooting Section. For the method of displaying with the transmission controller LED display, see SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS, Section 2.4 SAVING SERVICE CODE TO MEMORY in the Foreword to the Troubleshooting Section. ✩: Applicable only for mechanical governor specification machine.
3. TABLE OF SERVICE CODES AND USER CODES RELATED TO ENGINE CONTROLLER
No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Monitor panel display Engine mechaService code User code tronics Details of failure caution lamp (Existing, reset) (Existing) (Existing) C010 04 ON Abnormality in power source system C011 04 ON Abnormality in controller C012 02 ON Abnormality in pressure sensor right bank system C013 02 ON Abnormality in pressure sensor left bank system C014 04 ON Abnormality in governor (right) solenoid system C015 04 ON Abnormality in governor (left) solenoid system C016 02 ON Abnormality in governor cut relay (right) system C017 02 ON Abnormality in governor cut relay (left) system C018 02 ON Abnormality in rack sensor power source system C019 04 ON Abnormality in governor servo (right) system C01A 04 ON Abnormality in governor servo (left) system C01b 02 ON Abnormality in engine speed sensor A system C01C 02 ON Abnormality in engine speed sensor B system C01d 02 ON Abnormality in pre-stroke solenoid right bank system C01E 02 ON Abnormality in pre-stroke solenoid left bank system C021 04 ON Abnormality in connection of connector C022 03 OFF Engine overrun actuated C023 05 OFF Engine water temperature overheat warning
20-268 B
Central warning lamp
Controller LED display
(Existing) (Existing) FLASHES E. ↔ 1.0 FLASHES E. ↔ 1.1 FLASHES E. ↔ 1.2 FLASHES E. ↔ 1.3 FLASHES E. ↔ 1.4 FLASHES E. ↔ 1.5 FLASHES E. ↔ 1.6 FLASHES E. ↔ 1.7 FLASHES E. ↔ 1.8 FLASHES E. ↔ 1.9 FLASHES E. ↔ 1.A FLASHES E. ↔ 1.b FLASHES E. ↔ 1.C FLASHES E. ↔ 1.d FLASHES E. ↔ 1.E FLASHES E. ↔ 2.1 OFF E. ↔ 2.2 OFF E. ↔ 2.3
(Reset) 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.A 1.b 1.C 1.d 1.E 2.1 2.2 2.3
HD785-5
Monitor Controller panel display display
A-16
b071
E. ↔ 7.1 – b078 E. ↔ 7.8 Short circuit in pressure control valve solenoid E.C ↔ 7.1 E.C ↔ 7.8 system is displayed .................................................................. 20-566
b091
E. ↔ 9.1 – b098 E. ↔ 9.8 Disconnection in pressure control valve solenoid E.C ↔ 9.1 E.C ↔ 9.8 system is displayed .................................................................. 20-566
Abnormality in sensor system A-17 b0A2 b0A3 b0b2 b0b3 b0b4
E. ↔ A.2 a) E.C ↔ A.2 E. ↔ A.3 b) E.C ↔ A.3 E. ↔ b.2 c) E.C ↔ b.2 E. ↔ b.3 d) E.C ↔ b.3 E. ↔ b.4 e) E.C ↔ b.4
Abnormality in torque converter oil temperature sensor system is displayed ....... 20-568 Abnormality in fuel level sensor system is displayed ........................................... 20-569 Abnormality in cooling water temperature sensor system is displayed .............. 20-570 Abnormality in air pressure sensor system is displayed ....................................... 20-571 Abnormality in retarder brake oil temperature sensor is displayed ..................... 20-572
Warning display A-18 b0d1 b0d5 b0d6 b0d7 b0E5 b0F5
E. ↔ d.1 a) E.C ↔ d.1 E. ↔ d.5 b) E.C ↔ d.5 E. ↔ d.6 c) E.C ↔ d.6 E. ↔ d.7 d) E.C ↔ d.7 E. ↔ E.5 e) E.C ↔ E.5 E. ↔ F.5 f) E.C ↔ F.5
Transmission filter clogged warning is displayed .................................................. 20-573 Tilt warning is displayed ........................................................................................... 20-574 Drop in radiator water level warning is displayed ................................................. 20-575 Battery charge level warning is displayed .............................................................. 20-576 Steering oil temperature overheat warning is displayed ...................................... 20-577 Drop in engine oil pressure warning is displayed (mechanical governor specification machine) ........................................................ 20-578
E. ↔ F.6 g) Rear brake oil pressure warning is displayed ......................................................... 20-579 E.C ↔ F.6 E. ↔ b.7 A-19 b0b7 Abnormality in engine oil pressure sensor system is displayed E.C ↔ b.7 b0F6
(mechanical governor specification machine) ............................................................ 20-580 A-20 b0C1 A-21 b0d2 b0d3 b0E9 b0F3 b0d8 b0d9
HD785-5
E. ↔ C.1 Abnormality in connector connection is displayed .................................................... 20-581 E.C ↔ C.1 E. ↔ d.2 a) Torque converter oil temperature overheat warning is displayed ........................ 20-582 E.C ↔ d.2 E. ↔ d.3 b) Engine water temperature overheat warning is displayed ................................... 20-582 E.C ↔ d.3 E. ↔ E.9 c) Air pressure drop warning is displayed .................................................................. 20-582 E.C ↔ E.9 E. ↔ F.3 d) Retarder brake oil temperature overheat warning is displayed ............................ 20-582 E.C ↔ F.3 E. ↔ d.8 e) Engine overrun prevention brake actuated is displayed ....................................... 20-583 E.C ↔ d.8 E. ↔ d.9 f) Engine overshoot actuated is displayed ................................................................. 20-583 E.C ↔ d.9
20-503 B
fl Re-enacting failures in electrical system With failures in the electrical system, there are cases where failures, such as defective contact of wiring harnesses and connectors, occur only under special conditions particularly at the initial stage of the occurrence of the failure. (For example, when the engine is running at high speed or the truck is traveling at high speed on rough road surfaces) Therefore, investigate the values for the resistance and voltage at the locations indicated by the abnormal display, Even if no abnormality is found, it is necessary to investigate the conditions under which the failure occurred, and to try to re-enact the failure condition to carry out troubleshooting.
20-504 1
HD785-5
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal : Check with tester Voltage (V), current (A), resistance value Ω ATC3B,3A (male) TMD,TMB (male)
J02
64
Ω
2k Ω – 20k Ω (5) – chassis (10) – chassis (1) – chassis (25˚C – 120˚C)
Between (8) – (16) Between (5) – (9) Between (10) – (9) Between (1) – (2)
(8) – chassis
ATC3B
TMD
J02
27
(12) – chassis (15) – chassis (2) – chassis
(3) – chassis Between (2) – (3)
(V) 0.4 – 4.6 V
1. Between ATC5A (1) – ATC1 (16) :0Ω 2. ATC5A, ATC1 connectors are securely inserted.
ATC1
TMB
R04
(V)
(11) – chassis (13) – chassis (1) – chassis Between relay (1) and (2)
ATC1
TMB
20 – 30 V 100 – 500 Ω
R04
(V)
(11) – chassis (13) – chassis (1) – chassis Between relay (1) and (2)
ATC1
TMB
Ω
Ω
20 – 30 V 100 – 500 Ω
R04
(V)
(11) – chassis (13) – chassis (1) – chassis Between relay (1) and (2)
Ω
20 – 30 V 100 – 500 Ω
When transmission filter is normal, condition is as shown in table below. ATC5A (6) – chassis
TMD
J02
52
(6) – chassis (13) – chassis (1) – chassis Between (1) – (2)
ATC5A
TMD
SR3
(2) – chassis
(1) – chassis, (1) – (2)
Continuity
When radiator water level is normal, condition is as shown in table below. ATC5B TMD J02 01 03 (15) – chassis (4) – chassis (7) – chassis (8) – chassis (1) – chassis, (1) – (2) Continuity
HD785-5
Symptoms that appear in machine when there is abnormality Mechatronics abnormality display given, warning actuated
Only gives self-diagnostic display; does not take any action
No display at all is given on retarder oil temperature gauge display on monitor panel.
Only gives self-diagnostic display; does not take any action
Drop in engine oil pressure cannot be detected.
If there is abnormality when starting switch is turned ON, transmission is held at Neutral.
When starting switch is turned ON, machine cannot move off even when shift lever is operated.
Only gives self-diagnostic display; does not take any action
BCV is not actuated
Only gives self-diagnostic display; does not take any action
BCV is not actuated
Only gives self-diagnostic display; does not take any action
BCV is mistakenly actuated
Only gives self-diagnostic display; does not take any action
1. If operations are continued, dirt will circulate in transmission circuit. 2. Mechatronics abnormality display is not given. 3. Buzzer does not sound.
Only gives self-diagnostic display; does not take any action
1. If operations are continued, machine may roll over. 2. Mechatronics abnormality display is not given.
Only gives self-diagnostic display; does not take any action
1. If operations are continued, there will be overheating. 2. Mechatronics abnormality display is not given.
No continuity
When machine tilt angle is ± 15˚, condition is as shown in table below. (5) – chassis
Action of controller when abnormality is detected
20-525 1
TROUBLESHOOTING
Display code
Abnormal system fl Judgment conditions
b0d7
Battery charge warning dis-
E. ↔ d.7 play E.C↔ d.7 fl When battery charge
ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON MACHINE
Details of abnormality Check the wiring harnesses and equipment : Disconnection, short circuit in wiring harness given below (+): Positive, (–): Negative 1. Between ATC3B (1) – TMD (1) – J01 (1) – alternator terminal R 2. Defective charging circuit
switch is OFF with engine speed at 500 rpm or above.
b0F5
Engine oil pressure drop
E. ↔ F.5 warning E.C↔ F.5 fl When an abnormality is
recognized in the engine oil pressure with engine speed at 700 rpm or above.
b0E5
Steering oil temperature
1. Between ATC3B (12) – TMD (15) – J02 (2) – 27 (3) 2. Defective engine lubricating oil circuit 3. Defective engine oil pressure sensor
1. Between ATC3A (11) – TMA (8) – J01 (6) – 21 (1)
E. ↔ E.5 overheat warning E.C↔ E.5 fl When steering oil tem- 2. Defective steering oil temperature sensor perature switch is ON.
b0F6
Rear brake oil pressure
E. ↔ F.6 warning display E.C↔ F.6 fl When brake stroke
switch is ON for 2 seconds.
b0d3
Engine water temperature
E. ↔ d.3 overheat warning E.C↔d.3 fl When engine water
1. Between (+) ATC5A (8) – TMC (12) – J03 (2) – BLSL (1) Between BLSL (2) – BLSR (1) Between (–) BLSR (2) – GND.67 2. Defective brake stroke sensor Abnormal rise in engine water temperature.
temperature sensor signal is above 102˚C.
b0d2
Torque converter oil tem-
E. ↔ d.2 perature overheat warning E.C↔ d.2 fl According to network
Abnormal rise in torque converter oil temperature
data from monitor system.
b0E9
Air pressure drop warning
E. ↔ E.9 fl According to network data from monitor sysE.C↔ E.9
Abnormal drop in air pressure inside air tank
tem.
b0F3
Retarder oil temperature
E. ↔ F.3 overheat warning E.C↔ F.3 fl According to network
Abnormal rise in retarder oil temperature
data from monitor system.
b0d8
Engine overrun prevention
E. ↔ d.8 brake actuated display E.C↔ d.8 fl Overrun actuated with
Engine overrun prevention brake actuated display
transmission input shaft speed more than 2,600 rpm.
b0d9
E. ↔ d.9 E.C↔ d.9
fl
Engine overshoot display fl When d.8 does not detect engine overshoot display with engine speed at 2,600 rpm or above
Engine overshoot display (sudden spurt)
The top code in the Display code column shows the monitor panel display and the bottom code (in [ ]) shows the transmission controller LED display.
20-526 B
HD785-5
TESTING AND ADJUSTING
e)
A-21
Engine overrun prevention brake actuated is displayed
fl This shows that the engine overrun prevention brake has been actuated to protect the transmission.
Cause
1 YES
Normal
Has machine been traveling with transmission input shaft speed of more than 2600 rpm?
—
Defective controller
• Use the machine NO data monitor in the background mode of the machine monitor system to check the transmission input shaft speed. For details, see USER MODE AND SERVICE FUNCTION of the monitor panel.
f)
Remedy
Replace
Engine overshoot actuated is displayed
fl This shows that there has been engine overshoot (sudden spurt).
Cause
1 YES Has accelerator been depressed to raise engine speed to more than 2600 rpm?
• Use the machine NO data monitor in the background mode of the machine monitor system to check the engine speed. For details, see USER MODE AND SERVICE FUNCTION of the monitor panel.
HD785-5
Remedy
Abnormality in engine fuel injection system
Repair
Defective controller
Replace
20-583 B
OUTLINE
TROUBLESHOOTING
4. WHEN SYSTEM IS NORMAL A code is displayed on the controller LED under the assistant’s seat. No. Code
Conditions
1
0.0
When accelerator pedal is being depressed
2
0.0.
When accelerator pedal is not being depressed
fl If the above code is not displayed when the accelerator pedal is being depressed or not being depressed, it is necessary to adjust the accelerator link. If it is not properly adjusted, the ARSC system will not be able to judge correctly if the accelerator pedal is being depressed or not, so the ARSC may not work normally. fl Note that this function is not installed to the combination system of ASR and ARSC (the system that uses the ASR-II controller).
6. METHOD OF CLEARING SERVICE CODE Turn the machine starting switch to ON (the engine is not started) and disconnect connectors CR1 and CR2 under the assistant’s seat. When this is done, “– –” is displayed on the controller LED. When the “– –” changes from flashing and stays lighted up (3 seconds), the failure code has been cleared. fl When using the ARSC for the first time, always clear the service codes. After clearing the codes, connect connectors CR1 and CR2.
5. METHOD OF MODEL SELECTION, TIRE LARGE DIAMETER/SMALL DIAMETER, REFERENCE FOR FAILURE CODE When the machine starting switch is turned ON, the codes below are automatically displayed in the following order ((1) – (6)) on the controller LED. 1 LEDs all light up. 2 Model Code
Model name
32
HD325-6, HD465-6
46
HD465-5, HD605-5
78
HD785-5
98
HD985-5
3 Tire diameter Code
Tire diameter
B.–
Large diameter
S.–
Small diameter
For the HD325-6 and HD405-6, “– –” is displayed. For the HD985-5, “– –” is displayed. 4 Initial service code 5 Service code that occurred immediately before the service code in 4 6 Service code that occurred immediately before the service code in 5
HD785-5
20-903 B
TROUBLESHOOTING
OUTLINE
7. SPEED CODE JUDGMENT TABLE If the vehicle is equipped with ASR and ARSC, see the troubleshooting of the ASR-II even if troubleshooting of the ARSC.
Error display is given
Category No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
No error display is given
1 2 3 4 5 6 7 8
9 10 11
20-904 B
Nature of failure 0.1 (Abnormality in power source voltage) is displayed 1.0 (Disconnection in engine speed sensor system) is displayed 1.3 (Disconnection in transmission output shaft speed sensor system) is displayed 1.5 (Failure in retarder oil temperature sensor system) is displayed 1.7 (Failure in accelerator signal system) is displayed 1.8 (Failure in suspension pressure sensor “left” system) is displayed 1.9 (Failure in suspension pressure sensor “right” system) is displayed 4.2 (Disconnection in exhaust brake selector signal system) is displayed 4.3 (Disconnection in ARSC caution lamp system) is displayed 4.4 (Disconnection in READY lamp system) is displayed 4.5 (Disconnection in panel caution and buzzer system) is displayed 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed 5.3 (Short circuit with ground in ARSC caution lamp system) is displayed 5.4 (Short circuit with ground in READY output circuit system) is displayed 5.5 (Short circuit with ground in panel caution lamp and buzzer output system) is displayed 6.0 (Failure in engine speed system) is displayed 7.0 (Disconnection in travel speed display UP output system) is displayed 7.1 (Disconnection in travel speed display DOWN output system) is displayed 7.2 (Disconnection in travel speed display CLEAR output system) is displayed 7.3 (Short circuit with ground in travel speed display UP output system) is displayed 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed 8.1 (Short circuit with ground in pressure control valve system) is displayed 8.3 (Disconnection in pressure control valve system) is displayed 8.5 (Failure in pressure control valve (pressure control valve remains open)) is displayed 8.7 (Failure in pressure control valve (pressure control valve does not open)) is displayed 8.9 (Short circuit with ground in pressure switch valve system) is displayed 9.0 (Disconnection in pressure switch valve system) is displayed 9.1 (Failure in pressure switch valve system (remains open)) is displayed 9.2 (Failure in pressure switch valve system (does not open)) is displayed 9.3 (Disconnection in system switch) is displayed 9.4 (Short circuit with ground in system switch) is displayed 9.5 (Disconnection, short circuit with ground in travel speed setting switch system) is displayed Set speed cannot be set Failure code is always cleared (controller display window always shows “—”) or failure code cannot be cleared Retarder does not work when machine is empty, or effect of retarder is poor when machine is loaded (does not judge loaded/unloaded condition properly) Abnormality appears in other controller When traveling downhill, even when set speed is exceeded, no control is carried out Monitor lamp (buzzer) stays on (or off) READY lamp does not light up (or stays lighted up) Exhaust brake does not work properly Exhaust brake is actuated when exhaust brake switch is OFF; or Exhaust brake is not actuated when exhaust brake switch is ON There is difference between travel speed rod value and actual machine value Retarder lamp does not light up, or stays lighted up Travel speed display always gives display (or does not give any display)
Troubleshooting code
R-1 R-2 R-3 R-4 R-5 R-6 R-7 R-8 R-9 R-10 R-11 R-12 R-13 R-14 R-15 R-16 R-17 R-18 R-19 R-20 R-21 R-22 R-23 R-24 R -25 R-26 R-27 R-28 R-29 R-30 R-31 R-32 R-33 R-101 R-102 R-103 R-104 R-105 R-106 R-107 R-108
R-109 R-110 R-111
HD785-5
TROUBLESHOOTING
OUTLINE
Failure codes related to ARSC If the automatic retarder (ARSC) function of the ASR-II controller is turned on, the failure codes related to ARSC are added. For the method of troubleshooting, see the troubleshooting section for the ARSC system (R mode).
No error display is given
Error display is given
Category No.
HD785-5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5
6 7 8
Nature of failure 1.8 (Failure in suspension pressure sensor “left” system) is displayed 1.9 (Failure in suspension pressure sensor “right” system) is displayed 4.2 (Disconnection in exhaust brake selector signal system) is displayed 4.4 (Disconnection in READY lamp system) is displayed 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed 5.4 (Short circuit with ground in READY output circuit system) is displayed 7.0 (Disconnection in travel speed display UP output system) is displayed 7.1 (Disconnection in travel speed display DOWN output system) is displayed 7.2 (Disconnection in travel speed display CLEAR output system) is displayed 7.3 (Short circuit with ground in travel speed display UP output system) is displayed 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed 9.3 (Disconnection in system switch) is displayed 9.4 (Short circuit with ground in system switch) is displayed 9.5 (Disconnection, short circuit with ground in travel speed setting switch system) is displayed Set speed cannot be set Retarder does not work when machine is empty, or effect of retarder is poor when machine is loaded (does not judge loaded/unloaded condition properly) When traveling downhill, even when set speed is exceeded, no control is carried out READY lamp does not light up (or stays lighted up) Exhaust brake does not work properly Exhaust brake is actuated when exhaust brake switch is OFF; or Exhaust brake is not actuated when exhaust brake switch is ON There is difference between travel speed rod value and actual machine value Retarder lamp does not light up, or stays lighted up Travel speed display always gives display (or does not give any display)
Troubleshooting code
R-6 R-7 R-8 R-10 R-12 R-14 R-17 R-18 R-19 R-20 R-21 R-22 R-31 R-32 R-33 R-101 R-103 R-105 R-107 R-108
R-109 R-110 R-111
20-905 B
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
20-906 1
HD785-5
TROUBLESHOOTING
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU (1) (2) (3) (4) (5)
(6) (7) (8) (9) (10)
(11)
Stop the machine at a safe place, apply the parking brake, and stop the engine. Check that the troubleshooting switch is OFF, then turn the ABS/ASR main switch ON. Turn the starting switch ON. There is no need to start the engine. Turn the troubleshooting switch ON for at least 1 second, then turn it OFF again. When the troubleshooting switch is turned OFF, the troubleshooting lamp will flash, so count the number of flashes as shown in the procedure in Fig. 4. If you fail to count the number of flashes, wait for the flashing of the troubleshooting lamp to stop, then repeat the procedure for Step (4) to start the flashing again. After completing the counting of the number of flashes, turn the ABS/ASR main switch and starting switch OFF. Use the number of flashes to judge the location of the failure from Tables 1 and 2, check the applicable place with the INDEX (troubleshooting code), then carry out repairs. After completing repairs, check that the troubleshooting switch is OFF, then turn the ABS/ASR main switch ON. Drive the machine at a speed of less than 10 km/h and check that the warning lamps go OFF. After checking that the warning lamps go OFF, stop the machine again and apply the parking brake. If the warning lamps do not go out, there is still some failure, so repeat Steps (1) - (7) above to carry out troubleshooting again. After the warning lamps go OFF, delete the data according the method of deleting the trouble data of ECU, and then check that the number of flashing times of the troubleshooting lamp indicates that the system is normal. If the system is normal, it can be used for ordinary purpose.
Fig. 4 Flashing interval for troubleshooting lamp Note 1 : Flashes 2 times when ABS is installed independently Flashes 4 times when ABS/ASR is installed Note 2 : 2nd block: Indicates a failure mode in the left front or right rear system. • When normal: Flashes 1 time. • When abnormal: Flashes by the number of times corresponding to the failure mode. Note 3 : 3rd block: Indicates a failure mode in the right front or left rear system. • When normal: Flashes 1 time. • When abnormal: Flashes by the number of times corresponding to the failure mode.
HD785-5
20-1255 B
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU
TROUBLESHOOTING
INDEX (troubleshooting code) • Machines with ABS installed independently Number of flashing times 1st block 2nd block 3rd block 2 1 1 2 9 9 Number of flashing times 1st block 2nd block 3rd block 2 2 fl 2 10 fl 2 11 fl 2 6 fl 2 7 fl 2 3 fl 2 4 fl 2 9 fl 2 13 fl Number of flashing times 1st block 2nd block 3rd block 2 fl 2 2 fl 10 2 fl 11 2 fl 6 2 fl 7 2 fl 3 2 fl 4 2 fl 9 2 fl 13
Failure mode
Source voltage system Failure mode Controller system Left front ABS valve system Right rear ABS valve system Left front wheel speed sensor system Right rear wheel speed sensor system Left front wheel speed sensor output system Right rear wheel speed sensor output system Valve relay 1 system Valve relay 1 system Failure mode Controller system Right front ABS valve system Left rear ABS valve system Right front wheel speed sensor system Left rear wheel speed sensor system Right front wheel speed sensor output system Left rear wheel speed sensor output system Valve relay 2 system Valve relay 2 system
INDEX (Troubleshooting code) System is normal ABS – 18 INDEX (Troubleshooting code) ABS – 1 ABS – 3 ABS – 5 ABS – 7 ABS – 9 ABS – 11 ABS – 13 ABS – 15 ABS – 17 INDEX (Troubleshooting code) ABS – 1 ABS – 2 ABS – 4 ABS – 6 ABS – 8 ABS – 10 ABS – 12 ABS – 14 ABS – 16
In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is displayed when abnormal. (Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear systems are normal). Number of flashing times 1st block 2nd block 3rd block 2 10 1 (Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system” have failures simultaneously. Number of flashing times 1st block 2nd block 3rd block 2 10 6 (Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system” and “valve relay 2 system” have failures simultaneously. Number of flashing times 1st block 2nd block 3rd block 2 9 9
20-1256 B
HD785-5
METHOD OF TROUBLESHOOTING USING SELF-DIAGNOSTIC FUNCTION OF ECU
TROUBLESHOOTING
• Machines with ABS/ASR installed Number of flashing times 1st block 2nd block 3rd block 4 1 1 4 9 9 Number of flashing times 1st block 2nd block 3rd block 4 2 fl 4 10 fl 4 11 fl 4 6 fl 4 7 fl 4 3 fl 4 4 fl 4 9 fl 4 13 fl 4 14 fl Number of flashing times 1st block 2nd block 3rd block
Failure mode
Source voltage system Failure mode Controller system Left front ABS valve system Right rear ABS valve system Left front wheel speed sensor system Right rear wheel speed sensor system Left front wheel speed sensor output system Right rear wheel speed sensor output system Valve relay 1 system Valve relay 1 system ASR valve system Failure mode
INDEX (Troubleshooting code) System is normal ABS – 18 INDEX (Troubleshooting code) ABS – 1 ABS – 3 ABS – 5 ABS – 7 ABS – 9 ABS – 11 ABS – 13 ABS – 15 ABS – 17 ASR – 1 INDEX (Troubleshooting code)
4 fl 2 Controller system ABS – 1 4 fl 10 Right front ABS valve system ABS – 2 4 fl 11 Left rear ABS valve system ABS – 4 4 fl 6 Right front wheel speed sensor system ABS – 6 4 fl 7 Left rear wheel speed sensor system ABS – 8 4 fl 3 Right front wheel speed sensor output system ABS – 10 4 fl 4 Left rear wheel speed sensor output system ABS – 12 4 fl 9 Valve relay 2 system ABS – 14 4 fl 13 Valve relay 2 system ABS – 16 4 fl 14 ASR valve system ASR – 1 In the columns marked with fl, “1” is displayed when normal and “Failure mode in each block” is displayed when abnormal. (Explanation 1) When only the “left front ABS valve system” has a failure (The right front and left rear systems are normal). Number of flashing times 1st block 2nd block 3rd block 4 10 1 (Explanation 2) When the “left front ABS valve system” and the “right front wheel speed sensor system” have failures simultaneously. Number of flashing times 1st block 2nd block 3rd block 4 10 6 (Explanation 3) When only the “source voltage system” has a failure or when the “valve relay 1 system” and “valve relay 2 system” have failures simultaneously. Number of flashing times 1st block 2nd block 3rd block 4 9 9 HD785-5
20-1257 B
TROUBLESHOOTING
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER
SYSTEM CHECK SHEET FOR USING SYSTEM CHECKER Order of inspection
Order of inspection
Terminal for connecting system checker for tester 1234 1234
System checker, brake operation required for inspection
← Ω →Chassis
1
Controller ground
2
Controller power source
3
Relay resistance
4
Power relay 1
Actuate power relay Press check switch R1
5
Power relay 2
Actuate power relay Press check switch R2
6
Warning lamp control
Actuate power relay Press check switches R1 and R2 at same time
7
ASR information lamp
8
Warning lamp line
D1 + ← Ω →
9
ASR engine control terminal
DF + ← Ω → E3
10
Wheel speed sensor resistance
1L
Front left wheel
DF + ← Ω → DF –
Press wheel selector switch 1L
1R
Front right wheel
DF + ← Ω → DF –
Press wheel selector switch 1R
2L
Rear left wheel
DF + ← Ω → DF –
Press wheel selector switch 2L
2R
Rear right wheel
DF + ← Ω → DF –
Press wheel selector switch 2R
11
Wheel speed sensor insulation resistance
1L
Front left wheel
DF – ← Ω → 1234
Press wheel selector switch 1L
1R
Front right wheel
DF – ← Ω → 1234
Press wheel selector switch 1R
2L
Rear left wheel
DF – ← Ω → 1234
Press wheel selector switch 2L
2R
Rear right wheel
1234 DF – ← Ω → 1234
Press wheel selector switch 2R
+ ← Vo → 1234
Actuate power relay Press check switch R1 (Note 2)
R1← Ω →R2
D2← Lead →1234 1234
Connect 1234 1234 terminal and terminal D2 of checker with tester lead wire
1234 1234
Note 1 : Turn the starting switch OFF also when measuring. After measuring, turn it ON and carry out the next inspection. Note 2 : Remove fuse 2 before carrying out inspection. After the inspection, return it to the correct position.
20-1258 4
HD785-5
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ..................... 30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................................. 30- 4 SPECIAL TOOL LIST ...................................... 30- 6 STARTING MOTOR Removal and Installation ............................ 30- 9 ALTERNATOR Removal and Installation ........................... 30-10 ENGINE OIL COOLER Removal and Installation ........................... 30-11 LEFT BANK FUEL INJECTION PUMP Removal and Installation ........................... 30-12 RIGHT BANK FUEL INJECTION PUMP(WITHOUT GOVERNOR) Removal and Installation ........................... 30-13 AIR COMPRESSOR Removal and Installation ........................... 30-14 WATER PUMP Removal and Installation ........................... 30-15 AFTERCOOLER CORE Removal ...................................................... 30-16 Installation .................................................. 30-17 TURBOCHARGER Removal and Installation ........................... 30-18 NOZZLE HOLDER Removal and Installation ........................... 30-19 CYLINDER HEAD Removal ...................................................... 30-20 Installation .................................................. 30-21 EXHAUST BRAKE Removal and Installation ........................... 30-23 ENGINE Removal ...................................................... 30-24 Installation .................................................. 30-28 ENGINE FRONT SEAL Removal and Installation ........................... 30-29 ENGINE REAR SEAL Removal and Installation ........................... 30-32 RADIATOR, TORQUE CONVERTER COOLER Removal ...................................................... 30-36 Installation .................................................. 30-37 HD785-5
BRAKE COOLER Removal and Installation ........................... 30-38 OUTPUT SHAFT Removal and Installation ........................... 30-39 Disassembly ............................................... 30-41 Assembly .................................................... 30-42 TORQUE CONVERTER, TRANSMISSION Removal ...................................................... 30-44 Installation .................................................. 30-46 PROCEDURE FOR CENTERING THE ENGINE ASSEMBLY AND TORQUE CONVERTER, TRANSMISSION ASSEMBLY .................... 30-47 TORQUE CONVERTER, CONTROL VALVE Removal and Installation ........................... 30-48 Disassembly and Assembly ...................... 30-49 TORQUE CONVERTER AND TRANSMISSION Disconnection ............................................. 30-50 Connection .................................................. 30-51 TORQUE CONVERTER, PTO Disassembly ............................................... 30-52 Assembly .................................................... 30-58 TRANSMISSION Disassembly ............................................... 30-64 Assembly .................................................... 30-78 ECMV Disassembly and Assembly ...................... 30-95 DIFFERENTIAL (For standard differential) Removal ...................................................... 30-97 Installation .................................................. 30-98 Disassembly ............................................... 30-99 Assembly .................................................. 30-103 DIFFERENTIAL (With differential lock) Removal .................................................... 30-112 Installation ................................................ 30-113 Disassembly ............................................. 30-114 Assembly .................................................. 30-119 FRONT WHEEL Removal and Installation ......................... 30-129
30-1 2
REAR WHEEL Removal .................................................... 30-130 Installation ................................................ 30-131 FRONT BRAKE CALIPER Removal and Installation ......................... 30-132 Disassembly ............................................. 30-133 Assembly ............................................... 30-133-1 FRONT BRAKE CALIPER PAD Removal and Installation ......................... 30-134 FRONT WHEEL HUB Disassembly ............................................. 30-135 Assembly .................................................. 30-137 FINAL DRIVE CARRIER Removal and Installation ......................... 30-140 Disassembly and Assembly .................... 30-141 FINAL DRIVE Disassembly ............................................. 30-142 Assembly .................................................. 30-144 REAR BRAKE Removal and Installation ......................... 30-146 REAR WHEEL BRAKE Disassembly ............................................. 30-147 Assembly .................................................. 30-148 PARKING BRAKE PAD Removal .................................................... 30-150 Installation ............................................. 30-150-1 PARKING BRAKE CALIPER Removal and Installation ...................... 30-150-2 Disassembly and Assembly .................... 30-152 FRONT SUSPENSION CYLINDER Removal and Installation ......................... 30-153 Disassembly ............................................. 30-154 Assembly .................................................. 30-155 VARIABLE DAMPING SELECTOR VALVE Disassembly ............................................. 30-156 Assembly .................................................. 30-157 REAR SUSPENSION CYLINDER Removal and Installation ......................... 30-158 Disassembly ............................................. 30-159 Assembly .................................................. 30-160 AIR GOVERNOR Removal and Installation ......................... 30-161 Disassembly and Assembly .................... 30-162 BRAKE VALVE Removal and Installation ......................... 30-163 Disassembly ............................................. 30-164 Assembly .................................................. 30-166 PARKING BRAKE CHAMBER Removal and Installation ......................... 30-168 Disassembly ............................................. 30-169 Assembly .................................................. 30-170
30-2 B
REAR BRAKE CHAMBER Removal and Installation ......................... 30-172 Disassembly ............................................. 30-173 Assembly .................................................. 30-177 FRONT BRAKE CHAMBER Disassembly ............................................. 30-180 Assembly .................................................. 30-182 SLACK ADJUSTER Removal and Installation ......................... 30-184 Disassembly and Assembly .................... 30-185 BRAKE COOLING PUMP Removal and Installation ......................... 30-186 STEERING, HOIST PUMP Removal and Installation ......................... 30-187 TORQUE CONVERTER, TRANSMISSION PUMP Removal and Installation ......................... 30-188 EMERGENCY STEERING MOTOR PUMP Removal and Installation ......................... 30-189 STEERING VALVE Removal and Installation ......................... 30-190 Disassembly ............................................. 30-191 Assembly .................................................. 30-195 BRAKE CONTROL VALVE (BCV) Removal and Installation ......................... 30-202 DEMAND VALVE Removal and Installation ......................... 30-203 Disassembly and Assembly .................... 30-204 RELIEF VALVE Disassembly and Assembly .................... 30-205 HOIST VALVE Removal and Installation ......................... 30-206 Disassembly and Assembly .................... 30-208 STEERING CYLINDER Removal and Installation ......................... 30-210 Disassembly ............................................. 30-211 Assembly .................................................. 30-213 HOIST CYLINDER Removal and Installation ......................... 30-216 Disassembly ............................................. 30-217 Assembly .................................................. 30-218 BODY Removal .................................................... 30-219 Installation ................................................ 30-220 CONTROLLER Removal and Installation ......................... 30-221 AIR CONDITIONER COMPRESSOR Removal and Installation ......................... 30-222 RECEIVER TANK Removal and Installation ......................... 30-223 AIR CONDITIONER CONDENSER Removal and Installation ......................... 30-224
HD785-5
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
METHOD OF USING MANUAL 1. When removing or installing unit assemblies 1 When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. 2 Any special techniques applying only to the installation procedure are marked 1, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF cccc ASSEMBLY ............... Title of operation ...................................................................... Precautions related to safety when carrying out the operation 1. X X X X (1) ..................................................... Step in operation fl .................................................................. Technique or important point to remember when removing XXXX (1). 2. t t t t (2): ............................................... 1 Indicates that a technique is listed for use during installation 3. assembly (3) 6 .................................................................... Quantity of oil or water drained
INSTALLATION OF cccc ASSEMBLY .... . Title of operation • Carry out installation in the reverse order to removal. 1 ............................................................. Technique used during installation fl .................................................................. Technique or important point to remember when installing t t t t (2). • Adding water, oil ................................. Step in operation fl ............................................................ Point to remember when adding water or oil
-.........................................................Quantity when filling with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools 1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
HD785-5
30-3 2
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. fl Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number
Plug (nut end)
02 03 04 05 06
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628
Nut (elbow end) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628
2) Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04 05
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
Part Number
06 08 10 12 14 16 18 20 22 24 27
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734
30-4 A
Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
Taper 1/8
ød
Nominal number
øD
3) If the part is not under hydraulic pressure, the following corks can be used.
L DEW00401
HD785-5
DISASSEMBLY AND ASSEMBLY
FRONT BRAKE CALIPER
• Lock bolts (1) and (2) are different from the normal bolts: the tip (portion a) cuts into the surface of the pin. (Creates plastic deformation.) fl When tightening, even when resistance is felt, it is necessary to tighten further in order to cut into the surface. For this reason, if the tightening is less than the specified tightening torque, the bolt will not cut in sufficiently and it will not hold in position properly. b : Cut-in point c : Cut-in mark fl Be sure to install short torque pin (5) of torque pins (4) and (5) at the plate end. fl Install so that clearance d between disc (16) and torque pin (3) is 1.5 – 3.0 mm. fl Assemble the other pistons in the same way. 5. Install caliper assembly. For details, see INSTALLATION OF FRONT CALIPER ASSEMBLY.
HD785-5
30-133-2 B
DISASSEMBLY AND ASSEMBLY
FRONT SUSPENSION CYLINDER
ASSEMBLY OF FRONT SUSPENSION CYLINDER ASSEMBLY 1. Wear ring Install wear ring (14) to cylinder rod (5). 2. Flange 1) Using tool Q2, press fit bushing (13) in flange (8) and install U-packing (12). 2) Using a plastic hammer, press fit bushing (11) to retainer (7) and install dust seal (10). fl Be careful not to deform the bushing when installing it. fl Do not use a hydraulic press since it can break the bushing. 3. Cylinder rod assembly 1) Install stopper (9) to cylinder rod (5). 2) Install flange (8), retainer (7), and plate (6) to cylinder rod. 3) Using block, stand cylinder upright. fl Fill inside of cylinder with engine oil. -
Cylinder: 10 ¬ (EO10-CD)
4) Raise cylinder rod assembly (5), and assemble in cylinder. fl When assembling the rod assembly in the cylinder, if the rod assembly is inserted too far, the oil will spurt out, so stop at a position where the oil does not spurt out. fl After installing the suspension completely, adjust the oil and gas levels. For details, see TESTING AND ADJUSTING OF SUSPENSION CYLINDER. 5) Install flange (8), retainer (7), and plate (6) to cylinder with bolts (3). 6) Install air bleed valve (4). 9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} 4. Oil level valve, intake valve Install oil level valve (2) and intake valve (1). 9 Valve: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} 5. Cover Install cover.
HD785-5
30-155 B
DISASSEMBLY AND ASSEMBLY
REAR SUSPENSION CYLINDER
DISASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY 1. Cover Hanging the cylinder assembly, loosen band (1) and remove the button, then remove cover (2). 2. Intake valve and oil level valve 1) Remove the protector, then remove intake valve (4). 2) Drain oil from the cylinder.
3. Cylinder rod assembly Place the cylinder assembly on its end, upside down. 1) Remove flange mounting bolt (5), then remove plate (6). 2) Slowly hang cylinder rod assembly (7) with a crane to remove it from cylinder (10), without removing retainer (8) and flange (9).
4. Flange 1) Remove retainer (8) and flange (9) from rod assembly (7). 2) Remove U-packing (11), backup ring, and Oring (12) from flange (9). 3) Remove the bushing from flange (9). 4) Remove seal (13) and bushing from retainer (8).
5. Wear ring Remove wear ring (14) from rod (15).
HD785-5
30-159 2
DISASSEMBLY AND ASSEMBLY
REAR SUSPENSION CYLINDER
ASSEMBLY OF REAR SUSPENSION CYLINDER ASSEMBLY 1. Wear ring Install wear ring (14) to rode (15). 2. Flange 1) Press fit bushing to retainer (8) with tool Q2. 2) Install U-packing and O-ring (12) to flange (9). 3) Install backup ring and O-ring (12) to flange (9).
3. Retainer 1) Press fit bushing to retainer (8) with tool Q2. 2) Install seal (13) to retainer (8).
4. Cylinder rod assembly 1) Erect cylinder (10) by using a block. 2) Hang cylinder rod assembly (7) and install it to cylinder (10). 3) Install plate (6), retainer (8), and flange (9) together with mounting bolts (15). 3 Mounting bolt: 66.2 ± 7.4 Nm {6.8 ± 0.7 kgm} 5. Intake valve and oil level valve Turn the cylinder assembly in reverse. 1) Hang cylinder (10) until dimension becomes specified one. 2) Supply oil through oil level port with an oil pump until bubbles do not come out from the intake port any more. 3) After filling the oil, install intake valve (4) and oil level (3). 3 Intake valve and oil level valve: 44.1 ± 5 Nm {4.5 ± 0.5 kgm} 6. Cover 1) Install cover (2) and tighten band (1). 2) Install the protector of the intake valve and oil level valve.
30-160 B
HD785-5
40 MAINTENANCE STANDARD
Output shaft .................................................. 40- 2 Torque converter valve ................................ 40- 3 Torque converter .......................................... 40- 4 Transmission ................................................. 40- 6 ECMV (Electronic Control Modulation Valve) ...... 40-11 Front axle ...................................................... 40-12 Front axle (with ABS/ASR)(If equipped) ... 40-13-1 Rear axle support (HD785-5) ....................... 40-14 Rear axle support (HD985-5) .................... 40-14-1 Differential .................................................... 40-15 Final drive (HD785-5) .................................... 40-17 Final drive (HD985-5) ................................. 40-17-3 Front brake .................................................... 40-18 Rear brake ..................................................... 40-19 Rear brake (with ABS/ASR)(If equipped) ... 40-20-1 Parking brake ................................................ 40-21 Steering linkage ............................................ 40-22 Front suspension cylinder ........................... 40-24 Rear suspension cylinder ............................ 40-25 Parking brake chamber ................................ 40-26 Slack adjuster ............................................... 40-27 Hydraulic pump (SAR-160) (for torque converter and transmission)... 40-28 Hydraulic pump (SAR4-180+180: for steering, work equipment) (SAR4-285+285: for brake cooling) ............ 40-29 Demand valve ............................................... 40-30 Cross-over relief valve ................................. 40-30 Hoist valve .................................................... 40-31 Steering cylinder .......................................... 40-32 Hoist cylinder ................................................ 40-33
HD785-5
40-1 B
MAINTENANCE STANDARD
FRONT AXLE
HD785-5 Serial No.: 4210 and up HD985-5 Serial No.: 1052 and up
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
1
Wear of sliding surface of oil seal
330
0 – 0.140
Depth of wear: 0.1
2
Wear of outside part of shaft to fit bearing
220
0 – 0.029
219.801
3
Wear of outside part of shaft to fit bearing
180
0 – 0.025
179.830
4
Wear of inside part of wheel hub to fit bearing
340
– 0.070 – 0.127
339.960
5
Wear of inside part of wheel hub to fit bearing
280
– 0.060 – 0.112
279.965
HD785-5
Repair or replace
40-13 B
MAINTENANCE STANDARD
FINAL DRIVE
HD785-5 Serial No.: 4210 – 4253
Unit: mm
No.
Check item
1
Backlash between planet gear and sun gear
2
Backlash between planet gear and ring gear
3
Curvature of drive shaft
Criteria
Remedy
Standard backlash
Repair limit
0.26 – 0.58
1.2 Replace
0.30 – 0.78
1.0 Repair or replace
Repair limit: 1.5 TIR Standard size
Tolerance
Repair limit
51
± 0.1
49
Replace
4
Thickness of spacer
5
Outside diameter of tube to fit bearing
320
+0.002 – 0.034
319.754
6
Outside diameter of tube to fit bearing
300
0.000 – 0.032
299.778
7
Inside diameter of wheel hub to fit bearing
480
– 0.045 – 0.108
479.955
8
Inside diameter of wheel hub to fit bearing
460
– 0.045 – 0.108
459.955
40-17-1 B
Repair or replace
HD785-5
MAINTENANCE STANDARD
FINAL DRIVE
HD785-5 Serial No.: 4254 and up
Unit: mm
No.
Check item
1
Backlash between planet gear and sun gear
2
Backlash between planet gear and ring gear
3
Curvature of drive shaft
4
Thickness of spacer
5
Criteria
Remedy
Standard backlash
Repair limit
0.26 – 0.58
1.2 Replace
6
0.30 – 0.78
1.0 Repair or replace
Repair limit: 1.5 TIR Standard size
Tolerance
Repair limit
51
± 0.1
49
Outside diameter of tube to fit bearing
320
+0.002 – 0.034
319.754
Outside diameter of tube to fit bearing
300
0.000 – 0.032
299.778
HD785-5
Replace
Repair or replace
40-17-2 B
MAINTENANCE STANDARD
FINAL DRIVE
HD985-5 Serial No.: 1052 and up
Unit: mm
No.
Check item
1
Backlash between planet gear and sun gear
2
Backlash between planet gear and ring gear
3
Curvature of drive shaft
Criteria
Remedy
Standard backlash
Repair limit
0.26 – 0.58
1.2 Replace
0.30 – 0.78
1.0 Repair or replace
Repair limit: 1.5 TIR Standard size
Tolerance
Repair limit
51
± 0.1
49
Replace
4
Thickness of spacer
5
Outside diameter of tube to fit bearing
320
+0.002 – 0.034
319.754
6
Outside diameter of tube to fit bearing
300
0.000 – 0.032
299.778
7
Inside diameter of wheel hub to fit bearing
480
– 0.045 – 0.108
479.955
8
Inside diameter of wheel hub to fit bearing
460
– 0.045 – 0.108
459.955
HD785-5
Repair or replace
40-17-4 B
MAINTENANCE STANDARD
REAR BRAKE
HD785-5 Serial No.: 4254 and up
Unit: mm
No.
Check item
Criteria
Remedy
Standard backlash
Repair limit
1
Backlash between outer gear and plate
0.21 – 0.64
2.2
2
Backlash between inner gear and disc
0.21 – 0.64
2.2
Standard size
Repair limit
2.4
2.15
3
Thickness of plate
4
Thickness of disc
5.1
4.6
5
Thickness of damper
6.9
5.1
Standard warping
Repair limit
6
Distortion of disc wear surface
Max. 0.45
0.7
7
Distortion of plate and damper wear surface
Max. 0.50
0.7
Standard size
Repair limit
8
Assembly thickness of plate and disc
123.9
115.0
9
Contact surface of retainer oil seal
Replace
40-20 B
Standard size
Tolerance
Repair limit
ø 580
0 – 0.175
Depth of wear: 0.3
Repair or replace
HD785-5
MAINTENANCE STANDARD
REAR BRAKE
WITH ABS/ASR (IF EQUIPPED) HD785-5 Serial No.: 4254 and up
Unit: mm
No.
Check item Standard backlash
Repair limit
1
Backlash between outer gear and plate
0.21 – 0.64
2.2
2
Backlash between inner gear and disc
0.21 – 0.64
2.2
Standard size
Repair limit
2.4
2.15
5.1
4.6
3
Thickness of plate
4
Thickness of disc
Criteria
Remedy
Replace 5
6.9
5.1
Standard warping
Repair limit
Max. 0.45
0.7
Max. 0.50
0.7
Standard size
Repair limit
123.9
115.0
Thickness of damper
6
Distortion of disc wear surface
7
Distortion of plate and damper wear surface
8
Assembly thickness of plate and disc
9
Contact surface of retainer oil seal
40-20-2 B
Standard size
Tolerance
Repair limit
ø 580
0 – 0.175
Depth of wear: 0.3
Repair or replace
HD785-5
