SopManual HD255-5 PDF

SEBM009115
MACHINE MODEL SERIAL NUMBER

HD255-5 1001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.
• HD255-5 mount the SA6D125E-2 or SAA6D125E-3 engine.

For details of the engine, see the 125-2 or 125-3 Series Engine Shop Manual.
© 2006 1
All Rights Reserved 00-1
Printed in Japan 12-06(02) (15)
CONTENTS
No. of page
01 GENERAL ............................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ........................................................... 10-1
20 TESTING AND ADJUSTING ................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ............................................................................................................... 90-1
00-2 HD255-5
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The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the c Page to be newly added Add
table below.
b Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
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b 00-1 (15) 10-2 (9) 10-41 (9) 10-85 (9) 20-12 (4)
00-2 (3) 10-3 (9) 10-46 (1) 10-86 (9) 20-13 (10)
b 00-2-1 (15) 10-4 (9) 10-47 (1) 10-87 (9) 20-14 (10)
b 00-2-2 (15) 10-5 (9) 10-48 (1) 10-88 (9) 20-15 (10)
b 00-2-3 (15) 10-6 (1) 10-49 (1) 10-89 (9) 20-16 (10)
b 00-2-4 (15) 10-7 (1) 10-50 (1) 10-90 (9) 20-17 (10)
00-3 10-8 (1) 10-51 (12) 10-91 (9) 20-18 (10)
00-4 10-9 (7) 10-52 (1) 10-92 (9) 20-101 (13)
00-5 10-10 (1) 10-53 (1) 10-93 (9) 20-101-1 (14)
00-6 10-11 (1) 10-54 (1) 10-94 (9) 20-101-2 (10)
00-7 10-12 (1) 10-55 (1) 10-95 (9) 20-101-3 (4)
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00-15 10-19 (9) 10-61-2 (9) 10-104 (9) 20-109 (10)
00-16 10-20 (1) 10-61-3 (9) 10-105 (9) 20-110 (10)
00-17 10-21 (1) 10-62 (1) 10-106 (9) 20-111 (10)
00-18 10-22 (9) 10-63 (1) 10-107 (9) 20-112 (10)
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00-20 10-24 (1) 10-65 (1) 10-109 (9) 20-114 (10)
00-21 10-25 (1) 10-66 (1) 20-115 (10)
00-22 10-26 (1) 10-67 (1) 20-1 (4) 20-116 (10)
10-27 (1) 10-68 (1) 20-2 (10) 20-117 (10)
01-1 (9) 10-28 (1) 10-69 (9) 20-2-1 (10) 20-118 (10)
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01-5 (9) 10-32 (1) 10-73 (1) 20-6 (4) 20-122 (10)
01-6 (9) 10-33-1 (3) 10-76 (9) 20-6-1 (10) 20-123 (10)
01-7 (9) 10-33-2 (3) 10-77 (9) 20-6-2 (10) 20-124 (10)
01-8 (9) 10-34 (1) 10-78 (9) 20-6-3 (10) 20-125 (10)
01-9 (9) 10-35 (1) 10-79 (9) 20-6-4 (10) 20-126 (10)
01-10 (9) 10-36 (9) 10-80 (9) 20-7 (4) 20-127 (10)
01-11 (9) 10-37 (1) 10-81 (9) 20-8 (4) 20-128 (10)
01-12 (9) 10-38 (1) 10-82 (9) 20-9 (4) 20-129 (10)
10-39 (1) 10-83 (9) 20-10 (12) 20-130 (10)
10-1 (9) 10-40 (9) 10-84 (9) 20-11 (4) 20-131 (10)
HD255-5 00-2-1
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20-137 (10) 20-219-10 (4) 20-252 20-321 20-380 (10)
20-138 (10) 20-219-11 (10) 20-253 20-322 20-381 (10)
20-139 (10) 20-219-12 (10) 20-254 (10) 20-323 20-382 (10)
20-140 (10) 20-219-13 (10) 20-255 (10) 20-325 (10) 20-383 (10)
20-140-1 (13) 20-219-14 (10) 20-256 (10) 20-326 (10) 20-384 (10)
20-140-2 (13) 20-219-15 (10) 20-257 (4) 20-327 (10) 20-385 (10)
20-141 (10) 20-219-16 (10) 20-258 (4) 20-328 (10) 20-386 (10)
20-142 (10) 20-219-17 (10) 20-259 (10) 20-329 (10) 20-387 (10)
20-143 (10) 20-219-18 (10) 20-260 (10) 20-330 (10) 20-388 (10)
20-144 (10) 20-219-19 (10) 20-261 (4) 20-331 (10) 20-389 (10)
20-145 (10) 20-220 (10) 20-262 (4) 20-332 (10) 20-390 (10)
20-146 (10) 20-221 (10) 20-263 (4) 20-333 (10) 20-391 (10)
20-147 (12) 20-222 (10) 20-264 (4) 20-334 (10) 20-392 (10)
20-148 (10) 20-223 (10) 20-265 (4) 20-335 (10) 20-393 (10)
20-149 (10) 20-224 (10) 20-266 (4) 20-336 (10) 20-394 (10)
20-150 (10) 20-225 (10) 20-267 (4) 20-337 (10) 20-395 (10)
20-151 (10) 20-226 (10) 20-268 (4) 20-338 (10) 20-396 (10)
20-152 (10) 20-227 (10) 20-269 (4) 20-339 (10) 20-397 (10)
20-153 (10) 20-228 (10) 20-270 (10) 20-340 (10) 20-398 (10)
20-154 (10) 20-229 (10) 20-271 (10) 20-341 (10) 20-399 (10)
20-155 (10) 20-230 (10) 20-272 (10) 20-342 (10) 20-400 (10)
20-156 (10) 20-230-1 (10) 20-273 (10) 20-343 (10) 20-400-1 (10)
20-157 (12) 20-230-2 (10) 20-274 (10) 20-344 (10) 20-400-2 (10)
20-158 (12) 20-230-3 (10) 20-275 (10) 20-345 (10) 20-400-3 (10)
20-159 (10) 20-230-4 (10) 20-276 (10) 20-346 (10) 20-400-4 (10)
20-160 (10) 20-230-5 (10) 20-277 (10) 20-347 (10) 20-400-5 (10)
20-201 (10) 20-230-6 (10) 20-278 (10) 20-351 (10) 20-400-6 (10)
20-202 20-230-7 (10) 20-279 (10) 20-352 (10) 20-400-7 (10)
20-203 20-230-8 (10) 20-280 (10) 20-353 (10) 20-400-8 (10)
20-204 (10) 20-230-9 (10) 20-281 (10) 20-354 (10) 20-400-9 (10)
20-205 (10) 20-230-10 (10) 20-282 (10) 20-356 (10) 20-400-11 (10)
20-206 (10) 20-230-11 (10) 20-283 (10) 20-357 (10) 20-400-12 (10)
20-207 (10) 20-230-12 (10) 20-284 (10) 20-358 (10) 20-400-13 (10)
20-208 (10) 20-231 20-285 (10) 20-359 (10) 20-400-14 (10)
20-209 (10) 20-232 (10) 20-301 (10) 20-360 (10) 20-400-16 (10)
20-210 20-233 20-302 (10) 20-361 (10) 20-400-17 (10)
20-211 20-234 (4) 20-303 (10) 20-362 (10) 20-400-18 (10)
20-212 20-235 (4) 20-304 20-363 (10) 20-400-19 (10)
20-213 20-236 (4) 20-305 20-364 (10) 20-400-20 (10)
20-214 (10) 20-237 (4) 20-306 20-365 (10) 20-400-21 (10)
20-215 (10) 20-238 (4) 20-307 20-366 (10) 20-400-22 (10)
20-216 (4) 20-239 (10) 20-308 20-367 (10) 20-400-24 (10)
20-217 (4) 20-240 (4) 20-309 20-368 (10) 20-400-25 (10)
20-218 (4) 20-241 (4) 20-310 20-369 (10) 20-400-26 (10)
20-219 (4) 20-242 (4) 20-311 20-370 (10) 20-400-27 (10)
20-219-1 (4) 20-243 (10) 20-312 20-371 (10) 20-401 (4)
20-219-2 (4) 20-244 (10) 20-313 20-372 (10) 20-402 (4)
20-219-3 (10) 20-245 (4) 20-314 20-373 (10) 20-403 (4)
20-219-4 20-246 (4) 20-315 20-374 (10) 20-404 (4)
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20-405 20-451 (4) 20-552 20-726 (10) 30-27 (11)

20-406 (10) 20-452 (10) 20-553 20-727 (10) 30-28 (11)
20-407 (10) 20-453 (10) 20-554 20-728 (10) 30-29 (11)
20-407-1 (10) 20-454 (10) 20-555 20-729 (10) 30-30 (11)
20-408 (10) 20-455 (10) 20-556 20-730 (10) 30-31 (11)
20-409 (10) 20-471 (10) 20-601 20-731 (10) 30-32 (11)
20-410 (10) 20-472 (4) 20-602 20-732 (10) 30-33 (11)
20-411 (10) 20-473 (10) 20-603 20-733 (10) 30-34 (11)
20-412 (10) 20-474 (4) 20-604 20-734 (10) 30-35 (11)
20-413 (10) 20-475 (10) 20-605 20-735 (10) 30-36 (11)
20-414 (10) 20-476 (4) 20-606 20-736 (10) 30-36-1 (11)
20-415 (10) 20-477 (10) 20-607 20-737 (10) 30-36-2 (11)
20-415-1 (10) 20-478 (10) 20-608 20-738 (10) 30-36-3 (11)
20-416 (10) 20-479 (10) 20-609 20-739 (10) 30-36-4 (11)
20-417 (10) 20-480 (10) 20-610 20-740 (10) 30-36-5 (11)
20-417-1 (10) 20-481 (10) 20-611 20-741 (10) 30-36-6 (11)
20-418 (10) 20-501 (10) 20-612 20-742 (10) 30-36-7 (11)
20-419 (10) 20-502 (10) 20-613 20-743 (10) 30-36-8 (11)
20-419-1 (10) 20-503 (10) 20-614 20-744 (10) 30-36-9 (11)
20-420 (10) 20-504 (10) 20-615 20-745 (10) 30-36-10 (11)
20-420-1 (10) 20-505 (10) 20-616 20-746 (10) 30-36-11 (11)
20-421 (10) 20-505-1 (10) 20-617 20-747 (10) 30-36-12 (11)
20-422 (10) 20-505-2 (10) 20-618 20-748 (10) 30-36-13 (11)
20-423 (10) 20-506 (4) 20-619 20-749 (10) 30-36-14 (11)
20-424 (4) 20-507 (10) 20-620 20-750 (10) 30-36-15 (11)
20-425 (10) 20-508 (10) 20-621 20-751 (10) 30-36-16 (13)
20-426 (10) 20-509 (10) 20-622 20-752 (10) 30-36-17 (11)
20-427 (10) 20-509-1 (10) 20-623 20-753 (10) 30-36-18 (11)
20-428 (10) 20-509-2 (10) 20-624 30-36-19 (11)
20-428-1 (10) 20-510 (4) 20-701 (10) 30-1 (11) 30-36-20 (11)
20-429 (4) 20-511 (10) 20-702 (10) 30-2 (13) 30-36-21 (11)
20-430 (10) 20-512 (10) 20-703 (10) 30-4 (11) 30-36-22 (11)
20-431 (10) 20-513 (10) 20-704 (10) 30-5 (11) 30-36-23 (11)
20-431-1 (10) 20-513-1 (10) 20-705 (10) 30-6 (11) 30-36-24 (11)
20-431-2 (10) 20-513-2 (10) 20-706 (10) 30-7 (11) 30-36-25 (11)
20-432 (10) 20-514 (4) 20-707 (10) 30-8 (11) 30-36-26 (11)
20-433 (10) 20-515 (10) 20-708 (10) 30-9 (11) 30-36-27 (11)
20-434 (10) 20-516 (10) 20-709 (10) 30-10 (11) 30-36-28 (11)
20-435 (10) 20-517 (10) 20-710 (10) 30-11 (11) 30-36-29 (11)
20-436 (4) 20-517-1 (10) 20-711 (10) 30-12 (11) 30-36-30 (11)
20-437 (4) 20-517-2 (10) 20-712 (10) 30-13 (11) 30-36-31 (11)
20-438 (4) 20-518 (10) 20-713 (10) 30-14 (11) 30-36-32 (11)
20-439 (10) 20-519 (10) 20-714 (10) 30-15 (11) 30-36-33 (11)
20-440 (4) 20-519-1 (10) 20-715 (10) 30-16 (11) 30-37
20-441 (10) 20-520 (4) 20-716 (10) 30-17 (11) 30-38
20-442 (10) 20-521 (10) 20-717 (10) 30-18 (11) 30-39
20-443 (10) 20-522 (10) 20-718 (10) 30-19 (11) 30-40
20-444 (4) 20-523 (10) 20-719 (10) 30-20 (11) 30-41
20-445 (4) 20-524 (10) 20-720 (10) 30-21 (11) 30-42
20-446 (4) 20-525 (10) 20-721 (10) 30-22 (11) 30-43
20-447 (4) 20-526 (10) 20-722 (10) 30-23 (11) 30-44
20-448 (10) 20-527 (10) 20-723 (10) 30-24 (11) 30-45 (11)
20-449 (4) 20-528 (10) 20-724 (10) 30-25 (11) 30-46 (11)
20-450 (4) 20-551 20-725 (10) 30-26 (11) 30-47 (11)
HD255-5 00-2-3
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30-48 30-49 (11) 30-101 30-138 90-5 (9)

30-48-1 (2) 30-50 30-102 30-139 90-7 (9)
30-48-2 (2) 30-51 30-103 30-140 90-9 (9)
30-48-3 (2) 30-52 (11) 30-104 30-141 90-11 (9)
30-48-4 (2) 30-53 30-105 30-142 90-13 (9)
30-48-5 (2) 30-54 30-106 30-143 90-15 (9)
30-48-6 (2) 30-55 30-107 30-144 90-17 (9)
30-48-7 (2) 30-56 30-108 30-145 90-19 (9)
30-48-8 (2) 30-57 30-109 30-146 90-21 (9)
30-48-9 (2) 30-58 30-110 30-147 90-23 (9)
30-48-10 (2) 30-59 30-111 30-148 90-25 (9)
30-48-11 (2) 30-60 30-112 30-149 b 90-27 (15)
30-48-12 (2) 30-61 30-113 30-150 b 90-29 (15)
30-48-13 (2) 30-62 30-114 30-151 b 90-31 (15)
30-48-14 (2) 30-63 (11) 30-115 (13) 30-151-1 (11) b 90-33 (15)
30-48-15 (2) 30-64 (14) 30-115-1 (13) 30-151-2 (11) c 90-34-1 (15)
30-48-16 (2) 30-65 (13) 30-115-2 (14) 30-152 (11) c 90-34-3 (15)
30-48-17 (2) 30-66 (11) 30-115-3 (13) 30-153 c 90-34-5 (15)
30-48-18 (2) 30-67 (11) 30-115-4 (13) 30-154 c 90-34-7 (15)
30-48-19 (11) 30-68 (8) 30-115-5 (13) 90-35 (9)
30-48-20 (2) 30-68-1 (11) 30-115-6 (13) 40-1 (9) 90-37 (9)
30-48-21 (2) 30-68-2 (11) 30-115-7 (13) 40-1-2 (1) 90-38 (9)
30-48-22 (2) 30-69 30-115-8 (13) 40-2 (7) 90-39 (9)
30-48-23 (2) 30-70 30-115-9 (13) 40-3
30-48-24 (2) 30-71 (11) 30-115-10(13) 40-4
30-48-25 (2) 30-72 30-115-11(13) 40-5
30-48-26 (2) 30-73 (11) 30-115-12(13) 40-6
30-48-27 (2) 30-74 30-115-13(13) 40-7
30-48-28 (2) 30-75 30-115-14(13) 40-8
30-48-29 (2) 30-76 30-115-15(13) 40-8-1 (3)
30-48-30 (2) 30-77 (11) 30-115-16(13) 40-8-3 (3)
30-48-31 (2) 30-78 (11) 30-115-17(13) 40-8-4 (3)
30-48-32 (2) 30-79 (11) 30-115-18(13) 40-8-5 (3)
30-48-33 (2) 30-80 30-116 40-8-6 (4)
30-48-34 (2) 30-81 (11) 30-117 (11) 40-8-7 (3)
30-48-35 (2) 30-82 (11) 30-118 40-8-8 (3)
30-48-36 (2) 30-83 30-119 (11) 40-8-9 (3)
30-48-37 (2) 30-84 30-120 (11) 40-8-10 (3)
30-48-38 (2) 30-85 30-121 (11) 40-9
30-48-39 (2) 30-86 30-122 (11) 40-10
30-48-40 (2) 30-87 30-123 40-11
30-48-41 (2) 30-88 30-124 40-12
30-48-42 (2) 30-89 30-125 40-13
30-48-43 (2) 30-90 30-126 (11) 40-14
30-48-44 (2) 30-91 (11) 30-127 (11) 40-15
30-48-45 (2) 30-92 30-128 (11) 40-16
30-48-46 (2) 30-93 30-129 (11) 40-17
30-48-47 (2) 30-94 30-130 (11) 40-18
30-48-48 (2) 30-95 30-132 40-19
30-48-49 (2) 30-96 30-133 40-20
30-48-50 (2) 30-97 30-134 40-21
30-48-51 (11) 30-98 30-135
30-48-52 (2) 30-99 30-136 b 90-1 (15)
30-48-53 (2) 30-100 30-137 90-3 (9)
00-2-4 HD255-5
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Specifications ............................................... 01- 4
Weight table .................................................. 01-10
List of lubricants and coolant ...................... 01-11
HD255-5 01-1
(9)
GENERAL DIMENSIONS
DIMENSIONS
Serial No.: 1001 – 1600
Unit : mm
01-2 HD255-5
(9)
GENERAL DIMENSIONS
Serial No.: 1601 and up

Unit : mm
HD255-5 01-3
(9)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Serial No.: 1001 – 1600
Machine model HD255-5
Serial No. 1001 – 1011 1012 – 1600
Net kg 21,900
Max. payload kg 25,000
Gross weight kg 46,975
Weight
Net (front) kg (%) 10,730 (49)

distribution
Weight
(rear) kg (%) 11,170 (51)

Gross (front) kg (%) 15,030 (32)
(rear) kg (%) 31.945 (68)
Dump body
capacity
Struck m3 13.2
3
Heaped (2 : 1) m 17.7
Performance
Max. travel speed km/h 47

Gradeability (sin θ ) % 35 (unloaded)
Min. turning radius m 7.0
Dumping angle (angle to ground) (deg) 49
Overall length mm 7,290

Overall width mm 3,200
(without mirrors, steps and guards )
(with mirrors, steps and guards )
Dimensions
Overall height mm 3,560

Wheelbase mm 3,600
Tread
Front tires mm 2,700

Rear tires mm 2,180
Ground clearance mm 405
Model Komatsu SA6D125E-2G

Type 4-cycle, water-cooled, in-line, direct injec-
tion, with turbocharger and after-cooler
No. of cylinders - Bore x stroke mm 6 - 125 × 150
Piston displacement ¬ {cc} 11.04 {11,040}
Flywheel horsepower kW/rpm {HP/rpm} 235/2,100 {316/2,100}
Engine
Max. torque Nm/rpm {kgm/rpm} 1,284/1,400 {131/1,400}

Fuel consumption (rated) g/kW•h {g/HP•h} 216 {161}
High idling speed rpm 2,400 ± 50
Low idling speed rpm 750 ± 50
Starting motor 24V 7.5kW
Alternator 24 V50A
Battery 12V 150Ah × 2
01-4 HD255-5
(9)
Serial No. 1001 – 1011 1012 – 1600
Type TCA43-11A TCA43-11A
Torque converter Structure 3-element, 1-stage, 2-phase 3-element, 1-stage, 2-phase
Lock-up clutch Hydraulically actuated, wet- Hydraulically actuated, wet-

type, single disc clutch type, single disc clutch
Komatsu TORQFLOW plan- Komatsu TORQFLOW plan-

Type etary gear, fully automatic etary gear, fully automatic
Transmission Electrically-hydraulically actu- Electrically-hydraulically actu-

ated, force-feed type pump ated, force-feed type pump
Power train
No. of speeds F6, R1 F6, R1
Type Spiral bevel gear, splash Spiral bevel gear, splash

lubrication lubrication
Reduction gear Reduction ratio 3.97 3.97
Differential type Straight bevel gear, splash Straight bevel gear, splash
lubrication lubrication
Planetary gear, splash Planetary gear, splash

Type lubrication lubrication
Final drive
Reduction type 4.941 4.941
Steering
system
Type Full hydraulic Full hydraulic
Independent suspension Independent suspension

Type Front axle (MacPherson type) (MacPherson type)
Suspension
Rear axle Full floating Full floating
Suspension method Front axle Hydropneumatic Hydropneumatic
Rear axle Hydropneumatic Hydropneumatic
Size and no. Front tire 16.00 – 25 – 24PR × 2 (E3) 16.00 – 25 – 28PR × 2 (E3)
Tires
Rear tire 16.00 – 25 – 24PR × 4 (E3) 16.00 – 25 – 28PR × 4 (E3)

Tire inflation Front and rear kPa{kg/cm2} 490 {5.0} 620 {6.3}
pressure tires
Air over hydraulic, caliper Air over hydraulic, caliper

Main brake Front wheel disc type disc type
Rear wheel Air over hydraulic Air over hydraulic
Brakes
Oil-cooled, multiple disc brake Oil-cooled, multiple disc brake

Spring-boosted, internal Spring-boosted, internal
expanding type expanding type
Parking brake Air over hydraulic Air over hydraulic
Oil-cooled, multiple disc Oil-cooled, multiple disc
Retarder brake + exhaust brake brake + exhaust brake
HD255-5 01-5
(9)
Serial No. 1001 – 1600
For both steering and work Gear pump, tandem type

equipment
Type ¬ /min 227 (at 2,100 rpm)
Discharge amount
Hydraulic pump
For charging torque converter

(merges with retarder cooling)
Type Gear pump
Discharge amount ¬ /min 147 (at 2,100 rpm)

Hydraulic system
For brake cooling
Type Gear pump

Hoist cylinder
Type 3-stage piston type, double-

acting
Cylinder
No. – bore × stroke mm (210 – 160 –140) × 969
Steering cylinder
Type Piston type, double acting
No. – bore × stroke mm 2 – 60 × 340
01-6 HD255-5
(9)

Serial No. 1601 and up
Net kg 22,950
Max. payload kg 25,000
Gross weight kg 48,075
Weight
Net (front) kg (%) 11,015 (48)

distribution
Weight
(rear) kg (%) 11,935 (52)

Gross (front) kg (%) 15,385 (32)
(rear) kg (%) 32,690 (68)
Dump body
capacity
Struck m3 13.2
3
Heaped (2 : 1) m 17.7
Performance
Max. travel speed km/h 47

Gradeability (sin θ ) % 35 (unloaded)
Min. turning radius m 7.0
Dumping angle (angle to ground) (deg) 49
Overall length mm 7,390

(without mirrors, steps and guards )
(with mirrors, steps and guards )
Dimensions
Overall height mm 3,625

Wheelbase mm 3,600
Tread
Front tires mm 2,700

Rear tires mm 2,225
Ground clearance mm 400
Model Komatsu SAA6D125E-3

Type 4-cycle, water-cooled, in-line, direct injection,
with turbocharger and air cooled after cooler
No. of cylinders - Bore x stroke mm 6 - 125 × 150
Piston displacement ¬ {cc} 11.04 {11,040}
Flywheel horsepower kW/rpm {HP/rpm} 235/2,100 {316/2,100}
Engine
Max. torque Nm/rpm {kgm/rpm} 1,363/1,400 {139/1,400}

Fuel consumption (rated) g/kW•h {g/HP•h} 216 {161}
High idling speed rpm 2,420 +80
– 20
Low idling speed rpm 750 ± 50

Starting motor 24V 7.5kW
Alternator 24 V50A
Battery 12V 150Ah × 2
HD255-5 01-7
(9)
Type TCA43-11A
Torque converter Structure 3-element, 1-stage, 2-phase
Lock-up clutch Hydraulically actuated, wet-

type, single disc clutch
Komatsu TORQFLOW plan-

Type etary gear, fully automatic
Transmission Electrically-hydraulically actu-

ated, force-feed type pump
Power train
No. of speeds F6, R1
Type Spiral bevel gear, splash

lubrication
Reduction gear Reduction ratio 3.97
Differential type Straight bevel gear, splash

lubrication
Planetary gear, splash

Type lubrication
Final drive
Reduction type 4.941
Steering
system
Type Full hydraulic
Independent suspension
Type Front axle (MacPherson type)
Suspension
Rear axle Full floating
Suspension method Front axle Hydropneumatic
Rear axle Hydropneumatic
Size and no. Front tire 16.00 – 25 – 28PR × 2 (E3)

Tires
Rear tire 16.00 – 25 – 28PR × 4 (E3)

Tire inflation Front and rear kPa{kg/cm2} 620 {6.3}
pressure tires
Air over hydraulic, caliper

Main brake Front wheel disc type
Rear wheel Air over hydraulic
Brakes
Oil-cooled, multiple disc brake

Spring-boosted, internal
expanding type
Parking brake Air over hydraulic
Oil-cooled, multiple disc
Retarder brake + exhaust brake
01-8 HD255-5
(9)
For both steering and work Gear pump, tandem type

equipment
Type ¬ /min 227 (at 2,100 rpm)
Discharge amount
Hydraulic pump
For charging torque converter

(merges with retarder cooling)
Type Gear pump

Hydraulic system
For brake cooling
Type Gear pump

Hoist cylinder
Type 3-stage piston type, double-

acting
Cylinder
No. – bore × stroke mm (210 – 160 –140) × 969
Steering cylinder
Type Piston type, double acting
No. – bore × stroke mm 2 – 60 × 340
HD255-5 01-9
(9)
GENERAL WEIGHT TABLE
WEIGHT TABLE
Unit: kg
Serial No. 1001 – 1600 1601 and up
Engine assembly 1,100 1,250
Output shaft assembly 65 65
Cooling assembly 105 166
Fuel tank (individual part) 110 110
Torque converter assembly 250 250
Transmission assembly 660 660
Drive shaft assembly (front) 12 12
Drive shaft assembly (rear) 56 56
Rear axle assembly (1,994) (1,994)
• Differential 223 223
• Rear axle housing 554 554
• Final drive (one side) 670 × 2 670 × 2
• Rear brake (one side) 255 × 2 255 × 2
• Parking brake 36 36
• Front axle assembly (310) (310)
• Front axle (one side) 90 × 2 90 × 2
• Front brake (one side) 65 × 2 65 × 2
Front suspension cylinder (one side) 200 × 2 200 × 2
Rear suspension cylinder 92 × 2 92 × 2
Frame assembly 2,400 2,400
ROPS cab (including interior components) 750 750
Operator’s seat 40 44
Steering cylinder (one side) 19 × 2 19 × 2
Hoist cylinder (one side) 197 197
Demand valve 26 26
Steering valve 7 7
Hoist valve 40 40
Hydraulic tank 176 176
Hydraulic pump (SAR(3)-63+63H) 23 23
Hydraulic pump (SAR(3)-56+45) 23 23
Body assembly 7,340 7,270
01-10 HD255-5
(9)
GENERAL LIST OF LUBRICANTS AND COOLANT
LIST OF LUBRICANTS AND COOLANT

Serial No.: 1001 – 1600
AMBIENT TEMPERATURE CAPACITY (¬)
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C Specified Refill
SAE 30
SAE 10W
Engine oil pan 27 25
SAE 15W-40
SAE 10W-30
SAE 30
Transmission case 130 70
SAE 10W
Engine oil
Front brake oil 2 —
tank
SAE 10W
Front suspension 9 (each) —
Rear suspension 6 (each) —
Differential gear
case 18 18
SAE 30
Final drive case 7 (each) 7 (each)
ASTM D975 No. 2

Fuel tank Diesel fuel 374 —
ª
Cooling system Coolant Add antifreeze 48 —
ª ASTM D975 No.1
FUEL, OIL
Use the correct type for the ambient temperature fl Specified capacity: Total amount of oil includ-
as shown in the table above. ing oil for components and oil in piping
Refill capacity: Amount of oil needed to refill
COOLANT system during normal inspection and main-
Komatsu genuine super coolant (AF-ACL) is added tenance.
to the cooling water, so there is no need to change fl When starting the engine in an ambient tem-
it for temperatures down to -10˚C. perature of less than 0˚ C, always use SAE10W,
If the temperature goes below -10˚C, adjust the SAE10W-30, or SAE15W-40, even though the
density. For details, see the Operation and Main- temperature goes up to 10˚C during the day-
tenance Manual. time.
HD255-5 01-11
(9)
GENERAL LIST OF LUBRICANTS AND OOLANT

AMBIENT TEMPERATURE CAPACITY (¬)
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C Specified Refill
SAE 30
SAE 10W
Engine oil pan Engine oil 47 38
SAE 15W-40
SAE 10W-30
SAE 30
Transmission case 130 70
SAE 10W
Front brake oil 2 —

tank
Power SAE 10W
Front suspension line oil 9 (each) —
Rear suspension 6 (each) —
Differential gear
case 18 18
SAE 30
Final drive case 7 (each) 7 (each)
ASTM D975 No. 2

Fuel tank Diesel fuel 374 —
ª
Cooling system Coolant Add antifreeze 45 —
ª ASTM D975 No.1
FUEL, OIL
Use the correct type for the ambient temperature fl Specified capacity: Total amount of oil includ-
as shown in the table above. ing oil for components and oil in piping
Refill capacity: Amount of oil needed to refill
COOLANT system during normal inspection and main-
Komatsu genuine super coolant (AF-ACL) is added tenance.
to the cooling water, so there is no need to change fl When starting the engine in an ambient tem-
it for temperatures down to -10˚C. perature of less than 0˚ C, always use
If the temperature goes below -10˚C, adjust the SAE10W-30, or SAE15W-40, even though the
density. For details, see the Operation and Main- temperature goes up to 10˚C during the day-
tenance Manual. time.
01-12 HD255-5
(9)
10 STRUCTURE AND FUNCTION
Radiator, torque converter and brake oil Air governor .................................................. 10-46
cooler, and aftercooler ............................... 10- 2 Safety valve .................................................. 10-48
Power train skeleton .................................... 10- 4 Check valve ................................................... 10-48
Hydraulic system diagram for torque con- Double check valve ...................................... 10-49
verter, transmission, and brake cooling ... 10- 6 Hand brake valve (Reterder control valve) ... 10-50
Torque converter .......................................... 10- 8 Brake valve .................................................... 10-52
Main relief valve ........................................... 10-10 Parking brake control valve ......................... 10-55
Torque converter valve ................................ 10-12 Brake relay valve .......................................... 10-57
Transmission ................................................ 10-17 Brake relay valve
Transmission valve ...................................... 10-20 (Acts also as emergency relay) ................... 10-59
ECMV (Electronic Control Parking relay valve ....................................... 10-62
Modulation Valve) ...................................... 10-21 Parking brake quick release valve ............... 10-64
Front axle ...................................................... 10-26 Spring cylinder ............................................. 10-65
Rear axle ....................................................... 10-27 Slack adjuster ............................................... 10-66
Differential .................................................... 10-28 Front brake chamber .................................... 10-67
Final drive ..................................................... 10-29 Rear brake chamber ..................................... 10-68
Front brake .................................................... 10-30 Air drier (drying agent type) ........................ 10-69
Rear brake ..................................................... 10-31 Air system diagram ...................................... 10-71
Parking brake ................................................ 10-32 Hoist valve .................................................... 10-72
Steering column ........................................ 10-33-1 Hoist cylinder ................................................ 10-73
Steering linkage ............................................ 10-34 Automatic shift control system ................... 10-76
Demand valve ............................................... 10-35 Automatic retarder valve ............................. 10-86
Crossover relief valve .................................. 10-38 Horn valve ..................................................... 10-88
Steering valve ............................................... 10-39 Wiper switch ................................................. 10-88
Front suspension cylinder ........................... 10-40 Sensors, switches ......................................... 10-89
Rear suspension cylinder ............................ 10-41 Meter lamps ................................................ 10-100
HD255-5 10-1
(9)
RADIATOR, TORQUE CONVERTER AND BRAKE OIL COOLER,
STRUCTURE AND FUNCTION AND AFTERCOOLER

AND AFTERCOOLER
10-2 HD255-5
(9)
STRUCTURE AND FUNCTION AND AFTERCOOLER
1. Aftercooler A. From tank SPECIFICATIONS

2. Radiator B. From thermostat
3. Reservoir tank C. To oil cooler • Radiator
4. Oil cooler D. To water pump Type of core: CF26-2, 3.5/2P
5. Tank (Oil filler) E. From thermostat Total radiating surface area: 37.83 m2
F. From rear brake • Oil cooler
G. To transmission filter Type of core: PTO-LS
H. Aftercooler outlet Total radiating surface area: 3.255 m2
J. Aftercooler inlet • Aftercooler
Type of core: 4.0/2P
Total radiating surface area: 20.36 m2
HD255-5 10-3
(9)
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
POWER TRAIN SKELETON
10-4 HD255-5
(9)
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
1. Engine
2. Output shaft
3. Front drive shaft
4. Hydraulic pump
5. PTO
6. Torque converter
7. Transmission
8. Rear drive shaft
9. Differential gear
10. Drive shaft
11. Brake
12. Tire
13. Final drive
14. Parking brake
15. Hydraulic pump
HD255-5 10-5
(9)
HYDRAULIC SYSTEM DIAGRAM FOR TORQUE CONVERTER,
STRUCTURE AND FUNCTION TRANSMISSION, AND BRAKE COOLING
HYDRAULIC SYSTEM DIAGRAM FOR TORQUE CONVERTER,

TRANSMISSION, AND BRAKE COOLING
10-6 HD255-5
1
STRUCTURE AND FUNCTION TRANSMISSION
1. Input shaft 12. No. 2 clutch hub

2. Speedometer cable pickup port 13. No. 2 clutch
3. Oil pan 14. No. 2 ring gear (no. of teeth: 70)
4. Strainer 15. No. 2 clutch housing
5. Transmission lubrication oil relief valve 16. No. 3 clutch housing
6. Brake cooling oil relief valve 17. No. 3 clutch
7. No. 1 sun gear (no. of teeth: 34) 18. No. 3 clutch drum
8. No. 1 clutch hub 19. No. 3 clutch hub
9. No. 1 clutch 20. No. 4 clutch
10. No. 1 planetary pinion (no. of teeth: 24) 21. No. 4 planetary pinion (no. of teeth: 22)
11. No. 1 planetary carrier
10-18-2 HD255-5
(9)
STRUCTURE AND FUNCTION TRANSMISSION
22. No. 4 ring gear (no. of teeth: 90) 33. Output shaft
23. No. 4 sun gear (no. of teeth: 44) 34. No. 6 clutch piston
24. No. 5 clutch 35. Intermediate shaft
25. No. 5 planetary pinion (no. of teeth: 22) 36. No. 5 clutch piston
26. No. 5 ring gear (no. of teeth: 88) 37. No. 5 planetary pinion (no. of teeth: 20)
27. No. 5 sun gear (no. of teeth: 36) 38. No. 4 clutch piston
28. No. 6 clutch 39. No. 4, 5 planetary carrier
29. No. 6 ring gear (no. of teeth: 88) 40. No. 3 clutch piston
30. No. 6 planetary pinion (no. of teeth: 28) 41. No. 2 clutch piston
31. No. 6 planetary carrier 42. No. 1 clutch piston
32. No. 6 sun gear (no. of teeth: 32) 43. Transmission control valve (ECMV)
HD255-5 10-19
(9)
STRUCTURE AND FUNCTION TRANSMISSION VALVE
TRANSMISSION VALVE
1. ECMV (for High clutch) a. High clutch oil pressure R 1st 2nd 3rd L H
2. ECMV (for torque measurement port
converter lock-up b. Torque converter lock-up F1 0 0
clutch) clutch oil pressure
F2 0 0
3. ECMV (for Low clutch) measurement port
4. ECMV (for 3rd clutch) c. Low clutch oil pressure F3 0 0
5. ECMV (for 2nd clutch) measurement port
6. ECMV (for Reverse d. 3rd clutch oil pressure F4 0 0
clutch) measurement port F5 0 0
7. ECMV (for 1st clutch) e. 2nd clutch oil pressure
8. Fail-safe filter measurement port F6 0 0
9. Seat f. Reverse clutch oil pres-
N
10. Breather sure measurement port
g. 1st clutch oil pressure R1 0 0
measurement port
10-20 HD255-5
1
STRUCTURE AND FUNCTION ECMV
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
1. Connector
2. Spring
3. Pressure control valve spool
4. Proportional solenoid
5. Fill switch
6. Spring
7. Flow detector valve spool
a. Plug for measuring clutch

pressure
A. To clutch
B. From pump
C. Drain
HD255-2 10-21
1
STRUCTURE AND FUNCTION ECMV
OUTLINE OF ECMV
• The ECMV (Electronic Control Modulation
Valve) consists of two valves: the pressure
control valve and the flow detection valve.
• Pressure control valve

The proportional solenoid receives the flow
of electricity sent from the transmission con-
troller, and the pressure control valve converts
this into hydraulic pressure.
• Flow detection valve
This valve is actuated by a trigger from the
pressure control valve and has the following
functions.
1) The valve opens until the oil fills the
clutch. This reduces the time taken for
the oil to fill the clutch (filling time).
2) When the clutch is filled with oil, it closes
the valve, and at the same time, it sends
a signal (fill signal) to the controller to in-
form the controller that the filling is com-
pleted.
3) While oil pressure is applied to the clutch,
it outputs a signal (fill signal) to the con-
troller to inform the controller of the ex-
istence of the oil pressure.
Range A: Before shifting gear (when
draining)
Range B: Start of fill (during trigger)
Range C: Completion of fill
Range D: Pressure adjustment
Range E: During filling
ECMV AND PROPORTIONAL SOLENOID

• There is one proportional solenoid installed
to each ECMV.
It generates propulsion force as shown in the
diagram on the right according to the com-
mand current from the transmission control-
ler.
The propulsion force generated by the pro-
portional solenoid acts on the pressure con-
trol valve spool and generates oil pressure as
shown in the diagram on the right. In this
way, the command current is controlled and
the propulsion force varies to actuate the pres-
sure control valve and control the oil flow and
oil pressure.
ECMV AND FILL SWITCH

• There is one fill switch installed to each ECMV.
When the filling of the clutch is completed,
the fill switch is turned on by the action of the
flow detection valve. With this signal, the oil
pressure starts the build-up.
10-22 HD255-2
(9)
STRUCTURE AND FUNCTION DEMAND VALVE
DEMAND VALVE
1. Spool return spring a. From hydraulic pump

2. Demand spool b. From hydraulic pump
3. Check valve c. To hoist control valve
4. Check valve spring d. From emergency steering pump
5. Valve body e. To tank
6. Main relief valve f. To steering control valve
7. Main relief valve spring
8. Pilot poppet
9. Pilot poppet spring
10. Locknut
11. Adjustment screw
HD255-2 10-35
1
STRUCTURE AND FUNCTION DEMAND VALVE
OPERATION
1. Engine at low speed

• The oil from the steering pump enters port A.
The oil from the hoist pump enters port B,
but demand spool (2) is closed, so it pushes
open check valve (3) and enters port A to
merge with the oil from the steering pump.
At the same time, the oil passes through ori-
fice a of demand spool (2) and enters port C.
As a result, all the oil from the steering pump
and hoist pump flows to the steering valve.
2. Engine at mid-range speed

• The oil from the steering pump enters port A.
The oil from the hoist pump enters port B,
pushes open check valve (3), then enters port
A, and merges with the oil from the steering
pump.
When the oil pressure to the steering circuit
rises, the oil passes through orifice a of de-
mand spool (2), so the pressure of the oil en-
tering port C also rises.
When the pressure at port C becomes greater
than the pressure of spring (1), demand spool
(2) is pushed to the right and port B and port
D are connected.
As a result, part of the oil from the hoist pump
flows directly from port D to the hoist circuit.
All the oil from the steering pump and part of
the oil from the hoist pump flows to the steer-
ing valve.
10-36 HD255-2
(9)
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
1. Check ball 6. Shaft L. To steering cylinder

2. Pin 7. Spool P. From demand valve
3. Spring 8. Stator R. To steering cylinder
4. Housing 9. Rotor T. To hydraulic tank
5. Sleeve 10. End cover
HD255-2 10-39
1
STRUCTURE AND FUNCTION FRONT SUSPENSION CYLINDER
FRONT SUSPENSION CYLINDER
1. Top rod
2. Cover
3. Flange
4. Cylinder
10-40 HD255-2
(9)
STRUCTURE AND FUNCTION REAR SUSPENSION CYLINDER
REAR SUSPENSION CYLINDER
1. Valve 5. Flange
2. Valve 6. Retainer
3. Check ball 7. Rod
4. Cylinder
HD255-5 10-41
(9)
STRUCTURE AND FUNCTION HAND BRAKE VALVE
OPERATION
1. When brake is applied

When handle (7) is set to the brake position,
cam (1) pushes spring (2), and spring (2)
pushes piston (5) down.
As a result, the exhaust valve seat set to pis-
ton (5) is pushed against exhaust valve (4),
and exhaust valve (4) closes.
Inlet valve (6) and exhaust valve (4) form one
unit, and after exhaust valve (4) closes, inlet
valve (6) opens. When the handle is operated,
the compressed air is controlled, passes
through the inlet valve, and is sent to the re-
lay valve to actuate the rear brake chamber
cylinder and apply the retarder brake.
2. Balance position
When the air applied to the bottom of piston
(5) balances the force of spring (2), the piston
moves up slightly and closes inlet valve (6).
In this condition, valve seat (3) remains closed,
so the air pressure in the relay valve is main-
tained at a constant pressure. As a result, the
brake valve is at the balanced position and
maintains the air pressure set by the position
of the handle.
3. When relieving braking force

If handle (7) is moved in the relief direction,
the force of spring (2) is reduced, so the air
pressure at the bottom of the piston pushes
up piston (5). The exhaust valve opens, and
the pressure air in the relief valve is released
to the atmosphere through the exhaust valve.
When the air pressure at the bottom of the
piston and the force of spring (2) are balanced,
the exhaust valve closes again. This sets the
system to the balance condition, and the air
pressure in the relay valve is maintained in
that condition.
If handle (7) is moved further to the full re-
lease position, the force of spring (2) is lost,
so piston (5) is pushed up and all the pres-
sure air in the relay valve is released to the
atmosphere to relieve the braking force.
HD255-5 10-51
(12)
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
1. Plunger 10. Cover a. From dry air tank

2. Spring seat 11. Lower valve guide b. To relay valve
3. Brake pedal 12. Check valve c. From dry air tank
4. Piston 13. Lower valve spring d. To relay valve
5. Stop bolt 14. Relay piston return spring
6. Piston return spring 15. Upper ring retainer
7. Upper valve (top inlet 16. Upper link spring
valve) 17. Inner relay piston
8. Outer relay piston 18. Valve body
9. Lower valve (bottom inlet 19. Rubber spring
valve)
10-52 HD255-5
1
STRUCTURE AND FUNCTION BRAKE RELAY VALVE
BRAKE RELAY VALVE

Serial No. : 1001 – 1200
1. Cover
2. Relay piston
3. Valve body
4. Exhaust cover
A. Foot brake valve or retarder valve

B. From air tank
C. To brake chamber
HD255-5 10-57
(9)
STRUCTURE AND FUNCTION BRAKE RELAY VALVE (STD)
OPERATION
1. When brake pedal is depressed

Compressed air enters portion A at the top of
the relay piston and the piston is pushed
down, so exhaust valve seat (1) closes exhaust
port C, and also pushes valve (2) open.
When the valve opens, the compressed air
from the air tank passes through the valve and
is supplied to the brake chamber to apply the
brake.
2. When brake pedal is released

The compressed air at portion A at the top of
the piston is released from the brake valve,
so the pressure at portion A goes down. Re-
lay piston (4) is then pushed up by the com-
pressed air at portion B to open the exhaust
port, so the air in portion B is exhausted and
the brake is released.
10-58 HD255-5
1
BRAKE RELAY VALVE (ACTS ALSO AS EMERGENCY RELAY)

Serial No.: 1001 – 1200
OUTLINE 1. Cover a. From air tank

2. Spring b. From brake valve
• In normal operations, when the brake pedal 3. Exhaust valve seat c. From emergency
is depressed, it moves the relay valve and the 4. Inlet exhaust valve brake valve
air in the air reservoir is sent to the brake seat d. To brake chamber
chamber. If any failure in the air supply cir- 5. Body e. To brake chamber
cuit or leakage of air causes the air pressure 6. Relay piston
in the wet tank to drop below the specified 7. Valve guide
pressure (0.22 MPa {2.2 kg/cm2}, it also acts 8. Emergency piston
as an emergency relay valve.
HD255-5 10-59
(9)
OPERATION
1. When not operated (compressed air sup-

plied to dry air tank)
When the emergency brake valve is at the
TRAVEL position and the brake pedal is not
being depressed, the compressed air in the
wet air tank passes through filter (1), pushes
down check valve (2), and is supplied to the
dry air tank. The pressure in the dry air tank
rises until it is almost the same as the pres-
sure in the wet air tank. At the same time,
emergency piston (3) is pushed down by the
compressed air from the emergency brake
valve.
The air is supplied directly from the wet air
tank to the dry air tank.

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

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

The compressed air at top portion A of the
piston is released from the brake valve. When
the pressure at portion A goes down, relay
piston (7) is pushed up by the compressed air
in bottom portion B, the exhaust port opens,
and the air in portion B is released.
10-60 HD255-5
(9)
5. When emergency brake is actuated

(1) Automatic operation
i) If there is damage to the air circuit and
the pressure at the emergency brake
valve end (wet air tank end) drops
below approx. 0.22 MPa {2.2 kg/cm2},
emergency piston return spring (8)
acts to push emergency piston (3) up,
so exhaust valve seat (5) closes ex-
haust port C and opens valve (4).
When the valve opens, compressed
air from the dry air tank passes
through the valve and is supplied to
the brake chamber. In this way, if the
pressure in the emergency brake
valve air circuit goes below 0.22 MPa
{2.2 kg/cm2}, the emergency brake
starts to be applied.
ii) If the air pressure in the emergency
brake valve air circuit is between
approx. 0.31 MPa {3.2 kg/cm2} and 0.22
MPa {2.2 kg/cm 2}, the emergency
brake is not applied automatically.
However, in this condition, if the brake
valve is depressed, even if the brake
valve is kept in the same position, the
remaining pressure inside the brake
valve causes the emergency brake to
be actuated.
iii) To release the emergency brake, open
the drain valve of the air tank, or raise
the air pressure in the wet air tank to
above 0.39 MPa {4 kg/cm2}.
(2) Manual operation

i) If the emergency brake valve is moved
from the TRAVEL position to the
BRAKE position, the compressed air
between the emergency brake valve
and the emergency relay valve is re-
leased to the atmosphere.
If this happens, the circuit is set to the
same condition as in i) above, so the
emergency relay valve is actuated.
ii) To release the emergency brake, set
the emergency brake valve to the
TRAVEL position.
HD255-5 10-61
(9)
OUTLINE 1. Cover a. From air tank

2. Spring b. From brake valve
• In normal operations, when the brake pedal 3. Exhaust valve seat c. From emergency
is depressed, it moves the relay valve and the 4. Inlet exhaust valve brake valve
air in the air reservoir is sent to the brake seat d. To brake chamber
chamber. If any failure in the air supply cir- 5. Body e. To brake chamber
cuit or leakage of air causes the air pressure 6. Relay piston
in the wet tank to drop below the specified 7. Valve guide
pressure (0.31 MPa {3.2 kg/cm2}, it also acts 8. Emergency piston
as an emergency relay valve.
10-61-1 HD255-5
(9)
OPERATION
1. When not operated (compressed air sup-

plied to dry air tank)
When the emergency brake valve is at the
TRAVEL position and the brake pedal is not
being depressed, the compressed air in the
wet air tank passes through filter (1), pushes
down check valve (2), and is supplied to the
dry air tank. The pressure in the dry air tank
rises until it is almost the same as the pres-
sure in the wet air tank. At the same time,
emergency piston (3) is pushed down by the
compressed air from the emergency brake
valve.
The air is supplied directly from the wet air
tank to the dry air tank.

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

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

The compressed air at top portion A of the
piston is released from the brake valve. When
the pressure at portion A goes down, relay
piston (7) is pushed up by the compressed air
in bottom portion B, the exhaust port opens,
and the air in portion B is released.
HD255-5 10-61-2
(9)
5. When emergency brake is actuated

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

i) If the emergency brake valve is moved
from the TRAVEL position to the
BRAKE position, the compressed air
between the emergency brake valve
and the emergency relay valve is re-
leased to the atmosphere.
If this happens, the circuit is set to the
same condition as in i) above, so the
emergency relay valve is actuated.
ii) To release the emergency brake, set
the emergency brake valve to the
TRAVEL position.
10-61-3 HD255-5
(9)
STRUCTURE AND FUNCTION AIR DRIER (DRYING AGENT TYPE)
AIR DRIER (DRYING AGENT TYPE)

DR-5
1. Purge chamber
2. Spring
3. Check valve
4. Drier cylinder
5. Drying agent
6. Oil filter
7. Valve
8. Piston
9. Body
10. Heater
A. From compressor
B. To air tank
C. From air governor
HD255-5 10-69
(9)
STRUCTURE AND FUNCTION AIR DRIER (DRYING AGENT TYPE)
OPERATION
1. Dehumidifying
While the compressor is working, air from the
compressor enters port A of the air drier. The
air is cooled on the walls of the body and the
condensed water and oil are accumulated on
the bottom of the body. Then, the air passes
through oil filter (6) which is fitted with an oil
mist separator, where the fine drops of oil and
particles of dust are removed before the air
enters the drier cylinder. Any water still in-
cluded in the air is removed by drying agent
(5). When the air reaches the top of the drier
cylinder, it is completely dry. This dry air
passes through check valve (3) and the purge
chamber (1) and is sent to the air tank.
2. Restoring drying agent

When the air pressure in the circuit reaches
the set pressure, the command from the gov-
ernor sets the compressor in the unloading
mode. The same command is also sent to
the control ports of the air drier. Drain valve
(7) opens and the air in drier cylinder (4) is
released to the atmosphere. Following this
sudden drop in pressure, the dried air in the
purge chamber (1) passes through orifice “a”.
Because of the drop in pressure, the dry air
expands and becomes super-dry air. As it
flows back through the drier cylinder (4), it
picks up water from drying agent (5) and car-
ries it out to the atmosphere.
When the loading cycle starts again, the drain
valve (7) closes according to the command
from the governor, and the cylinder returns
to dehumidifying action.
10-70 HD255-5
(13)
STRUCTURE AND FUNCTION AIR SYSTEM DIAGRAM
AIR SYSTEM DIAGRAM
1. Air governor
2. Wet air tank
3. Air drier (Desiccant type)
4. Cool tank
5. Air compressor
HD255-5 10-71
(9)
STRUCTURE AND FUNCTION HOIST VALVE
HOIST VALVE
1. Body 5. Case 9. Main relief valve A. From demand valve

2. Check valve 6. Detent 10. Case B. To cylinder
3. Hoist spool 7. Plug 11. Lever C. To hydraulic tank
4. Shaft 8. Plug 12. Ball D. To cylinder
10-72 HD255-5
1
STRUCTURE AND FUNCTION HOIST CYLINDER
HOIST CYLINDER
1. Piston rod SPECIFICATIONS

2. Crank • Cylinder bore - stroke
3. Cylinder No. 1 140 mm - 316 mm
6. Piston Normal pressure: 20.6 MPa {210 kg/cm2}
7. Piston nut Type: 3-stage piston, double acting
HD255-5 10-73
1
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(TRANSMISSION CONTROL SYSTEM WITH ALL ELECTRONIC MODULATION)
SYSTEM DIAGRAM
Serial No.: 1001 – 1600
OUTLINE
• The automatic shift control system receives Each clutch pack in the transmission is
the shift lever position signal, accelerator equipped with an electronically controlled
pedal acceleration signal, transmission speed modulation valve, and each clutch pack is in-
signal, and signals from other switches and dependently controlled.
sensors, and the shift controller acts to auto- In this way, the initial pressure for each clutch,
matically control the shift of the transmission build-up ratio, and torque-off time are con-
to the optimum speed range. The shift controlled to match the conditions of the machine.
troller also drives and controls the torque con- As a result, it contributes to the reduction of
verter lock-up solenoid and overrun preven- shock when shifting gears, prevention of shift
tion solenoid valve in addition to the shift con- hunting, and improvement in the durability
trol. of the clutches.
10-76 HD255-5
(9)
SYSTEM DIAGRAM
HD255-5 10-77
(9)
INPUT AND OUTPUT SIGNALS

Serial No.: 1001 – 1600
CN1 (MIC-17P)
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 – Output 10 – Output
3 Sensor power supply Output 12 – Output
4 Engine overrun solenoid power supply Output 13 Engine overrun solenoid output Output
5 Exhaust brake solenoid power supply Output 14 Exhaust brake solenoid output Output
6 Caution Output 15 Transmission cutout relay Output
7 Battery direct Output 16 GND Input
8 GND Input 17 Power supply (+24V) Input
9 Power supply (+24V) Input
CN2 (MIC-21P)
1 Solenoid power supply Input 12 Solenoid power supply Input
2 ECMV solenoid 1st (+) Output 13 ECMV solenoid 1st/3rd (-) Output
3 ECMV solenoid 3rd (+) Output 14 Sensor power +12V Output
4 ECMV solenoid 2nd (+) Output 15 ECMV solenoid 2nd/R (-) Output
5 ECMV solenoid R (+) Output 16 – Output
6 – Output 17 ECMV solenoid Low (-) Output
7 ECMV solenoid Low (+) Output 18 – Output
8 – Output 19 ECMV solenoid Hi (-) Output
9 ECMV solenoid Hi (+) Output 20 ECMV solenoid L/C (-) Output
10 ECMV solenoid L/C (+) Output 21 Power GND Input
11 – Output
CN3 (040-36P)
1 Connector check 0 Input 19 – Input
2 Transmission input speed Input 20 – Input
3 Transmission output speed Input 21 – Input
4 – Input 22 – Input
5 – Output 23 – Input
6 Acceleration sensor power supply Output 24 – Input
7 Torque converter inlet oil pressure (+) Input 25 – Input
8 Torque converter outlet oil pressure (+) Input 26 – Input
10 Emergency escape switch Input 28 – Input
11 Exhaust brake switch ON/OFF Input 29 Transmission valve inlet oil temperature Input
12 Transmission intermediate shaft speed Input 30 – Input
13 Engine speed Input 31 Accelerator opening ratio Input
14 GND Input 32 – Input
16 GND (Analog) Input 34 – Input
17 Torque converter inlet oil pressure GND Input 35 – Input
18 Torque converter outlet oil pressure GND Input 36 – Input
CN5 (040-36P)
2 Rear brake ON/OFF Input 20 – Input
3 Body float signal Input 21 – Input
4 – Input 22 Shift lever R input signal Input
5 Failure mode cancel Input 23 Shift lever N input signal Input
6 – Input 24 Shift lever D input signal Input
7 – Input 25 Shift lever 5 input signal Input
10 Clutch L fill switch input Input 28 Shift lever L input signal Input
12 Clutch H fill switch input Input 30 Model selection select 1 Input
13 Clutch 1 fill switch input Input 31 Model selection select 2 Input
16 Clutch R fill switch input Input 34 – Input
17 Clutch L/C fill switch input Input 35 – Input
10-78 HD255-5
(9)

CN1 (MIC-17P)
3 Sensor power supply Output 12 – Output
4 Engine overrun solenoid power supply Output 13 Engine overrun solenoid output Output
5 Exhaust brake solenoid power supply Output 14 Exhaust brake solenoid output Output
6 Caution Output 15 Transmission cutout relay Output
7 Battery direct Output 16 GND Input
8 GND Input 17 Power supply (+24V) Input
9 Power supply (+24V) Input
CN2 (MIC-21P)
1 Solenoid power supply Input 12 Solenoid power supply Input
2 ECMV solenoid 1st (+) Output 13 ECMV solenoid 1st/3rd (-) Output
3 ECMV solenoid 3rd (+) Output 14 Sensor power +12V Output
4 ECMV solenoid 2nd (+) Output 15 ECMV solenoid 2nd/R (-) Output
5 ECMV solenoid R (+) Output 16 – Output
6 – Output 17 ECMV solenoid Low (-) Output
7 ECMV solenoid Low (+) Output 18 – Output
8 – Output 19 ECMV solenoid Hi (-) Output
9 ECMV solenoid Hi (+) Output 20 ECMV solenoid L/C (-) Output
10 ECMV solenoid L/C (+) Output 21 Power GND Input
11 – Output
CN3 (040-36P)
2 Transmission input speed Input 20 – Input
3 Transmission output speed Input 21 – Input
5 Tachometer driver command Output 23 – Input
6 Acceleration sensor power supply Output 24 – Input
7 Torque converter inlet oil pressure (+) Input 25 – Input
8 Torque converter outlet oil pressure (+) Input 26 – Input
10 Emergency escape switch Input 28 – Input
11 Exhaust brake switch ON/OFF Input 29 Transmission valve inlet oil temperature Input
12 Transmission intermediate shaft speed Input 30 – Input
13 Engine speed Input 31 Accelerator opening ratio Input
14 GND Input 32 – Input
16 GND (Analog) Input 34 – Input
17 Torque converter inlet oil pressure GND Input 35 – Input
18 Torque converter outlet oil pressure GND Input 36 – Input
CN5 (040-36P)
2 Rear brake ON/OFF Input 20 – Input
3 Body float signal Input 21 – Input
4 – Input 22 Shift lever R input signal Input
5 Failure mode cancel Input 23 Shift lever N input signal Input
6 – Input 24 Shift lever D input signal Input
10 Clutch L fill switch input Input 28 Shift lever L input signal Input
11 – Input 29 Shift limit switch Input
12 Clutch H fill switch input Input 30 Model selection select 1 Input
16 Clutch R fill switch input Input 34 – Input
17 Clutch L/C fill switch input Input 35 – Input
HD255-5 10-79
(9)
TRANSMISSION CONTROLLER
1. Self-diagnostic display
window
2. Connector
3. Case
4. Printboard
5. Model selector switch
(Rotary switch 1)
6. Model selector switch
(Rotary switch 2)
OUTLINE
• This transmission controller is designed to 4. Sensors are located at three points (transmis-
control the system, so it has a built-in com- sion input shaft, intermediate shaft, and out-
puter. put shaft) to make it possible to detect any
It has the following features and functions. slipping of the transmission clutches. It also
1. When the accelerator is fully operated in high acts to protect the transmission when there
power mode, it changes the shift-up point to is any abnormality in the hydraulic system.
match the acceleration of the machine. 5. It has finely divided self-diagnostic functions
It has an [Acceleration response variable shift for both the input and output systems.
point] function. 6. The content of the self-diagnostic display is
2. The braking mode is the mode when the ac- shown with 2-digit numbers.
celerator pedal is not operated or the brake is 7. The content of the self-diagnosis is recorded
used. in memory, so even when the main switch is
The gear shifting point is raised and the brake turned off it is possible to check details of fail-
cooling pump speed is also increased to im- ures.
prove the cooling effect of the retarder. 8. The location of any existing failure is dis-
At the same time it also enables the braking played on the monitor panel.
force of the engine to be used effectively. 9. It has an emergency travel function for use if
3. It drives and controls the torque converter there is any failure in the electrical system.
lock-up solenoid valve, overrun prevention 10. It is located separately from the gearshift le-
module valve, and exhaust brake solenoid. ver.
10-80 HD255-5
(9)
Gearshift lever position and automatic gear Mode Set conditions

shifting range
Serial No.: 1001 – 1600 When either of the following
• The automatic gear-shifting range for each conditions is satisfied
gearshift lever position is shown in the table Braking 1. Rear brake signal ON
below. mode (Foot brake, retarder, or
engine brake actuated)
2. Foot removed from accel-
erator pedal
When both the following

conditions are fulfilled.
High power 1. Rear brake signal ON
mode (Foot brake, retarder, or
erator pedal
Braking mode:
Both the shift-down point and shift-up point
are raised and the engine speed is kept high
to ensure sufficient cooling oil for the retarder
and to increase the braking effect of the en-
gine.
High power mode:

This mode allows the machine to use its
Gearshifting characteristics power to the full. However, if the machine is
• The shifting up and shifting down of the trans- traveling empty or there is a low load on the
mission is carried out in accordance with the machine (high acceleration), the acceleration
shift map stored in the controller memory. of the machine is detected and the transmis-
There are two types of shift map to match the sion is shifted up earlier to improve the accel-
conditions of each input signal. eration. This also improves fuel consumption,
The setting for each mode is as shown in the reduces noise, and reduces gearshifting
following table. shock. An acceleration response type vari-
able shift point is used.
HD255-5 10-81
(9)
Gearshift lever position and automatic gear Mode Set conditions

shifting range
Serial No.: 1601 and up When either of the following
• The automatic gear-shifting range for each conditions is satisfied
gearshift lever position is shown in the table Braking 1. Rear brake signal ON
below. mode (Foot brake, retarder, or
erator pedal
When both the following

conditions are fulfilled.
High power 1. Rear brake signal ON
mode (Foot brake, retarder, or
erator pedal
Braking mode:
Both the shift-down point and shift-up point
are raised and the engine speed is kept high
to ensure sufficient cooling oil for the retarder
and to increase the braking effect of the en-
gine.
High power mode:

This mode allows the machine to use its
power to the full. However, if the machine is
traveling empty or there is a low load on the
machine (high acceleration), the acceleration
of the machine is detected and the transmis-
sion is shifted up earlier to improve the accel-
Gearshifting characteristics eration. This also improves fuel consumption,
• The shifting up and shifting down of the trans- reduces noise, and reduces gearshifting
mission is carried out in accordance with the shock. An acceleration response type vari-
shift map stored in the controller memory. able shift point is used.
There are two types of shift map to match the
conditions of each input signal.
The setting for each mode is as shown in the
following table.
10-82 HD255-5
(9)
Automatic gearshifting graph Automatic shift method

• The shift-up point and shift-down point for 1) Gearshift lever at D position
each mode, the torque converter lock-up ON/ When shifting up (when in high power
OFF point, and auto brake ON/OFF point are mode)
as shown in the table below. i) If the gearshift lever is set to the D
position, the transmission enters the
Auto Shift Auto F2 torque converter range.
Shift down brake OFF up brake ON
ii) When the accelerator pedal is de-
pressed, the engine speed rises and
1550
2350
2450
Braking 2600 the machine accelerates. When the
mode
transmission input shaft speed
reaches 1,500 rpm, the lock-up clutch
High power is engaged and the torque converter
1500
2100
2180
2230
mode is directly engaged to provide direct

drive.
Lock-up OFF
Lock-up ON (F2 – F6) iii) If the engine speed rises further and
Lock-up ON (F1)
reaches 2,230 rpm (2,100 rpm when
accelerating suddenly), the transmis-
1516
1100
1250
1500
Lock-up sion is shifted up to F3.

At the shift-up point, the lock-up
clutch is automatically disengaged
Lock-up ON (F2) when coasting
momentarily to reduce the shock
when shifting gear.
Transmission input shaft speed (rpm) iv) Immediately after shifting up, the
engine speed will drop, but as the
machine accelerates, the engine
speed will rise again. The transmis-
sion will shift up to F4 – F6 in turn
under the same condition described
1. When there is low acceleration in high-
in Section iii).
power mode
The shift-up point for F1 → F2, F2 → F3, F3 →
When shifting down (when in high
F4, F4 → F5, F5 → F6 is 1,230 rpm.
power mode)
2. When there is maximum acceleration shift-
i) If the load increases and the engine
up in high power mode
speed drops below 1,500 rpm, the
i) The shift-up point for F1 → F2, F2 → F3,
transmission is shifted down to the
F3 → F4 is raised to 2,100 rpm.
speed range below.
ii) The shift-up point for F4 → F5 is raised to
(For example, when traveling in F6,
2,180 rpm.
it is shifted down to F5.)
iii) The shift-up point for F5 → F6 is raised to
ii) If the travel speed drops further, the
2,230 rpm.
transmission is shifted down in turn
3. At high power mode
to F2, and if the engine speed drops
The shift-down point for F6 → F5, F5 → F4, F4
to 1,100 rpm when traveling in F2,
→ F3 is 1,500 rpm.
the torque converter lock-up clutch
4. Lock-up
is disengaged to set to torque con-
i) The lock-up is not actuated when travel-
verter drive.
ing in reverse.
ii) When coasting or slowing down (when
fl The actual situation may differ slightly
the accelerator pedal is released without
from the above explanation according to
the brake being operated), the lock-up re-
the travel conditions and the set speed
mains ON down to F3, but from F2 and
or actuation conditions. For details, see
below the lock-up remains OFF.
the automatic gearshifting graph.
HD255-5 10-83
(9)
2) Gearshift lever at position 5, 4, 3, or L Safety functions

The method for automatic shifting from i) Shift-down inhibitor function
F1 to F5 (F4, F3, F2) is the same as for When the gearshift lever is operated D → 5 –
“Gearshift lever at D position”. L, 5 → 4 → L, 4 → 3 – L, 3 → L during travel
3) Gearshift lever at R position operation.
The lock-up is not actuated at the R posi- For example, if the machine is traveling in D
tion. The safety functions related to travel (F6), and the gearshift lever is operated to 4,
in reverse are directional inhibit and re- the transmission will not shift directly F6 →
verse safety (if equipped). If the opera- F4. It will shift down in order F6→ F5 → F4 in
tion is not carried out correctly, the trans- accordannce with the travel speed.
mission is kept at N. (This is to prevent the transmission from
jumping two speed ranges because of mis-
4) Gearshift lever at N position taken operation by the operator. Engine over-
This is the neutral position. None of the run prevention circuit)
transmission clutches are actuated. ii) Starting neutral safety function
If the gearshift lever is at any position other
Gearshift prevention interval than N, this circuit prevents the engine from
• In the automatic shift range, to prevent any starting even when the starting switch is
mistaken actuation caused by excessive turned to the START position.
changes in the speed when shifting gear, a (Safety circuit to prevent the machine from
gearshift prevention interval is provided. This suddenly moving by mistake when the engine
prevents the gear from shifting within a cer- starts)
tain interval of time. iii) Direction inhibitor function
The gearshift prevention interval enables fine If the machine is traveling forward at a speed
control of the gearshifting pattern through use of 4 km/h or more and the gearshift lever is
of the all-range modulation system. moved to the R position by mistake, the trans-
The approximate values for the gearshifting mission will not shift to REVERSE. (Improve-
pattern and gearshift prevention interval are ment of durability and reliability by prevent-
shown in the table below. ing excessive load on power train)
iv) Power train overrun prevention rear brake
function
Gearshift If the engine speed is above 2,600 rpm, while
Gearshift prevention Example of gearshifting
pattern interval (sec) ( : Gearshift prevention interval) traveling, the rear brake is automatically ap-
plied.
Shift up F3→F4, F4→F5
→shift up 0.2 (Improvement in durability and reliability by
(Short) preventing overrun of the engine, torque con-
F3→F4 F4→F3 verter, or transmission)
Shift up 2.55
→shift up v) REVERSE safety (if equipped)
(Long)
The machine cannot travel in reverse if the
F5→F4, F4→F3 body is at any position other than FLOAT.
Shift down 0.2
→shift up (Function to prevent overturning)
(Short)
Shift down F5→F4 F4→F5

→shift up 2.55
(Long)
10-84 HD255-5
(9)
SHIFT LEVER SWITCH
1. Lever FUNCTION
2. Detent • The direction of travel (forward or reverse) is
3. Lock button selected by the action of the operator, and an
4. Screening plate electric signal is sent to the transmission con-
5. Photo interrupter troller (AESC). The lever position is displayed
on the indicator (with night lighting) to the
left of the gearshift lever. (The lever position
is displayed on the monitor panel, too.)
• In addition, to prevent mistaken operation of
the gearshift lever, the lever is equipped with
a lock button.
HD255-5 10-85
(9)
STRUCTURE AND FUNCTION AUTOMATIC RETARDER VALVE
AUTOMATIC RETARDER VALVE

Serial No.: 1001 – 1200
1. Exhaust valve OUTLINE

2. Coil • If the speed of the transmission output shaft
3. Spool exceeds 2,600 rpm, the retarder brake (rear
4. Spring brake) is automatically applied to prevent
5. Valve seat overrun of the engine.
6. Body
SPECIFICATIONS
A. Drain
• Voltage: DC24V
• Max. air pressure: 1MPa {10 kg/cm2}
10-86 HD255-5
(9)
STRUCTURE AND FUNCTION AUTOMATIC RETARDER VALVE
1. Core A: Input port FUNCTION

2. Coil assembly B: Output port • The input port and output port are connected
3. Spring C: Exhaust port by passing electricity through the coil of the
4. Plunger solenoid valve.
5. Valve seat In this way auto retarder is actuated.
6. Rod
7. Valve
8. Spring
9. Body
10. Connector
HD255-5 10-87
(9)
STRUCTURE AND FUNCTION HORN VALVE, WIPER SWITCH
HORN VALVE
Serial No.: 1001 – 1600
FUNCTION
• When the horn button on the steering wheel
is pressed, the electric circuit is closed and
electricity flows to the coil to form an electro-
magnet that raises the piston.
Compressed air then flows to sound the horn.
1. Coil assembly
2. Core
3. Plunger
4. Filter
5. Terminal
WIPER SWITCH
1. Ball FUNCTION
2. Spring • This switch is used to actuate the wiper and
3. Terminal base washer.
4. Bar Turn the knob to actuate the wiper, and press
5. Rotor the knob to actuate the washer.
6. Body
7. Shaft
8. Knob
9. Connector
10-88 HD255-5
(9)
STRUCTURE AND FUNCTION SENSORS, SWITCHES
SENSORS, SWITCHES
TRANSMISSION SPEED SENSOR
1. Connector FUNCTION
2. Flange • This speed sensor is installed to the input, in-
3. Sensor termediate, and output gears of the transmis-
sion. It generates a pulse voltage according
to the speed of the gear teeth and sends the
signal to the controller and monitor panel.
TRANSMISSION OIL TEMPERATURE

SENSOR
1. Thermistor FUNCTION
2. Body • This sensor is installed to the transmission
3. Connector filter, and the change in temperature is taken
as a change in resistance in the thermistor,
and the signal is sent to the shift controller.
HD255-5 10-89
(9)
TRANSMISSION OIL FILTER CLOGGING SENSOR
1. Body FUNCTION
2. Tube • This sensor are installed to each filter, and
3. Connector when the filter becomes clogged, and the dif-
ference in pressure between the low-pressure
A: Low pressure pickup port side and high-pressure side reaches the speci-
B: High pressure pickup port fied pressure, the switch goes OFF. The cau-
tion lamp flashes to warn of abnormality.
Actuating pressure:
Transmission oil filter sensor:
275 ± 20 kPa {2.8 ± 0.2 kg/cm2}
Principle of switch: Pressure difference sliding

piston type
REAR BRAKE CHAMBER STROKE SENSOR
1. Ball FUNCTION
2. Shaft • The brake stroke sensor is installed to the
3. Switch brake chamber. If the air piston in the brake
4. Wiring harness chamber goes beyond the specified stroke,
5. Connector the rod installed to the brake chamber pushes
the ball and shuts off the electric current. The
switch is turned OFF, the caution lamp lights
up, and the alarm buzzer sounds to warn the
operator of the abnormality.
10-90 HD255-5
(9)
ACCELERATOR SENSOR
Serial No.: 1001 – 1600
1. Connector FUNCTION
2. Lever • The accelerator sensor is installed at the bot-
3. Body tom of the operator's cab, and the accelera-
4. Potentiometer tor pedal and sensor are connected by a link.
5. Coupling When the accelerator pedal is depressed, the
6. Shaft movement is transmitted through the link to
7. Stopper rotate the shaft of the potentiometer inside
the accelerator sensor, and the resistance
value changes. A certain voltage is impressed
between pins (1) and (3) of the potentiometer,
and a voltage signal corresponding to the
amount the accelerator pedal is depressed is
sent to the controller from No. 2 pin.
HD255-5 10-91
(9)
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
• This is installed under the operator’s cab. The
accelerator pedal and accelerator sensor are
connected by a link. When the accelerator
pedal is depressed, the movement is passed
through the link and rotates the shaft of the
potentiometer inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 – 3
pins of the potentiometer. A voltage signal
corresponding to the angle of the accelerator
pedal is sent from the No. 2 pin to the PMC.
Idling validation signal

• This is installed under the operator’s cab.
When the accelerator pedal is released, sig-
nal 2 (No. 5 pin) is connected to the ground;
when the accelerator pedal is depressed, sig-
nal 3 (No. 6 pin) is connected to the ground.
The PMC then detects the condition.
10-92 HD255-5
(9)
PARKING BRAKE SWITCH
1. Port OUTLINE
2. Diaphragm • When the parking brake is released, the com-
3. Cover pressed air from the air tank actuates the dia-
4. Connector phragm and closes the contacts of the switch.
BIMETAL TIMER
Serial No.: 1001 – 1600
1. Body FUNCTION
2. Wire • This is a timer which actuates the heater re-
3. Connector lay for the electrical intake air heater.
• In cold weather, when electricity flows to the
timer, the bimetal is heated by the heater in-
side the timer, and after the fixed time passes,
it switches OFF.
HD255-5 10-93
(9)
STOP LAMP SWITCH
FUNCTION
• When the brake pedal is pressed, air pressure
acts on the switch to light up the lamps.
1. Terminal (A)
2. Terminal (B)
3. Spring
4. Plate
5. Block
6. Diaphragm
7. Body
SHIFT LIMIT SWITCH

1. Knob OUTLINE
2. Body Shift limit switch
3. Spring • This switch is installed at the lower right of
4. Connector front panel. When the shift lever is in the D
5. Spring or L range, it controls the speed ranges that
6. Spring are covered by automatic gear shifting.
This switch is very effective if used when go-
ing downhill or when working in jobsites
where there are speed limits.
10-94 HD255-5
(9)
LAMPS
1. Body
2. Bracket
3. Valve
4. Cable
5. Connector
HD255-5 10-95
(9)
LAMPS
1. Body
2. Bracket
3. Valve
4. Cable
5. Connector
10-96 HD255-5
(9)
COMBINATION SWITCH
1. Switch assembly 9. Body assembly 17. Plate

2. Yoke 10. Ring 18. Ball
3. Spring 12. Wiring harness 19. Connector
4. Pin 13. Pin 20. Plate assembly
5. Ratchet 14. Ball 21. Band
6. Spring 15. Ring 22. Switch assembly
7. Plate 16. Ball
8. Cam
HD255-5 10-97
(9)
RELAY SWITCH (5-PIN)
1. Case
2. Base
RELAY SWITCH (6-PIN)
1. Case
2. Base
10-98 HD255-5
(9)
BUZZER
1. Cover
2. Plate
3. Wire
4. Connector
HD255-5 10-99
(9)
STRUCTURE AND FUNCTION METER LAMPS
METER LAMPS
Serial No.: 1001 – 1200
1. Service meter 13. Cold start switch

2. Torque converter oil temperature gauge 14. Emergency steering pilot lamp (if equipped)
3. Air pressure gauge 15. Rear brake caution lamp
4. Retarder oil temperature gauge 16. Pilot lamp for retarder
5. Engine water temperature gauge 17. Parking brake oil level pilot lamp
6. Speedometer 18. Charge level caution lamp
7. Turn signal pilot lamp 19. Front brake oil level pilot lamp
8. Head lamp high beam pilot lamp 20. Engine oil pressure caution lamp
9. Turn signal pilot lamp 21. Central warning lamp
10. Engine tachometer 22. Exhaust brake switch
11. Fuel gauge 23. Fog lamp switch (if equipped)
12. Shift indicator
10-100 HD255-5
(9)
Serial No.: 1201 – 1600
1. Torque converter oil temperature gauge 14. Emergency steering

2. Air pressure gauge (machine with emergency steering specs.)
3. Retarder oil temperature gauge 15. Cold start switch
4. Engine water temperature gauge 16. Exhaust brake switch
5. Speedometer 17. Rear brake caution lamp
6. Turn signal pilot lamp 18. Pilot lamp for retarder
7. Headlamp high beam pilot lamp 19. Parking brake oil level pilot lamp
8. Turn signal pilot lamp 20. Charge level caution lamp
9. Engine tachometer 21. Fog lamp switch (if equipped)
10. Fuel gauge 22. Front brake oil level pilot lamp
11. Shift indicator 23. Yellow rotary lamp switch (if equipped)
12. Hazard lamp switch (if equipped) 24. Engine oil pressure caution lamp
13. Service meter 25. Central warning lamp
HD255-5 10-101
(9)
1. Torque converter oil thermometer 15. Emergency steering pilot lamp

2. Air pressure gauge 16. Gear shift limiter switch
3. Retarder oil thermometer 17. Exhaust brake switch
4. Engine coolant thermometer 18. Transmission oil filter clogging caution lamp
5. Speedometer 19. Preheater pilot lamp
6. Turn signal pilot lamp 20. Rear brake caution lamp
7. Headlamp high beam pilot lamp 21. Retarder pilot lamp
8. Turn signal pilot lamp 22. Parking brake oil level pilot lamp
9. Engine tachometer (with service meter) 23. Charge level caution lamp
10. Fuel level gauge 24. Fog lamp switch (if equipped)
11. Engine controller warning lamp 25. Yellow rotary lamp switch (if equipped)
12. Gear shift indicator 26. Front brake oil level pilot lamp
13. Hazard lamp switch (if equipped) 27. Engine oil pressure caution lamp
14. Emergency steering switch 28. Centralized warning lamp
10-102 HD255-5
(9)
DISPLAY AND FUNCTION OF METER LAMPS

Serial No.: 1001 – 1200
Display Symbol Display item Display range Display method
section
1–8 Digital display

Gear shift indicator R, N, E When gear speed is abnormal, “E” is
displayed
When normal, lamp lights up
Below specified When abnormal, lamp lights up, and
Engine oil pressure pressure centralized warning lamp and buzzer
Caution
are turned ON, too
When charge is When normal, lamp goes off

Charge level defective When abnormal, lamp lights up
Lowering of rear When normal, lamp goes off

Rear brake brake oil pressure When rear brake malfunctions, lamp
flashes
Below specified
Air pressure gauge pressure
Indication with meter
When abnormal, centralized warning
lamp and buzzer are turned ON
Engine coolant
thermometer Above 102°C
Meter
Torque converter oil

thermometer Above 120°C Indication with meter
Retarder oil Indication with meter

thermometer Above 120°C When abnormal, centralized warning
Fuel level gauge Below _ level Indication with meter
Cold start (Preheating When operated

engine when cold)
When operated, lamp lights up
Emergency steering When operated
(if equipped)

Parking When operated When shift lever is at position other than N,
(Emergency brake) centralized warning lamp and buzzer are
turned ON
 Rear brake
Retarder, foot brake, 
Pilot
 When operated When operated, lamp lights up

 auto-retarder, 
emergency brake 
High beam When operated

Turn signal When operated
(Left, right)
When oil level of

front brake oil When normal, lamp goes off
Front brake oil level reservoir is below When abnormal, lamp lights up
specified level
10-104 HD255-5
(9)

section
Service meter
When charge is normal, meter operates

Service meter 0 – 99999 h Ratio of meter to clock time is 1:1
Service meter indicator — While service meter is in operation,

indicator flashes
LAMPS IN DASHBOARD
Serial No.: 1001 – 1200
section
Exhaust brake When operated

Pilot
Fog lamp When operated
HD255-5 10-105
(9)

Serial No.: 1201 – 1600
section

displayed
Caution
are turned ON, too


flashes
Below specified
Engine coolant
Meter


Emergency steering When operated When operated, lamp lights up

turned ON
 Rear brake
 Retarder, foot brake,  When operated When operated, lamp lights up
emergency brake 
Pilot

(Left, right)
When oil level of

specified level
10-106 HD255-5
(9)

section
Service meter
When charge is normal, meter operates

Service meter 0 – 99999 h Ratio of meter to clock time is 1:1
Service meter indicator — While service meter is in operation,

indicator flashes
LAMPS IN DASHBOARD
Serial No.: 1201 – 1600
section
Cold start (Preheating

engine when cold) When operated

Pilot
Fog lamp When operated When operated, lamp lights up
Yellow rotary lamp When operated
Hazard lamp When operated
HD255-5 10-107
(9)

section
When abnormal, lamp lights up
Engine controller When error code display (controller LED)
Engine controller alarm at abnormal Centralized warning lamp and buzzer are
turned ON

displayed
Caution

are turned ON, too


flashes
Below specified
Engine coolant
Meter


Emergency steering When operated When operated, lamp lights up

turned ON
 Rear brake
 Retarder, foot brake,  When operated When operated, lamp lights up
emergency brake 
Pilot

(Left, right)
When oil level of

specified level
10-108 HD255-5
(9)

section
Service
meter
Service meter When charge is normal, meter operates

(with engine tachometer) 0.0 – 99999.9 h Ratio of meter to clock time is 1:1
LAMPS IN DASHBOARD
section
Pilot
Gear shift limiter When operated When operated, lamp lights up
When transmission
Caution
Transmission oil filter oil filter is clogged

clogging caution Oil pressure: Above When abnormal, lamp lights up
275 kPa {28 kg/cm2}
Preheater lamp When operated

Pilot
Fog lamp When operated When operated, lamp lights up
Yellow rotary lamp When operated
Hazard lamp When operated
HD255-5 10-109
(9)
20 TESTING AND ADJUSTING
Standard value table for engine related

parts .............................................................. 20-2
Standard value table for chassis ................... 20-3
Standard value table for electrical system ... 20-7
Testing and adjusting ................................. 20-101
Troubleshooting ......................................... 20-201
fl Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is re-
moved when the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt or other rotating parts.
HD255-5 20-1
4
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Serial No.: 1001 – 1599
Model HD255-5
␣␣␣
Engine SA6D125E-2
Item Measurement conditions Unit Standard value Permissible

value
High idling rpm 2,450 ± 50 2,450 ± 50
Engine speed Low idling rpm 780 ± 25 780 ± 25
Rated speed rpm 2,100 ± 50 2,100 ± 50
Bosch
At sudden acceleration index Max. 6.0 —
Exhaust gas color
Bosch
At high idling index Max. 2.0 —
Intake valve mm 0.43 —

Valve clearance
(Cold)
Exhaust valve mm 0.80 —
Compression pressure MPa Min. 3.1

Oil temperature: 40 – 60˚C {kg/cm2} {Min. 32} Min. 2.2
(SAE30 oil) (engine speed) {Min. 22}
(rpm) (160 – 200)
Blow-by pressure (Water temperature: Operating range) kPa Max. 1.47 Max. 2.94
(reference value) At rated output {mmH2O} {Max. 150} {Max. 300}
(Water temperature: Operating range)

At high idling
(SAE30) MPa 0.34–0.49{3.5–5.0} Min. 0.2 {2.0}
Oil pressure (SEA10W) {kg/cm2} 0.25–0.44{2.5–4.5} Min. 0.18 {1.8}
At low idling
(SAE30) Min. 0.15 {1.5} Min. 0.07 {0.7}
(SEA10W) Min. 0.1 {1.0} Min. 0.07 {0.7}
Whole speed range

Oil temperature
(inside oil pan) °C 80 – 110 Max. 120
Fuel injection timing Before top dead center deg. 26 ± 1 26 ± 1
Belt tension (alternator) Deflection when pressed with Max. 8

finger force of approx. 58.8 N {6 kg} mm 8 – 12 Min. 12
Air supply pressure kPa Min. 1.4 Min. 1.13

At torque converter stall {mmHg} {Min. 1,050} {Min. 850}
Exhaust temperature Whole range °C Max. 700 Max. 700
20-2 HD255-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Model HD255-5
␣␣␣
Engine SAA6D125E-3
Item Measurement conditions Unit Standard value Permissible

value
+80 +80
High idling rpm 2,420 –20 2,420 –20
Engine speed Low idling rpm 750 ± 50 750 ± 50
Rated speed rpm 2,100 ± 50 2,100 ± 50
Bosch
At sudden acceleration index Max. 40 % —
Exhaust gas color
Bosch
At high idling index Max. 10 % —
Intake valve mm 0.33 —

Valve clearance
(Cold)
Exhaust valve mm 0.71 —
Compression pressure MPa Min. 2.9

Oil temperature: 40 – 60˚C {kg/cm2} {Min. 30} Min. 2.0
(SAE30 oil) (engine speed) {Min. 20}
(rpm) (150 – 200)
Blow-by pressure (Water temperature: Operating range) kPa Max. 0.98 Max. 1.96
(reference value) At rated output {mmH2O} {Max. 100} {Max. 200}
(Water temperature: Operating range)

At high idling
(SAE30) MPa 0.39–0.69{4.0–7.0} Min. 0.2 {2.0}
Oil pressure (SEA10W) {kg/cm2} 0.34–0.64{3.5–6.5} Min. 0.18 {1.8}
At low idling
(SAE30) Min. 0.15 {1.5} Min. 0.07 {0.7}
(SEA10W) Min. 0.1 {1.0} Min. 0.07 {0.7}
Whole speed range

Oil temperature
(inside oil pan) °C 80 – 110 Max. 120
Fuel injection timing Before top dead center deg. — —
Belt tension (alternator) Deflection when pressed with Max. 8

finger force of approx. 58.8 N {6 kg} mm 8 – 12 Min. 12
Air supply pressure kPa Min. 107 Min. 87

At torque converter stall {mmHg} {Min. 800} {Min. 650}
Exhaust temperature Whole range °C Max. 650 Max. 700
HD255-5 20-2-1
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Serial No.: 1001 – 1599
Compo- Standard Permissible
nent Item Measurement conditions Unit value value
F1 • Engine coolant temperature: 8.8 ± 5% 8.8 ± 5%

Within operating range
• Transmission oil temperature:
F2 60 – 80˚C 12.4 ± 5% 12.4 ± 5%
• At engine speed of 2400 rpm
• When empty
F3 16.8 ± 5% 16.8 ± 5%
Perfor-
mance Travel speed F4 km/h 23.7 ± 5% 23.7 ± 5%
F5 32.9 ± 5% 32.9 ± 5%
F6 46.5 ± 5% 46.5 ± 5%
R 7.9 ± 5% 7.9 ± 5%
Shift up • Engine coolant temperature: 2,230 ± 50 2,230 ± 50

Automatic shift control

60 – 80˚C 1,500 ± 35 1,500 ± 35
Shift down • Hydraulic oil temperature:
45 – 55˚C
• “Braking mode” refers to when 1,400 ± 35 1,400 ± 35
the accelerator is OFF or the (F2 to F1 only) (F2 to F1 only)
rear brake is ON.
Shift up 2,450 ± 50 2,450 ± 50
Braking
mode
Shift down 1,550 ± 35 1,550 ± 35
F1 • F2 1,500 ± 50 1,500 ± 50
Set
Auto lock-up
F3 – F6 1,250 ± 50 1,250 ± 50
Engine speed
F1 • F2 rpm 1,100 ± 50 1,100 ± 50

Reset
F3 – F6 1,100 ± 50 1,100 ± 50
prevention
2,600 ± 10 2,600 ± 10
Overrun
Set
Reset 2,350 ± 10 2,350 ± 10
Same as shift Same as shift

down for au- down for au-
Down-shift inhibitor tomatic shift tomatic shift
control given control given
above above

85 – 110˚C
converter
Torque
• Hydraulic oil temperature:

Engine speed at torque 45 – 55˚C 1,890 ± 75 1,890 ± 75
converter stall • Engine coolant temperature:
HD255-5 20-3
(10)

Starting to • Operating effort at a point 150 Max.34.3 Max.34.3

depress mm from pedal fulcrum {Max.3.5} {Max.3.5}
Operating N
effort {kg) 34.3 ± 9.8
Accel- Fully 34.3 ± 9.8
erator depressed {3.5 ± 1.0} {3.5 ± 1.0}
pedal
´Starting to • Travel at a point 150 mm from
Travel depress pedal fulcrum mm 32 ± 5 32 ± 5
↔ fully
depressed
N 15.7 ± 3.9 Max.19.6

Operating effort • At center of lever knob {1.6 ± 0.4}
{kg) {Max.2.0}
R–Ñ
Gear- N–D
shift
lever D–5 mm 18.5 ± 1 18.5 ± 2
Travel
5–4
4–3
3–L
0.84 ± 0.1 0.84 ± 0.1
Oil pressure at inlet port • Oil temperature: 60 – 80˚C {8.6 ± 1} {8.6 ± 1}
• Engine: Full throttle 0.78 ± 0.12 0.78 ± 0.12
Oil pressure at outlet port {8.0 ± 1.2} {8.0 ± 1.2}
Torque
con- MPa 1.9 ± 0.13 1.9 ± 0.13
Lock-up pressure {19 ± 1.5}
verter {kg/cm2} {19 ± 1.5}
3.4 ± 0.1 3.4 ± 0.1
Low idling • Oil temperature: 60 – 80˚C {35 ± 1.0}
Main relief {35 ± 1.0}
pressure
3.4 ± 0.1 3.4 ± 0.1
High idling {35 ± 1.0} {35 ± 1.0}
1.7 ± 0.15 1.7 ± 0.15
H, 2nd • Oil temperature: 60 – 80˚C {17 ± 1.5} {17 ± 1.5}
L {19 ± 1.5} {19 ± 1.5}
Control 1.81 ± 0.15 1.81 ± 0.15

3rd {18.5 ± 1.5}
valve set {18.5 ± 1.5}
Trans-
mission MPa 2.8 ± 0.15 2.8 ± 0.15
1st {29 ± 1.5}
pres- {kg/cm2} {29 ± 1.5}
sure
3.1 ± 0.15 3.1 ± 0.15
R {32 ± 1.5} {32 ± 1.5}
• Oil temperature: 60 – 80˚C
(using EO10-CD)
or 0.15 ± 0.03 0.15 ± 0.03
Lubrication pressure {1.5 ± 0.3} {1.5 ± 0.3}
Oil temperature: 60 – 100˚C
(Using EO30-CD)
16.00-25-24PR • When empty 0.5
(Front and 0.5
Tires {5.0} {5.0}
Standard rear wheels) MPa
(inflation
pressure) tires 16.00-25-28PR {kg/cm2} 0.62 0.62
(Front and {6.3} {6.3}
rear wheels)
20-4 HD255-5
4

F1 • Engine coolant temperature: 9.2 ± 5% 8.8 ± 5%

F2 60 – 80˚C 13.0 ± 5% 12.4 ± 5%
• At engine speed of 2400 rpm
• When empty
F3 17.5 ± 5% 16.8 ± 5%
Perfor-
mance Travel speed F4 km/h 24.7 ± 5% 23.7 ± 5%
F5 33.9 ± 5% 32.9 ± 5%
F6 47.5 ± 5% 46.5 ± 5%
R 7.9 ± 5% 7.9 ± 5%
Automatic shift control
Shift up • Engine coolant temperature: 2,230 ± 50 2,230 ± 50

Shift down 60 – 80˚C 1,500 ± 35 1,500 ± 35
45 – 55˚C
Shift up • “Braking mode” refers to when 2,450 ± 50 2,450 ± 50
Braking the accelerator is OFF or the
mode rear brake is ON.
Shift down 1,550 ± 35 1,550 ± 35
F1 • F2 1,500 ± 50 1,500 ± 50
Set
Auto lock-up
F3 – F6 1,250 ± 50 1,250 ± 50
F1 • F2 rpm 1,100 ± 50 1,100 ± 50

Engine speed
Reset
F3 – F6 1,100 ± 50 1,100 ± 50
prevention
2,600 ± 10 2,600 ± 10
Overrun
Set
Reset 2,350 ± 10 2,350 ± 10
Same as shift Same as shift

down for au- down for au-
Down-shift inhibitor tomatic shift tomatic shift
control given control given
above above

85 – 110˚C
converter
Torque
Engine speed at torque 45 – 55˚C

converter stall • Engine coolant temperature: 1,890 ± 75 1,890 ± 75
HD255-5 20-6-1
(10)

Starting to • Operating effort at a point 150 22.5 ± 4.9 22.5 ± 4.9
depress mm from pedal fulcrum {2.3 ± 0.5} {2.3 ± 0.5}
Operating N
effort {kg)
Accel- Fully 42.1+2.9
– 7.8
+2.9
42.1 – 7.8
erator depressed {4.3 +0.3
– 0.8 } {4.3 +0.3
– 0.8 }
pedal
´Starting to • Travel at a point 150 mm from
depress pedal fulcrum
Travel
↔ fully
mm 45 ± 5 45 ± 5
depressed
N 15.7 ± 3.9 Max.19.6

Operating effort • At center of lever knob {1.6 ± 0.4}
{kg) {Max.2.0}
R–Ñ
Gear- N–D
shift
lever D–5 mm 18.5 ± 1 18.5 ± 2
Travel
5–4
4–3
3–L
0.84 ± 0.1 0.84 ± 0.1
Oil pressure at inlet port • Oil temperature: 60 – 80˚C {8.6 ± 1} {8.6 ± 1}
Oil pressure at outlet port {8.0 ± 1.2} {8.0 ± 1.2}
Torque
con- MPa 1.9 ± 0.13 1.9 ± 0.13
Lock-up pressure {19 ± 1.5}
verter {kg/cm2} {19 ± 1.5}
3.4 ± 0.1 3.4 ± 0.1
Low idling • Oil temperature: 60 – 80˚C {35 ± 1.0}
Main relief {35 ± 1.0}
pressure
3.4 ± 0.1 3.4 ± 0.1
High idling {35 ± 1.0} {35 ± 1.0}
1.7 ± 0.15 1.7 ± 0.15
H, 2nd • Oil temperature: 60 – 80˚C {17 ± 1.5} {17 ± 1.5}
L {19 ± 1.5} {19 ± 1.5}
Control 1.81 ± 0.15 1.81 ± 0.15
3rd {18.5 ± 1.5}
valve set {18.5 ± 1.5}
Trans-
mission MPa 2.8 ± 0.15 2.8 ± 0.15
1st {29 ± 1.5}
pres- {kg/cm2} {29 ± 1.5}
sure
3.1 ± 0.15 3.1 ± 0.15
R {32 ± 1.5} {32 ± 1.5}
(using EO10-CD)
or 0.15 ± 0.03 0.15 ± 0.03
Lubrication pressure {1.5 ± 0.3} {1.5 ± 0.3}
Oil temperature: 60 – 100˚C
(Using EO30-CD)
• When empty
Tires Standard 16.00-R25 MPa 0.69 0.69
(inflation (Front and {7.0}
pressure) tires {kg/cm2} {7.0}
rear wheels)
20-6-2 HD255-5
(10)

Operating effort • With machine stopped (empty) N Max.29.4 Max.35.3
(turning speed for (if it is impossible with the {kg) {Max.3.0} {Max.3.6}
steering wheel: 30 rpm) machine stopped, travel at low
speed with engine at low idling)
• Length at circumference of
Play steering wheel
Steering • Engine stopped, until tires start mm Max. 100 Max. 100
wheel to move
No. of turns • Lock → lock Turns 3.4 ± 0.4 3.4 ± 0.6

Left
→ right • Oil temperature: 60 – 80˚C Max. 3.0 Max. 5.0
Turning time • Engine speed: Whole range sec.
Right • Lock → lock Max. 3.0 Max. 5.0
→ left
• Oil temperature: 45 – 55˚C +0.5 +0.5

Steering • Engine: Full throttle MPa 17.2 0 17.2 0
valve Relief pressure +5 +5
• Demand valve relief valve {kg/cm2} {175 –0 } {175 –0 }
N Max.29.4 Max.29.4
Operating effort • Tip of pedal {kg) {Max.3.0} {Max.3.0}
Brake
pedal
Travel mm 78 ± 8 78 ± 15
N 9.8 – 39.2 4.9 – 58.8
Retarder Operating effort • At point 10 mm from tip of lever {kg) {1.0 – 4.0} {0.5 – 6.0}
control
lever Travel deg 0 – 84 ± 3 0 – 84 ± 6
Parking N Max.19.6 Max.29.4
brake lever Operating effort • Tip of lever {kg) {Max.2.0} {Max.3.0}
Emergency
brake lever N Max.19.6 Max.19.6
Operating effort • Tip of lever {kg) {Max.2.0} {Max.2.0}
(opt)
Cut-out pressure 0.81 ± 0.03 0.81 ± 0.03

Air MPa {8.3 ±␣ 0.3} {8.3 ±␣ 0.3}
governor {kg/cm2}
Cut-in pressure 0.7 ± 0.03 0.7 ± 0.03
{7.0 ±␣ 0.3} {7.0 ±␣ 0.3}
Service 25t payload • Initial speed: 32 km/h Max. 17.4 Max. 17.4
brake • Distance from starting to lose
brakin speed to stopping
distance Empty • Max. actuating air pressure: Max. 14.9 Max. 14.9
8.3 kg/cm2 m
Retarder 25t payload • Max. hydraulic pressure Max. 28 Max. 28
brake Rear: 5.7 MPa {58 kg/cm2}
braking Front: 17.2 MPa {175 kg/cm2}
distance Empty • On flat, dry road surface Max. 25.9 Max. 25.9
Brakes Front • Max. actuating air pressure: Min. 17.2 Min. 17.2
chamber 814 kPa {8.3 kg/cm2} {Min. 175} {Min. 175}
• Engine: Stopped
Brake Rear chamber • When first operated MPa Min. 5.7 Min. 5.7
actuating (service) {kg/cm2} {Min. 58} {Min. 58}
pressure
Rear chamber Min. 4.9 Min. 4.9
(retarder) {Min. 50} {Min. 50}
Stopping distance when • Carrying 25t payload

emergency brake is • Initial speed: 32 km/h m Max. 52.1 Max. 52.1
applied • On flat, dry road surface
HD255-5 20-6-3
(10)

• With 25t payload

Braking capacity (sin θ ) • After adjusting clearance % Min. 25 Min. 25
Parking between disc and pad
brake
• F2
Starting test • Torque converter stall rpm Min. 1,600 Min. 1,600
HOLD • Center of control lever knob Max.49 Max.49

→ RAISE {Max.5} {Max.5}
RAISE Must return Must return
smoothly smoothly
→ HOLD (return spring) (return spring)
HOLD Max.49 Max.49
Operating → LOWER {Max.5} {Max.5}
N
effort LOWER {kg) Must return
smoothly —
→ HOLD (return spring)
LOWER Max.68.7 Max.68.7
→ FLOAT {Max.7} {Max.7}
Hoist
lever FLOAT Max.68.7 Max.68.7
→ LOWER {Max.7} {Max.7}
RAISE 12.9 12.9
↔ HOLD (A)
HOLD 11.3 11.3

↔ LOWER (B)
Travel mm
LOWER 9.8 9.8
↔ FLOAT (C)
HOLD 21.1 21.1

↔ FLOAT

Hoist Relief pressure • Engine: Full throttle MPa 20.6 ±␣ 0.5 20.6 ±␣ 0.5
valve • Measure at end of stroke when {kg/cm2} {210 ± 5} {210 ± 5}
raising body
Lifting speed
• Oil temperature: 45 – 55˚C 7 ± 1.5 7 ± 1.5
• Engine: Full throttle sec.
Lowering speed • Use FLOAT when lowering 13 ± 1.5 13 ± 1.5
Body
• Set with No. 2 cylinder extended mm Max. 30 Max. 30
Hydraulic drift 200 mm
• Hydraulic drift after 5 minutes
• On flat road surface

A • When empty 245.7 ± 10 245.7 ± 10
Front
B Front Rear 351 ± 10 351 ± 10
Installed mm
length
Suspen-
sion Rear A 184 ± 10 184 ± 10
cylinder
2.79 ± 0.5 2.79 ± 0.5

Front {28.5 ± 5} {28.5 ± 5}
MPa
Pressure {kg/cm2} 2.3 ± 0.5 2.3 ± 0.5
Rear {23.0 ± 5} {23.0 ± 5}
20-6-4 HD255-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Sys- Connector Inpsec- Measurement

Name of component tion Judgement table
tem No. method conditions
Measure resistance
If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
11,12,14,16 2) Disconnect
Relay 17,18,20,21 Between (1) – (2) 100 – 500 Ω each connec-
(5 poles type) 121,CN3 Between (3) – (6) Max. 1 Ω tor.
CND,CNE
HAZ Between (3) – (5) Min. 1 MΩ
Transmission controller system
Measure resistance
13,15 below, it is normal switch OFF.
CNA Between (5) – (6) 100 – 500 Ω 2) Disconnect
each connec-
Relay CNB Between (3) – (4) Max. 1 MΩ tor.
(6 poles type) CNC
Between (1) – (2) Min. 1 MΩ
CN7
Measure resistance
H.SW (male) If the condition is as shown in the table 1) Turn starting

L.SW (male) below, it is normal switch OFF.
2) Disconnect
R.SW (male) When switch Between each connec-
Pressure control fill 1.SW (male) is OFF (1) – chassis Min. 1 MΩ tor.
switch 2.SW (male)
3.SW (male)
L/C.SW(male)
HD255-5 20-9
4
Serial No.: 1201 – 1599

Measure resistance
If the condition is as shown in the table 1) Start engine.
below, it is normal 2) Disconnect
wiring.
Engine oil pressure EOP Oil pressure above
0.07 MPa {0.7 kg/cm2} No continuity
sensor (terminal)
Pilot lamp system
Oil pressure below

0.03 MPa {0.3 kg/cm2} Continuity
With engine running (above 1/2 throttle) 1) Start engine.

Measure voltage
→ 27.5 – 29.5 V
Between
alternator ª With deteriorated batteries or after
Alternator terminal R starting in cold areas, it may take time
and for the voltage to rise.
chassis
Measure voltage
If the condition is within the range 1) Turn starting

shown in the table below, it is normal switch ON.
Torque 2) Start engine.
Torque converter inlet
oil pressure sensor converter Between (3) – (1) 1–5V
IN
Measure resistance Measure resistance Measure resistance Measure voltage

Torque converter Torque 2) Start engine.
outlet oil pressure converter Between (3) – (1) 1–5V
sensor OUT

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

Transmission interme- 2) Disconnect
diate shaft speed N2 (male) Between (1) – (2) 500 – 1,000 Ω N2.
sensor

2) Disconnect
Transmission output N3 (male) Between (1) – (2) 500 – 1,000 Ω N3.
shaft speed sensor
20-10 HD255-5
(12)

Measure resistance
If the condition is as shown in the table 1) Start engine.
below, it is normal 2) Disconnect
wiring.
Engine oil pressure EOP Oil pressure above
0.07 MPa {0.7 kg/cm2} No continuity
sensor (terminal)
Pilot lamp system
Oil pressure below

0.03 MPa {0.3 kg/cm2} Continuity
With engine running (above 1/2 throttle) 1) Start engine.

Measure voltage
→ 27.5 – 29.5 V
Between
alternator ª With deteriorated batteries or after
Alternator terminal R starting in cold areas, it may take time
and for the voltage to rise.
chassis
Measure voltage

2) Start engine.
Torque converter inlet Torgucon-
oil pressure sensor verter IN Between (3) – (1) 1–5V
Measure resistance Measure resistance Measure resistance Measure voltage

Torque converter Torgucon- 2) Start engine.
outlet oil pressure verter OUT Between (3) – (1) 1–5V
sensor

2) Disconnect
Transmission input
shaft speed sensor
N1 (male) Between (1) – (2) 500 – 1,000 Ω N1.

Transmission interme- 2) Disconnect
diate shaft speed N2 (male) Between (1) – (2) 500 – 1,000 Ω N2.
sensor

2) Disconnect
Transmission output N3 (male) Between (1) – (2) 500 – 1,000 Ω N3.
shaft speed sensor
HD255-5 20-13
(10)

below, it is normal switch ON.
Voltage value 2) Insert T–
adapter.
When When not
selected selected
Between (3)–(2) R Min.1.0V Max.15.0V
Measure voltage Between (4)–(2) N Min.1.0V Max.15.0V
Between (5)–(2) D Min.1.0V Max.15.0V
Gearshift lever SF (male)
Between (6)–(2) 5 Min.1.0V Max.15.0V
Between (9)–(2) L Min.1.0V Max.15.0V
Between (1) – (2) 11.0 – 13.0V

Measure resistance
H.PS (male) 2) Disconnect

L.PS (male) Between (1) – (2) 5 – 25 Ω connector

R.PS (male) each.
Pressure control valve 1.PS (male)
solenoid
2.PS (male)
3.PS (male)
L/C.PS(male)
Measure resistance Measure resistance

2) Disconnect
Exhaust brake Between (1) – (2) 20 – 45 Ω EXH1.
solenoid EXH1(male)

2) Disconnect
Automatic retarder Between (1) – (2) 20 – 52 Ω ARS.
ARS (male)
solenoid

Measure resistance

2) Disconnect
Oil tem- 37 – 50 kΩ TC, SE.
Transmission oil perature (25˚C)Between
TC, SE
temperature sensor Oil temperature (1) – (2)
100˚C 3.5 – 4.0 kΩ
20-14 HD255-5
(10)

Measure resistance
R01, R05, If the condition is as shown in the table 1) Turn starting
R06, R08, 2) Disconnect
Relay R09, R13, Between (1) – (2) 100 – 500 Ω each connec-
(5 poles type) R14, R16, Between (3) – (6) Max. 1 Ω tor.
R17, R18,
R19, R20, Between (3) – (5) Min. 1 MΩ
R21, R22
Measure resistance
R02,
R03, Between (5) – (6) 100 – 500 Ω 2) Disconnect
each connec-
Relay R04, Between (3) – (4) Max. 1 MΩ tor.
(6 poles type) R07,
Between (1) – (2) Min. 1 MΩ
R15␣
Measure resistance
H.SW (male) If the condition is as shown in the table 1) Turn starting

L.SW (male) 2) Disconnect
R.SW (male) When switch each connec-
is OFF Min. 1 MΩ
Pressure control fill 1.SW (male) Between tor.
switch 2.SW (male) When switch (1) – chassis
is ON Max. 1 Ω
3.SW (male)
L/C.SW(male)
HD255-5 20-15
(10)

If the condition is as shown in the table 1) Insert T-

below, it is normal adapter in
Potentiometer WAS.
2) Turn starting
Between (3) – (1) 4.6 – 5.4 V switch ON.
Between (2) – (3) 0.3 – 4.5 V
Measure voltage
Switch
Accelerator pedal WAS Potentiometer
(Throttle sensor) Pin Voltage
voltage
Between Max. 0.446 V Max. 1 V

(5) – (4) Min. 0.446 V 15 – 30 V
Between Max. 0.446 V 20 – 30 V
(6) – (4) Min. 0.446 V Max. 1 V
Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance
If the condition is as shown in the table 1) Disconnect

below, it is normal NE.
2) Turn starting
Between (1) – (2) 85 – 210 Ω switch OFF.
Engine Ne speed sensor NE (male)
Between (1), (2) –
chassis ground Min. 1 MΩ
Engine controller system
If the condition is as shown in the table 1) Disconnect G.

below, it is normal 2) Turn starting
switch OFF.
Between (1) – (2) 1.4 k – 3.5 kΩ
Engine G speed sensor G (male)
Between (1), (2) –

below, it is normal PSL.
2) Turn starting
Low engine oil pressure PSL Position Engine Resistance switch OFF.
switch (terminal)
Between switch Stop Max. 1 Ω
terminal –
chassis ground Min. 600 rpm Min. 1 MΩ

below, it is normal PSH.
2) Turn starting
High engine oil pres- PSH Position Engine Resistance switch OFF.
sure switch (terminal) Between switch Stop Max. 1 Ω
terminal –
chassis ground Min. 1,300rpm Min. 1 MΩ

below, it is normal TWL.
2) Turn starting
Low engine coolant Between (1) – (2) 9 k – 0.3 kΩ switch OFF.
TWL (male)
temperature sensor Between (1), (2) –
20-16 HD255-5
(10)


below, it is normal TWH.
2) Turn starting
High engine coolant Between (1) – (2) 90 k – 3.5 kΩ switch OFF.
temperature sensor TWH (male)
Between (1), (2) –

below, it is normal THL.
2) Turn starting
Fuel temperature Between (1) – (2) 9 k – 0.3 kΩ switch OFF.
sensor THL (male)
Between (1), (2) –
Measure resistance

below, it is normal OL.
2) Turn starting
Pin Oil level Resistance switch OFF.
Engine oil level switch OL (male)
Between (1) – When normal Max. 1 Ω
chassis ground When low Min. 1 MΩ
Measure voltage

PIM.
Between (1) – (3) 4.6 – 5.4 V 2) Turn starting
Boost pressure sensor PIM (male)
Between (2) – (3) 0.3 – 4.7 V switch ON.
Measure voltage

PFUEL.
Common rail fuel PFUEL Between (1) – (3) 4.6 – 5.4 V 2) Turn starting
pressure sensor (male) switch ON.
Between (2) – (3) 0.3 – 4.7 V

below, it is normal PCV1.
2) Turn starting
PCV1 Between (1) – (2) 2.3 – 5.3 Ω switch OFF.
Fuel supply pump PCV1 (male) Between (1), (2) –

below, it is normal PCV2.
2) Turn starting
PCV2 Between (1) – (2) 2.3 – 5.3 Ω switch OFF.
Fuel supply pump PCV2 (male) Between (1), (2) –
HD255-5 20-17
(10)

Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance
below, it is normal CN1.
2) Turn starting
Between (1) – (2) 0.4 – 1.1 Ω switch OFF.
No. 1 injector solenoid CN1 (male)
Between (1), (2) –

2) Turn starting
Between (1), (2) –

2) Turn starting
Between (1) – (2) 0.4 – 1.1 Ω
No. 3 injector solenoid CN3 (male) switch OFF.

Between (1), (2) –

2) Turn starting
Between (1), (2) –

2) Turn starting
Between (1), (2) –

2) Turn starting
Between (1), (2) –
20-18 HD255-5
(10)
Tools for testing, adjusting and troubleshooting .............................................................................. 20-101-1

Sketches of special tools ..................................................................................................................... 20-101-3
Adjusting valve clearance ....................................................................................................................... 20-102
Measuring compression pressure ......................................................................................................... 20-104
Measuring blow-by ................................................................................................................................. 20-106
Adjusting fan belt tension ...................................................................................................................... 20-108
Testing and adjusting alternator belt tension ....................................................................................... 20-109
Measuring engine speed ........................................................................................................................ 20-110
Measuring engine oil pressure .............................................................................................................. 20-112
Measuring boost pressure ...................................................................................................................... 20-113
Measuring exhaust gas temperature ..................................................................................................... 20-114
Measuring exhaust gas color ................................................................................................................. 20-115
Testing and adjusting fuel injection timing ........................................................................................... 20-116
Bleeding air from fuel injection pump ................................................................................................... 20-118
Handling equipment in fuel circuit ........................................................................................................ 20-119
Releasing remaining pressure in fuel system ....................................................................................... 20-119
Measuring fuel pressure ......................................................................................................................... 20-120
Bleeding air from fuel circuit .................................................................................................................. 20-121
Reduced cylinder mode operation for engine ...................................................................................... 20-123
Checking for leakage in fuel circuit ........................................................................................................ 20-124
Adjusting engine stop motor cable ....................................................................................................... 20-125
Adjusting accelerator pedal .................................................................................................................... 20-126
Adjusting engine speed sensor .............................................................................................................. 20-127
Testing oil pressure of torque converter valve ..................................................................................... 20-128
Testing torque converter stall speed ..................................................................................................... 20-129
Testing brake pressure ............................................................................................................................ 20-130
Bleeding air from brake circuit ............................................................................................................... 20-131
Testing and adjusting parking brake performance ............................................................................... 20-132
Testing wear of front brake pad ............................................................................................................. 20-133
Testing wear of rear brake disc .............................................................................................................. 20-134
Testing and adjusting suspension cylinder ........................................................................................... 20-135
Testing and adjusting air governor set pressure .................................................................................. 20-140
Inspection of air drier (desiccant type) ............................................................................................... 20-140-1
Adjusting hoist lever linkage .................................................................................................................. 20-141
Adjusting body positioner ...................................................................................................................... 20-142
Testing and adjusting hydraulic pressure in steering, hoist circuit .................................................... 20-143
Bleeding air from hydraulic cylinder (steering cylinder) ..................................................................... 20-146
Emergency travel when there is failure in electrical system ............................................................... 20-147
Method for emergency escape when there is failure in electrical system ......................................... 20-148
Procedure for moving machine when transmission valve fails .......................................................... 20-154
Procedure for flushing torque converter, transmission hydraulic circuit ........................................... 20-156
Pm clinic check sheet .............................................................................................................................. 20-157
HD255-5 20-101
(13)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or measure- Symbol Part No. Part Name Remarks

ment item
Engine speed A 799-205-1100 Tachometer KIT Digital display: 6 – 99999.9 rpm
799-101-1500 Thermometer
Coolant, exhaust, and oil
temperatures B –99.9 – 1,299˚C
799-201-1110 Cable
Pressure gauge: 2.4,5.9,39.2,58,8 MPa

799-101-5002 Hydraulic tester {25,60,400,600kg/cm2}
1
Oil pressure C 790-261-1204 Digital hydraulic tester Pressure gauge: 49.0MPa{500 kg/cm 2}
2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
0 – 6.9 MPa {0 – 70 kg/cm2}

1 795-502-1590 Compression gauge Kit Part No.: 795-502-1205
Compression pressure D
2 795-471-1410 Adapter —
1 799-201-1511 Nozzle
2 799-201-1450 Adapter Kit Part No.: 799-201-1504

Blow-by pressure E
3 799-201-1571 Tube
Specified range:
4 799-201-1541 Gauge 0 – 4.9 kPa {0 – 500mmH2O}
F Commercially
Valve clearance available Thickness gauge —
799-201-9001 Handy smoke checker

Exhaust color G Bosch index: 0 – 9
Commercially
available Smoke meter
79A-264-0090 Push-pull scale 0 – 490 N {0 – 50 kg}

Operating effort H
79A-264-0020 Push-pull scale 0 – 294 N {0 – 30 kg}
I Commercially
Stroke, hydraulic drift available Scale —
J Commercially
Work equipment speed available Stop watch —
Disc wear K 567-98-71311 Disc gauge For brake
L Commercially
Voltage, resistance available Digital tester
This includes all the T-adapters

used on this machine. De-
pending on the attachments
Sensors, wiring and specifications, the follow-
M 799-601-7400 T-adapter kit ing part numbers are also
harnesses
available.
• 799-601-2900
799-601-7000
(
• 799-601-7300 799-601-7200 )
20-101-1 HD255-5
(14)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or measure- Symbol Part No. Part Name Remarks

ment item
Injection timing N 795-471-1200 Gauge assembly
adjustment
1 792-610-1130 Pump assembly
2 792-610-1110 Hose
Pump, joint assembly
3 792-610-1120 Joint [Kit Part No. 792-610-1100]
4 07020-21730 Fitting
5 792-610-1140 Joint
Suspension cylinder
adjustment 6 792-610-1250 Valve assembly
 Kit Part No.  P
  7 792-610-1260 Nipple
 792-610-1000 
8 792-610-1480 Stem
Gas charge tool assembly
9 792-610-1640 Joint [Kit Part No. 792-610-1200]
10 792-610-1400 Regulator assembly
10
(a) 792-610-1430 Gauge 24.5 MPa {250 kg/cm2}
10
(b) 792-610-1440 Gauge 9.8 MPa {100 kg/cm2}
Intake pressure R 799-401-2310 Pressure gauge 200 kPa {1,500 mmHg}
Moving machine when

transmission valve fails S 793T-685-1110 Plate
HD255-5 20-101-2
(10)
TESTING AND ADJUSTING SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to this sketch.
Tool S
20-101-3 HD255-5
4
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Serial No.: 1001 – 1599
fl When adjusting the valve clearance, adjust as fol-
lows to bring the clearance between the valve and
rocker arm to the standard value.
1) Remove the cylinder head cover.
fl For the No. 3 cylinder, remove intake con-
nector (1).
fl For the No. 4 cylinder, remove brake cyl-
inder (2).
2) Rotate the crankshaft in the normal direction
to align 1 • 6 TOP line on the crankshaft pul-
ley with pointer (3) when the No. 1 cylinder is
at compression top dead center. When rotat-
ing, check the movement of the valves.
3) When the No. 1 cylinder is at compression top
dead center, adjust the valves marked b in
the valve arrangement chart. Then set so that
the No. 6 cylinder is at compression top dead
center and adjust the valve clearance of the
valves marked c.
fl Valve arrangement
Cylinder No. 1 2 3 4 5 6
Exhaust valve b c b c b c
Intake valve b b c b c c
4) To adjust the valve clearance, loosen locknut

(7) of adjustment screw (6), then insert tool F
between the top of crosshead (4) and rocker
arm (3), and turn adjustment screw (3) until
the clearance is a sliding fit. Then tighten lock-
nut (7) to hold the adjustment screw in posi-
tion.
3 Locknut :
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
5) Next, rotate the crankshaft one turn in the nor-
mal direction and adjust the clearance of the
remaining valves marked c.
fl After adjusting No. 1 cylinder at compres-
sion top dead center, it is also possible to
turn the crankshaft 120˚ each time and
adjust the valve clearance of the intake
and exhaust valves of each cylinder ac-
cording to the firing order.
• The firing order is as follows: 1-5-3-6-2-4
fl After tightening the locknut, check the
valve clearance again.
20-102 HD255-5
(10)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

1. Open up the engine hood.
2. Disconnect 6 fuel high-pressure tubes (1).

• Remove the tube clamps also.
3. Remove cylinder head cover (2).

3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
4. Rotate the crankshaft in the normal direction, and

align 1.6 line a on the damper with pointer (3) to
set the No. 1 cylinder to compression top dead
center.
fl At compression top dead center, the rocker
arm can be moved by hand by the amount of
the valve clearance. If the rocker arm does not
move, the crankshaft is not at compression
top dead center, so rotate it one more turn.
5. To adjust the valve clearance, insert feeler gauge

F into clearance b between rocker arm (4) and
cross head (5), and adjust the valve clearance with
adjustment screw (6).
fl Insert the feeler gauge and turn the adjust-
ment screw until the clearance is a sliding fit.
6. Hold adjustment screw (6) in position and tighten

locknut (7).
3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm}
fl After tightening the locknut, check the clear-
ance again.
7. Rotate the crankshaft 120˚ each time the normal

direction and repeat the procedure in Steps 4 to 6
to adjust the clearance of the intake and exhaust
valves of each cylinder according to the firing or-
der.
fl Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After completing the measurement, return to the

original condition.
fl For details of the assembly of the fuel high-
pressure tube, see DISASSEMBLY AND AS-
SEMBLY.
HD255-5 20-103
(10)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
Serial No.: 1001 – 1599
fl When measuring the compression pressure, be
careful not to touch the exhaust manifold or muf-
fler, or to get caught in the fan, fan belt, or other
rotating parts.
1) Adjust valve clearance.
fl For details, see ADJUSTING VALVE
CLEARANCE.
2) Warm up the engine so that the oil tempera-
ture is 40 – 60˚C.
3) Remove the nozzle holder assembly from the
cylinder to be measured.
fl For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4) Install tool D2 in the nozzle holder mount, then
connect tool D1.
5) Disconnect connector (1) of the fuel stop mo-
tor.
6) Crank the engine with the starting motor and
measure the compression pressure.
fl Measure the compression pressure at the
point where the gauge indicator remains
steady.
fl When measuring the compression pres-
sure, check that the engine speed is cor-
rect.
fl After measuring the compression pres-
sure, install the nozzle holder assembly.
fl For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
20-104 HD255-5
(10)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

¤ When measuring the compression pressure, be
careful not to touch the exhaust manifold or
muffler and burn yourself, or to get caught in
any rotating parts.
fl Measure the compression pressure with the en-
gine warmed up (engine oil temperature: 40 –
60˚C).
2. Disconnect 6 fuel high-pressure tubes (1).

• Remove the tube clamps also.
3. Remove cylinder head cover (2).

9.8 ± 1 Nm {1.0 ± 0.1 kgm}
4. Disconnect the injector wiring harness to remove

fuel injector (3).
5. Fit adapter D2 and connect to compression gauge

D1.
fl Coat the connection of the adapter and gauge
with a small amount of engine oil to make
leakage more difficult.
fl Secure the adapter with the injector holder.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
6. Disconnect 2 engine centralized connectors (4)

(CN EG2 and EG3).
¤ If the connectors are not disconnected, there
is a danger that the engine may start during
the measurement, so disconnect them with-
out fail.
¤ Cover the connector at the controller end
with vinyl to prevent short circuits and leak-
ages of electricity.
7. Crank the engine with the starting motor and

measure the compression pressure.
fl Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.
8. After completing the measurement, remove the

measuring equipment and return to the original
condition.
fl For details of the assembly of the fuel injec-
tor and fuel high-pressure tub, see DISAS-
SEMBLY AND ASSEMBLY.
HD255-5 20-105
(10)
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
Serial No.: 1001 – 1599
PROCEDURE FOR MEASURING BLOW-BY
1. Before measuring the blow-by, warm up the en-
gine thoroughly and raise the coolant tempera-
ture to the operating range.
2. Stop the engine, install adapter E2 to tool E1, then

install to crank breather hose (1).
3. Install tube E3 to tool E1, then connect to tool E5

{0 – 500 mmH2O}.
4. Operate the engine at torque converter stall, and

measure the blow-by pressure.
fl Measure the blow-by pressure carefully. For
details, see TESTING TORQUE CONVERTER
STALL SPEED.
PRECAUTIONS WHEN MEASURING

BLOW-BY
fl The blow-by should be measured with the engine
running at rated output.
• However, when measuring in the field, a similar
value can be obtained at torque converter stall
speed.
• In this case, the blow-by value will be about 80%
of the value at rated output.
fl Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems con-
nected with defective blow-by, such as excessive
oil consumption, defective exhaust gas color, and
prematurely dirty or deteriorated oil.
20-106 HD255-5
(10)
TESTING AND ADJUSTING MEASURING BLOW-BY

2. Install nozzle E1, adapter E2 and hose E3 to blow-

by hose (1), then connect to gauge E5.
3. Start the engine and raise the temperature of the

cooling water to the operating range.
4. Turn the parking brake switch ON, depress the

parking brake pedal, then set the gearshift lever
to the D position.
¤ If the gearshift lever is operated to any posi-
tion other than the D position, the machine
may move off even if the brake is being de-
pressed, so always measure at the D posi-
tion.
5. Depress the accelerator pedal gradually, run the

engine at high idling and stall the torque con-
verter, and measure the blow-by pressure.
¤ There is danger of damage to the internal
parts of the transmission, so never operate
the gearshift lever to any position other than
the D position during the stall operation.
fl After completing the measurement, run the
engine at low idling, then return the gearshift
lever to the N position.

measuring equipment and set to the original con-
dition.
HD255-5 20-107
(10)
TESTING AND ADJUSTING ADJUSTING FAN BELT TENSION
ADJUSTING FAN BELT TENSION

fl If the deflection of the belt when it is pressed with
a finger force of approx. 58.8 N {6 kg}. at a point a
midway between the alternator pulley and the fan
pulley is not within the standard value (approx.
13 mm), or when carrying out maintenance after
replacing the belt, adjust the belt tension as fol-
lows.
1) Loosen locknut (1) of the alternator assembly
and locknut (2) of the adjustment bolt.
2) Loosen locknut (4) of block (3).
3) Use adjustment nut (5) to adjust the deflec-

tion to the specified value.
4) After adjusting to the specified deflection,

tighten nuts (1), (2), and (4) in order.
20-108 HD255-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
1. Testing
Press the intermediate point of the belt between
alternator pulley (1) and fan pulley (2) (part
marked with the arrow) with a finger and mea-
sure the deflection of the belt.
fl Force to press belt: Approx. 58.8 N {6 kg}
fl Deflection: Approx. 10 mm
2. Adjusting
fl If the deflection of the belt is out of the stan-
dard range, adjust it according to the follow-
ing procedure.
1) Loosen mounting bolts and nuts (4) of alter-
nator (3) and mounting bolt (6) of adjustment
rod (5).
2) Loosen locknut (7) and move alternator (3)
with adjustment nut (8) to adjust the belt ten-
sion.
3) Tighten locknut (7).
4) Tighten mounting bolts and nuts (4) of alter-
nator (3) and mounting bolt (6) of adjustment
rod (5).
fl After finishing adjustment, check the belt ten-
sion again.
HD255-5 20-109
(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

Serial No.: 1001 – 1599
¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
fl Measure the engine speed under the following
conditions.
1) Coolant temperature: Within operating range
2) Engine oil temperature: 70 – 90˚C
3) Hydraulic temperature: 45 – 55˚C
1. Remove cable (1) from the speed pick-up port,

then install the adapter of tachometer A.
2. Connect tachometer A and the adapter with the

cable.
¤ Be careful not to touch any hot parts or get
caught in any rotating parts when measur-
ing.
3. Start the engine and measure the engine speed

at high idling and low idling.
fl For details of measuring the torque converter
stall speed, see TESTING TORQUE CON-
VERTER STALL SPEED.
20-110 HD255-5
(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED

fl Measure the engine speed under the following
conditions.
1) Coolant temperature: Within operating range
2) Engine oil temperature: 70 – 90˚C
3) Hydraulic temperature: 45 – 55˚C
1. Stick a piece of silver paper to crank pulley (1).
2. Install probe [3] of tachometer A to stand [2] and

direct it from the frame toward the damper.
3. Connect tachometer [4] and the adapter with the

cable.
ing.
4. Start the engine and measure the engine speed

at high idling and low idling.
fl For details of measuring the torque converter
stall speed, see TESTING TORQUE CON-
VERTER STALL SPEED.
HD255-5 20-111
(10)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

Serial No.: 1001 – 1599
PRESSURE
¤ Always stop the engine before removing or in-
stalling the tubes or oil pressure gauge.
fl Before measuring the oil pressure, remove all dirt
and mud from around the mount.
fl Warm up the engine thoroughly to raise the cool-
ant temperature to the operating range.
1. Remove plug (1), then install the adapter of oil

pressure gauge KIT C1 and oil pressure gauge C2
(9.8 MPa {10 kg/cm2}).
2. Start the engine, and measure the oil pressure.

20-112 HD255-5
(10)
TESTING AND ADJUSTING MEASURING BOOST PRESSURE
MEASURING BOOST PRESSURE

Serial No.: 1001 – 1599
1. Remove the boost pressure measurement plug

(2), then install coupler (1) inside oil pressure
gauge KIT C.
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge R 200 kPa {1500
mmHg}.
ing.
Note:
Operate the engine speed at midrange or above,
and use the self-seal portion of the gauge to bleed
the oil inside the hose.
• Insert the gauge about half way, repeat the
action to open the self-seal portion, and bleed
the oil.
fl If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
3. Run the engine at full throttle to stall the torque

converter, and read the pressure indicated by the
gauge.
fl For details of measuring the torque converter stall

speed, see TESTING TORQUE CONVERTER
STALL SPEED.
HD255-5 20-113
(10)
TESTING AND ADJUSTING MEASURING EXHAUST GAS TEMPERATURE
MEASURING EXHAUST GAS

TEMPERATURE
¤ The temperature sensor must be installed to the
exhaust manifold, so if the machine has been
operated, wait for the manifold temperature to
drop before installing the sensor.
fl Raise the coolant temperature to the operating
range before measuring.
1. Remove the heat insulation cover.
2. Remove the plug from the exhaust manifold and

install temperature sensor (1).
• Temperature sensor
: 6215-11-8180
(cable length 610 mm) or
: 6215-11-8170
(cable length 490 mm)
3. Connect to digital temperature gauge B with the

wiring harness.
MEASUREMENT PROCEDURE
1) Measuring by torque converter stall
fl If the exhaust temperature is measured only
under torque converter stall condition, the
torque converter will overheat before the sen-
sor core warms up and a stable value can be
obtained.
(1) Use the full stall condition (torque converter
stall + hydraulic relief) to raise the exhaust
temperature (approx. 650˚C: standard value).
(2) From the above condition, cancel the hydrau-
lic relief and continue only the torque con-
verter stall. (The temperature will start to go
down. If the temperature does not go down
but goes up instead, raise the set tempera-
ture for Step (1).)
(3) Record the stable temperature when the tem-
perature starts to go down.
2) When measuring the maximum value for the
exhaust temperature Carry out actual work
and measure the maximum value during op-
eration.
fl Use the PEAK mode (it can store the maxi-
mum value in memory) of the tempera-
ture gauge function.
20-114 HD255-5
(10)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
• When measuring in the field where there is no air
or electric power supply, use a Handy Smoke
Checker; when recording formal data, use a
Smoke Meter.
MEASURING WITH HANDY SMOKE

CHECKER
¤ Be careful not to touch the exhaust pipe or any
other hot parts when removing or installing the
measuring tools.
¤ Raise the body and lock it with the safety pin.
fl Measure the exhaust color when the engine is
warmed up (oil temperature: 60˚C).
1) Install filter paper to tool G.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle at the same time to
collect the exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
MEASURING WITH SMOKE METER

¤ Be careful not to touch the exhaust pipe or any
other hot parts when removing or installing the
measuring tools.
¤ Raise the body and lock it with the safety pin.
fl Measure the exhaust color when the engine is
warmed up (oil temperature: 60˚C).
1) Insert the probe [1] into the outlet port of the
exhaust pipe, and tighten the clip to secure it
to the exhaust pipe.
2) Connect the air hose [4] and the socket of the
probe hose [2] and accelerator switch [3] to
tool G.
fl Keep the pressure of the air supply be-
low 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V socket.
fl When connecting the cord, check that the
power switch is OFF.
4) Loosen the cap nut [5] of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the ex-
haust gas cannot leak.
5) Turn the power switch ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal at the same time and
collect the exhaust gas on the filter.
7) Place the filter paper used to catch the exhaust
gas color on top of at least 10 sheets of un-
used filter paper inside the filter paper holder,
and read the value shown.
HD255-5 20-115
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Serial No.: 1001 – 1599
1. Disconnect fuel injection pipe (1) and spill tube
(2) of No.1 piston, then remove No.1 nozzle holder
assembly (3).
fl Before removing the No. 1 and No. 4 nozzle
holder assemblies, remove the exhaust muf-
fler and air intake connector as in ADJUST-
ING VALVE CLEARANCE.
2. Align the No. 1 cylinder with the stamped “1 • 6”

line of the compression top dead center. At this
time, however, the fuel injection timing line on
the fuel injection pump must be near the line on
the fuel injection pump body.
3. Set dial gauge (N) to the nozzle holder hole where

the nozzle holder assembly has been removed.
(See the diagram.)
4. Set the long hand on the scale of dial gauge (N)

to 0 when the piston is at the top dead center.
fl Rotate the crankshaft in the normal direction
and in the reverse direction to align the top
dead center.
fl Record the value indicated by the short hand
on the dial gauge.
5. Rotate the crankshaft approx. 45˚ in the reverse

direction from the No.1 cylinder TOP position.
6. Rotate the crankshaft again slowly in the normal

direction and set to specified dimension “C”.
fl Specified dimension C: 3.8 ± 0.2 mm
fl Always rotate the crankshaft in the normal di-
rection to align the position.
fl Continue to rotate in the normal direction and
check that the dial gauge scale is 0 ± 0.2 mm
when the No.1 cylinder is at TOP (top dead
center) (the dial gauge indicator moves in re-
verse). If it is not 0 ± 0.2 mm, carry out the
procedure from Step 4 again.
7. Check that line “a” on the fuel injection pump is

aligned with line “b” on the coupling when the
specified dimension is correct.
20-116 HD255-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
8. If the lines are not aligned, loosen bolt (4) in the

oblong hole, move coupling (5) to align the lines,
then tighten bolt (4) again.
3 Bolt (4): 78.5 ± 5 Nm {8 ± 0.5 kgm}
HD255-5 20-117
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL INJECTION PUMP
BLEEDING AIR FROM FUEL

INJECTION PUMP
Serial No.: 1001 – 1599
1. Loosen air bleed plug (1) of the fuel filter, then
operate priming pump (2).
2. When no more bubbles come out with the fuel

from air bleed plug (1), tighten air bleed plug (1).
3. Loosen the joint bolt of the fuel injection pump

inlet hose, then operate priming pump (2) to bleed
the air from the hose between the filter and fuel
injection pump.
4. Continue to operate priming pump (2) and loosen

plug (3) in the hose at the fuel injection pump re-
turn side to bleed the air.
fl When all the air is bled, the operation of the prim-

ing pump will become heavier.
20-118 HD255-5
(10)
HANDLING EQUIPMENT IN FUEL CIRCUIT,
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN FUEL SYSTEM
HANDLING EQUIPMENT IN RELEASING REMAINING

FUEL CIRCUIT PRESSURE IN FUEL SYSTEM
Serial No.: 1601 and up Serial No.: 1601 and up
fl Precautions when carrying out inspection and fl When the engine running, pressure is gener-
maintenance of fuel system. ated in both the low-pressure circuit and high-
With the common rail type fuel injection sys- pressure circuit of the fuel line.
tem, more precise equipment is used than on Low-pressure circuit:
the conventional fuel injection pump and Feed pump – fuel filter – fuel supply pump
nozzle, so problems may occur if dirt or dust High-pressure circuit:
get in. Fuel supply pump – common rail – fuel
When carrying out inspection or maintenance injector
of the fuel line, pay more attention than usual fl For both the low-pressure circuit and high-
to prevent dirt or dust from getting in. If there pressure circuit, the pressure automatically
is any dirt stuck to any part, use clean fuel to goes down to a safe level 30 seconds after
wash it off completely. the engine is stopped.
fl Precautions when replacing fuel filter car- fl The remaining pressure in the fuel circuit must
tridge. be completely released before carrying out
Always use a genuine Komatsu part for the inspection of the fuel system or removal or
fuel filter cartridge. installation of the equipment. Always obey the
With the common rail type fuel injection sys- following precautions when carrying out the
tem, more precise equipment is used than on operation.
the conventional fuel injection pump and ¤ When inspecting the fuel line or removing
nozzle. To prevent dirt or dust from getting or installing equipment, wait for at least 30
in, so a special filter with highly efficient fil- seconds after the engine is stopped to re-
tering performance is used. For this reason, lease the remaining pressure in the fuel sys-
do not use imitation filters. If they are used, tem before starting the operation. (There is
there is danger of problems occurring in the still pressure remaining in the circuit, so do
fuel line. not start operations immediately after the
engine is stopped).
HD255-5 20-119
(10)
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

fl Measure the fuel pressure only for the low-pres-
sure circuit between the feed pump – fuel filter –
fuel supply pump.
¤ The high-pressure circuit between the fuel sup-

ply pump-common rail-fuel injector is under
extremely high pressure, so it cannot be mea-
sured.
1. Remove the fuel filter top cover.
2. Remove fuel pressure measurement plug (1).
3. Fir nipple [1] and hose [2] then connect pressure

gauge C2.
fl Use a 0.98 MPa {10 kg/cm2} oil pressure gauge.
4. Start the engine and measure the fuel pressure

at high idling.
fl For details of the standard value, see
TROUBLESHOOTING OF ENGINE CONTROL-
LER SYSTEM (G MODE).

measuring equipment and set to the original con-
dition.
20-120 HD255-5
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT

fl Bleeding the air as follows if the engine has run

out of fuel or the fuel circuit equipment has been
removed and installed.
1. Remove fuel filter (1), fill with fuel, then install

again.
fl When filling, use clean fuel and be careful not
to let dirt get in.
fl Add fuel through inlet port portion a (8 places)
of the filter. Portion b is the outlet port (clean
side) after the fuel has been filtered, so never
add fuel from here.
fl If clean fuel is not available, do not remove
the filter. Operate the priming pump to fill
the filter with fuel.
HD255-5 20-121
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
2. Remove air bleed plug (2) of the fuel filter and Air bleeding steps
operate priming pump (4). i) Remove air bleeding plug (2) of fuel
fl Continue operating the priming pump filter (1) and operate priming pump
until flow out from the plug hole. When (4).
fuel comes out, install the plug. • Continue to operate the priming
3 Air bleed plug: pump until fuel is confirmed to
7.8 – 9.8 Nm {0.8 – 1.0 kgm} flow out of the air bleeding plug
hole and then tighten it.
3. There are the following two cases that the 3 Air bleeding plug:
engine does not start up easily after bleeding 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
air from CRI, (Common Rail Injection System), ii) Remove fuel pressure measuring plug
i.e. even after carrying out the items 1 and 2 (3) for the fuel filter and operate prim-
above. ing pump (4).
fl If air has not been removed completely, • Continue to operate the priming
leaving some in the system, cranking up pump until fuel is confirmed to
the engine with the engine starting mo- flow out of the air bleeding plug
tor cannot get rid of the remaining air in a hole and then tighten it.
short span of time. Thus the engine start- 3 Fuel pressure measuring plug:
up becomes difficult. 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
1) In the cases that the fuel has run out, that iii) Loosen air bleeder (5) of the fuel sup-
the fuel filter has been replaced or that ply pump (only after loosening the
some fuel device has been removed and lock nut) and operate priming pump
installed. (4) 90 to 100 times.
• Most of the fuel is left in the fuel cir- • Continue to operate the priming
cuit, so the engine may be started af- pump until fuel is confirmed to
ter bleeding air with the air bleeding flow out of air bleeder (5) and then
methods introduced in the items 1 and tighten it.
2 above.
3 Air bleeder
2) In the case that a number of fuel devices
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
have been removed and installed in
• Still continue to operate the prim-
course of engine overhauling.
ing pump until it becomes harder
• Little fuel is left in the fuel circuit, so
to operate and a relief sound of
air cannot be got rid of completely
overflow valve (6) in the fuel sup-
with the air bleeding methods intro-
ply pump is heard. (A high pitch
duced in the items 1 and 2 above (i.e.
sound) It requires approx. 50
ordinary method). In that case, bleed
times of operation to reach that
air in the following manner.
stage.
iv) Push in the knob of priming pump (4)
to tighten it.
v) Crank up the engine with the engine
starting motor for start-up.
fl Do not keep the engine starting
motor running idly for more than
20 seconds. Moreover try to start
up the engine only after two
minute pause.
fl If the engine does not start up
even after repeating to crank for
20 seconds 4 times, insufficient air
bleeding is suspected of. In that
case, start the air bleeding steps
once again from the beginning.
20-122 HD255-5
(10)
BLEEDING AIR FROM FUEL CIRCUIT,
TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION FOR ENGINE
REDUCED CYLINDER MODE

4. Loosen air bleeder (5) of the fuel supply pump
OPERATION FOR ENGINE
and operate priming pump (4) 90 to 100 times. Serial No.: 1601 and up
fl Continue operating the priming pump
until fuel flows out from the bleeder. fl Reduced cylinder mode operation for the en-
When fuel comes out, tighten the bleeder, gine means setting the fuel injectors of a
then operate several times until priming single cylinder or multiple cylinders electroni-
pump becomes stiff. cally to the NO injection condition to run the
3 Air bleeder: engine on a reduced number of cylinders. The
4.9 – 6.9 Nm {0.5 – 0.7 kgm} reduced cylinder mode operation is used
when it is thought that one of the engine cyl-
5. Crank the engine with the starting motor and inders is not giving normal output (combus-
start the engine. tion). It is a method to determine which cyl-
fl When the engine is cranked, the air in the inder is not operating normally.
high-pressure circuit is automatically bled. fl The reduced cylinder mode operation is car-
fl If the engine does not start, the air has ried out by using the reduced cylinder mode
probably been not properly bled from the operation setting function on the monitor
low-pressure circuit, so repeat the proce- panel.
dure from Step 2. fl For details of the method of operation, see
the TROUBLESHOOTING, Monitor panel dis-
play and special functions.
HD255-5 20-123
(10)
TESTING AND ADJUSTING CHECKING FOR LEAKAGE IN FUEL CIRCUIT
CHECKING FOR LEAKAGE IN

FUEL CIRCUIT
¤ With the fuel system, the high-pressure cir- 7. Check the fuel piping and equipment for fuel
cuit is under extremely high pressure, so if leakage.
fuel leaks when the engine is running, there fl Check the high-pressure circuit for fuel
is danger of fire. leakage, particularly at the places sprayed
Check for fuel leakage as follows when with color checker.
checking the fuel circuit or when equipment fl If there is fuel leakage, carry out repairs,
has been removed and installed. then repeat the check from Step 2.
fl To make it easier to check for fuel leakage, 8. Start the engine, run it at high idling, then ap-
wipe the engine itself and the surrounding ply load to the engine.
area clean and remove all oil and grease be- fl Carry out dump relief.
fore starting the inspection.
9. Check the fuel piping and equipment for fuel
1. Spray the fuel supply pump, common rail, fuel leakage.
injector, and high-pressure piping connec- fl Check the high-pressure circuit for fuel
tions with a color checker (developing solu- leakage, particularly at the places sprayed
tion). with color checker.
fl If there is fuel leakage, carry out repairs,
2. Start the engine, run it at under 1,000 rpm, then repeat the check from Step 2.
and when the speed stabilizes, stop the en- fl If no fuel leakage is found, the check is
gine. complete.

leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
then repeat the check from Step 2.
4. Start the engine and run it at low idling.

leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
then repeat the check from Step 2.
6. Start the engine and run it at high idling.
20-124 HD255-5
(10)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ENGINE STOP

MOTOR CABLE
Serial No.: 1001 – 1599
1. Temporarily install the ball joints connecting the
fuel injection pump to the engine stop motor
cable.
2. Pull the stop lever of the fuel injection pump to
the engine stop position (NO INJECTION), then
connect ball joint (2) temporarily to the stop lever
and secure cable (3) to bracket (1) to adjust to stan-
dard length a.
fl Standard length a: 130 mm
fl Travel of engine stop motor: 35 mm
fl The engine stop motor is delivered with the
cable in the pulled position.
fl Stop lever (4) is in the OPERATION position
(held by return spring) when the lever is free.
3. Adjust the clearance by adjusting the amount of

the ball joint screwed in.
4. After adjusting the clearance, tighten all nuts.
5. Turn the engine starting switch ON/OFF repeat-

edly and check that the engine stop motor works
smoothly. In particular, check again that stop le-
ver (4) has room to move in the direction of the
arrow.
fl Check visually that there is 5 mm slack in the
engine stop motor cable and that the stop le-
ver returns fully to the OPERATION position
when the engine is running. The OPERATION
position is maintained by the action of the
engine stop lever spring.
HD255-5 20-125
(10)
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
ADJUSTING ACCELERATOR PEDAL

1. Adjust dimension a of low idling stopper bolt (1),
then adjust clearance b at the low idling end.
Dimension a of stopper bolt: 19.0 mm
Clearance b: 2.5 ±␣ 0.1 mm
2. Adjust dimension c of high idling stopper bolt (2),

then adjust clearance d at the high idling end.
Dimension c of stopper bolt: 25.0 mm
Clearance d: 0.8 ±␣ 0.1 mm
3. After adjusting, measure the output voltage of the

accelerator sensor.
Sensor output voltage:
See STANDARD VALUE TABLE
4. Adjust rod (3) to the specified dimension.
5. After adjusting the accelerator sensor, set the ac-

celerator pedal to low idling position, then adjust
the amount that rod (4) is screwed in so that the
fuel injection pump control lever is at the low
idling position.
20-126 HD255-5
(10)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

Serial No.: 1001 – 1599
SENSOR
1. Screw in until the tip of sensor (1) contacts gear
(2).
fl When bringing the tip of the sensor into con-
tact with the gear, tighten lightly by hand and
check that there is contact. Never use a
wrench to tighten.
2. When sensor (1) contacts gear (2), turn back 1/2 –

1 turn.
3. Tighten locknut (3).

3 Locknut : 58.8 ±␣ 9.8 Nm {6 ±␣ 1 kgm} Serial No.: 1601 and up
fl Be particularly careful when handling the sen-
sor wiring to ensure that no excessive force
is brought to bear on the wiring.
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
fl Standard clearance: 1.5 mm
HD255-5 20-127
(10)
TESTING AND ADJUSTING TESTING OIL PRESSURE OF TORQUE CONVERTER VALVE
TESTING OIL PRESSURE OF

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

1) Raise the transmission oil temperature.
fl Oil temperature when measuring:
60 – 80˚C
2) Remove plug (1), then install tool C1 (5.9 MPa
{60 kg/cm2}).
3) Start the engine, place the gearshift lever at
N, and measure the hydraulic pressure at low
idling and high idling.
2. Testing hydraulic pressure at torque converter in-

let port (relief)
1) Check that there is no abnormality.
For details, see Testing main relief pressure.
{25 kg/cm2}).
3) Start the engine, and measure the hydraulic
pressure at high idling.
3. Testing hydraulic pressure at torque converter

output port
{25 kg/cm2}).
3) Start the engine, and measure the hydraulic
pressure at high idling.
4. Testing torque converter lock-up pressure

2) Install the checker.
For details, see Procedure for operating shift
checker + modulation checker.
{60 kg/cm2}). Start the engine, set the speed
range of checker O to N, and turn the lock-up
ON.
4) Measure the hydraulic pressure with the en-
gine at high idling.
20-128 HD255-5
(10)
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
TESTING TORQUE CONVERTER

STALL SPEED
¤ Stop the machine on flat ground and block the
tires.
1. Remove rotation pickup port cable, and install tool
(adapter).
2. Raise the engine water temperature to the oper-
ating range.
3. Measure the engine high idling and low idling
speeds with tool A (tachometer).
fl If the speed is too low, carry out troubleshoot-
ing for the engine.
4. Raise the temperature of the hydraulic oil and
transmission oil.
fl Oil temperature when measuring:
Hydraulic oil 45 – 55˚C
Transmission 60 – 80˚C
5. Apply the parking brake, depress the brake pedal
fully, then operate the gearshift lever and set to
D.
6. Gradually depress the accelerator pedal to run the
engine at high idling and stall the torque con-
verter. Just before the indicator enters the white
range (point A in the green range of the torque
converter oil temperature gauge), lower the en-
gine speed to low idling and return the gearshift
lever to the N position.
Keep the gearshift lever at the N position, and run
the engine at a midrange speed until the oil tem-
perature goes down to point B in the green range
on the torque converter oil temperature gauge.
Lower the engine speed to low idling, repeat Steps
4) – 6), equalize the oil temperature in the torque
converter and transmission, and measure the stall
speed when the oil temperature is approx. 80˚C
(point B in the green range on the torque con-
verter oil temperature gauge).
fl Measure the stall speed 2 or 3 times.
¤ Do not operate the gearshift lever with the
accelerator pedal kept depressed.
This will cause a large shock, and will reduce
the service life of the machine.
fl The stall speed may vary according to the follow-
ing conditions, so always measure the stall speed
at the time of delivery.
1) Variations according to the engine serial num-
ber
2) Variations in engine output due to atmo-
spheric pressure and temperature
3) Variations in consumption torque of accesso-
ries
4) Variations due to features of the torque con-
verter
5) Variations according to the method of mea-
suring the stall
HD255-5 20-129
(10)
TESTING AND ADJUSTING TESTING BRAKE PRESSURE
TESTING BRAKE PRESSURE

¤ Stop the machine on level ground, apply the
parking brake, and put blocks under the tires.
1. Rear brake actuating pressure

1) Raise the air pressure to the specified pres-
sure.
2) Remove air bleed plug (1) and install tool C1
(hydraulic pressure gauge: 5.9 MPa {60 kg/
cm2}).
3) Measure the hydraulic pressure when the
brake pedal and retarder lever are operated.
fl After measuring the hydraulic pressure,
install the plug and bleed the air.
2. Front brake actuating pressure

1) Raise the air pressure to the specified pres-
sure.
2) Remove air bleed plug (2), and install tool C1
(hydraulic pressure gauge: 39.2 MPa {400 kg/
cm2}).
3) Measure the hydraulic pressure when the
brake pedal is operated.
fl After measuring the hydraulic pressure, in-
stall the plug and bleed the air.
20-130 HD255-5
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE

CIRCUIT
fl Start the engine and wait for the air gauge to en-
ter the green range, then bleed the air from the
circuit as follows.
1. Brake chambers
fl Bleed the air from the front brake chambers
(2 at the top) and the rear brake chambers (2
at the bottom).
fl The rear brake chambers use hydraulic oil, so
run the engine when bleeding the air.
1) Depress the brake pedal, then loosen air bleed
plug (1) 3/4 turns. Tighten the plug again, then
release the pedal.
2) Continue this procedure until no more
bubbles come out from the air bleed plug
hole, then bleed the air from the slack adjuster.
2. Slack adjuster
Bleed the air from plug (3) or (4) in the same way
as for the rear brake chamber.
3. Rear brake
Bleed the air from plug (5) in the same way as for
the rear brake chamber.
4. Front brake
fl The oil tank is separately installed, so always
check the oil level while bleeding the air.
Loosen plug (6), and bleed the air in the same
way as for the front brake chamber.
HD255-5 20-131
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE

PARKING BRAKE PERFORMANCE
• TESTING BY STARTING MACHINE
(EMPTY)
1) Stop the machine on level ground and apply
the parking brake.
2) Place the gearshift lever in the D (F2) posi-
tion.
3) Raise the engine speed gradually and mea-
sure the engine speed when the machine
starts to move.
fl When the machine starts to move, release
the accelerator pedal, and depress the
brake pedal and return the gearshift lever
to N at the same time.
fl If the engine speed when the machine
starts to move is lower than the standard
value, adjust the parking brake as follows.
• MEASURING CLEARANCE OF PARKING

BRAKE
fl If any abnormal heat is produced in the park-
ing brake drum or the travel of the parking
brake lever (dimension a) is not within the
standard value, adjust as follows.
fl Standard travel for lever: 10 – 15 mm
• ADJUSTING CLEARANCE OF PARKING

BRAKE
1. Stop the machine on flat ground so that the drum
adjustment hole is at the front of the adjustment
screw.
¤ Block the tires to prevent the machine from mov-
ing.
2. Using a screwdriver, turn the adjustment screw
in the direction of the arrow to bring the drum
and shoe into tight contact.
3. After bringing the drum and shoe into tight con-
tact, turn the adjustment screw back 15 clicks to
set to the standard clearance.
fl Standard clearance: 0.36 mm
4. After adjusting the clearance, check the travel of
the parking brake lever.
fl If the adjustment screw does not turn prop-
erly, it will cause defective adjustment of the
clearance, so disassemble the adjustment
screw and check.
20-132 HD255-5
(10)
TESTING AND ADJUSTING TESTING WEAR OF FRONT BRAKE PAD
TESTING WEAR OF FRONT

BRAKE PAD
1. Visual check
Check visually, and if the pad has reached the wear
limit line, replace the pad.
2. Checking with gauge

1) Depress the brake pedal, keep the pad pressed
against the disc, then insert inspection gauge
[1] into indicator hole (1) of the caliper.
2) If the stepped part of the gauge contacts the
mouth of the hole, the pad has reached the
wear limit, so replace it.
fl Replace the pads on the left and right sides at
the same time.
fl The pad wear is not the same for both left
and right sides, so check the wear of all pads.
HD255-5 20-133
(10)
TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC
TESTING WEAR OF REAR

BRAKE DISC
¤ Install and remove plugs and gauges with the
brake cooling oil temperature below 60˚C and
with the retarder brake control lever at the OFF
position.
¤ If the disc is near the wear limit, check the wear
frequently, regardless of the maintenance inter-
val. In addition, check the performance of the
retarder carefully.
1. Remove air bleed plug (1) of the rear brake, then
install disc wear measurement gauge K.
When installing, tighten nipple [2] completely and
pull rod [1] of disc wear measurement gauge K
fully.
fl Pull rod [1] of gauge K fully before operating
the retarder brake.
2. Turn the starting switch ON, and check that the
air pressure gauge is in the green range.
3. If the air pressure is low, start the engine and run
it at 2000 rpm until the air pressure gauge enters
the green range. When it enters the green range,
turn the starting switch OFF.
4. Pull rod [1] of disc wear measurement gauge K
fully, then operate the retarder brake control le-
ver slowly (take approx. 10 sec.) to apply the
brake.
5. In this condition, push in rod [1] of disc wear mea-
surement gauge K until it contacts the piston.
6. If mark a on disc wear measurement gauge K goes
in beyond the end face (portion b) of the case,
the disc has reached the wear limit.
7. After checking the brake wear, pull back rod [1] of
wear measurement gauge K fully, then release the
retarder brake.
¤ After checking the wear, if the retarder brake
control lever is pulled suddenly, there is
seious danger that the rod of the disc wear
measurement gauge may fly out suddenly.
for this reason, when the rod is fully pulled,
release it, then pull the retarder control
lever slowly over a period of approx. 10 sec-
onds. (Release the retarder brake.)
8. After measuring the brake wear, install the air
bleed plug, and bleed the air.
For details, see Bleeding air from brake circuit.
20-134 HD255-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER

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

1) Check that the bottom of the cylinder cover is
within the range marked by arrows for the cyl-
inder dimension.
2. Releasing nitrogen gas

1) Front suspension cylinder
i) Set hydraulic jack [1] (50t) under the main
frame.
ii) Loosen oil level valve (1) gradually 2 – 3
turns.
fl When releasing the nitrogen gas, there is
danger that releasing the gas from the
valve core of supply valve (3) will dam-
age the valve core, so remove the gas at
the oil level valve.
fl When the oil level valve is loosened, if oil
and gas spurt out together, tighten the
valve slightly, and allow time for the gas
to escape slowly.
iii) Operate the hydraulic jack so that dimen-
sion a of the cylinder is the specified di-
mension for the oil level.
Dimension a: 56 ± 3 mm
2) Rear suspension cylinder

fl The precautions when handling the oil
level valve are the same as when releas-
ing the nitrogen gas from the front sus-
pension cylinder.
HD255-5 20-135
(10)
i) Set block [2] between the stopper and axle

housing.
fl Thickness of block: 25 mm
ii) Loosen oil level valve (1) 2 – 3 turns.
¤ When loosening the oil level valve, release the

nitrogen gas gradually from the slit.
¤ If the nitrogen gas is not completely released,
the system is always under pressure from high
pressure gas.
3. Adjusting oil level

A. Front suspension
fl Release the nitrogen gas before adjusting the
oil level.
1) Remove oil level valve (1), and install joint P5.
2) Install fitting P4 to joint P3, then connect hose
P2 and volume pump P1.
3) Loosen air bleed valve (4), then operate vol-
ume pump P1 until no more bubbles come
out with the oil from air bleed side hole [a].
4) When no more bubbles come out with the oil,
tighten air bleed valve (4).
5) Remove air supply valve (3), then operate vol-
ume pump P1.
6) When no more bubbles come out with the oil,
tighten air supply valve (3).
7) After completion of filling with oil, remove
the volume pump, then install oil level valve
(1).
B. Rear suspension
There is no air bleed valve (4) or air bleed side
hole [a] at the rear, so carry out Steps 1), 2),
5), 6), and 7).
20-136 HD255-5
(10)
4. Charging suspension cylinder with gas

1) Remove air supply valve cap (5).
2) Set tool P as shown in the diagram.
fl Before installing regulator P10, blow the
connector filter with nitrogen gas at 1.0
MPa {10 kg/cm2} or more to blow out all
dirt or dust. (Dirt or dust in the system
causes failures.)
3) Open valve [c] of the gas cylinder, and check
the pressure reading of gauge P10a (internal
pressure of gas cylinder).
fl The pressure indicated must be at least
1.0 MPa {10 kg/cm2} higher than the pres-
sure inside the suspension cylinder (max.
pressure inside suspension cylinder: 2.8
MPa {29 kg/cm2}).
4) Turn handle [d] of regulator P10 slowly coun-
terclockwise, set the pressure reading of
gauge P10b to 1.0 MPa {10 kg/cm2} above the
internal pressure of the suspension cylinder,
then operate valves P6 and P9 to fill the sus-
pension cylinder with nitrogen gas.
fl Fill the left and right cylinders in the same
way.
5) When dimension a of the left and right cylin-
ders reaches the standard value, turn handle
[d] of regulator P10 counterclockwise to stop
the flow of nitrogen gas.
fl Standard dimension a: See STANDARD
VALUE TABLE.
6) Turn handle [e] of P9 fully back, loosen air
bleed plug [f], release the gas inside the hose,
then remove tool P.
fl Be careful not to lose the O-ring of the
supply valve.
HD255-5 20-137
(10)
5. Adjusting installed length of cylinder

fl Carry out adjustment of the installed length
of the cylinder with the machine empty and
on level ground.
1) To remove the sliding resistance of the cylin-
der (catching of bushing or packing), drive the
machine forward approx. 15 m and stop sud-
denly, then drive in reverse to the original
position and stop again suddenly. Repeat this
cycle 3 – 4 times.
Finally, allow the machine to stop slowly with-
out depressing the brake. Then measure the
installed length.
fl Do not use the foot brake when braking the
machine. Use the retarder control lever to
brake the machine.
2) If the result of the check shows that the in-
stalled length is too long, release nitrogen gas
to adjust the length.
fl Loosen the oil level valve slightly to release
the nitrogen gas. When doing this, release
only a small amount of gas; do not make the
cylinder move.
fl If too much nitrogen gas is released and the
cylinder moves, the installed length may go
below the specified length.
fl Do not press the tip of the valve core. If the
tip of the valve core is pressed, the valve core
may be damaged.
3) After releasing nitrogen gas and adjusting the
installed length, repeat Step 1) to check the
installed length again.
4) Repeat the above Steps 1) – 3) to adjust the
cylinder to the specified length.
5) Finally, check that there is no leakage of gas
from the valve core, oil level valve, and pis-
ton rod gland.
fl Use soapy water to check for leakage of
gas.
fl If there is any leakage of gas from the
valve core, use tool [1] and remove the
valve core.
9 Valve core :
25.5 ± 8.8 Nm {2.6 ± 0.6 kgm}
20-138 HD255-5
(10)
Note 1: Checking after changing oil and gas

After the oil and gas have been changed, op-
eration of the machine causes the gas to dis-
solve in the new oil inside the cylinder until
it is saturated, so the volume of gas is re-
duced and the installed length of the sus-
pension goes below the specified limit.
Therefore, 48 hours after changing the oil
and gas, check the installed length of the sus-
pension and adjust the gas if the length is
not within the specified value.
2: Checking for changes in installed length
caused by variation in ambient temperature
Depending on the ambient temperature
when the machine is working, the gas in the
suspension may expand or contract, so the
installed length will also change. In territo-
ries where there are big differences in tem-
perature throughout the year, inspect daily
and adjust to keep the installed length within
the specified range.
HD255-5 20-139
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING AIR GOVERNOR SET PRESSURE
TESTING AND ADJUSTING AIR

GOVERNOR SET PRESSURE
TESTING
1. Open the drain valve and drain the air from the
tank.
2. Install tool C1 (2.9 MPa {30 kg/cm2}) to tank (3).
3. Close the drain valve, then start the engine and

raise the air pressure inside the tank. Measure
the pressure when the air governor is actuated
and the air compressor is cut off (no-load opera-
tion).
4. Run the engine at low idling and use the brake

pedal to lower the air pressure. Measure the pres-
sure when the air compressor is cut in (starts to
operate).
ADJUSTMENT
If the air pressure is not within the standard value,
adjust as follows.
1. Stop the engine.
2. Loosen locknut (1) and turn adjustment screw (2)

to adjust.
fl Turn the adjustment screw as follows.
TIGHTEN to DECREASE pressure
LOOSEN to INCREASE pressure
fl After carrying out the above adjustment, mea-
sure the pressure again to check that it is
within the standard value.
20-140 HD255-5
(10)
TESTING AND ADJUSTING INSPECTION OF AIR DRIER (DESICCANT TYPE)
INSPECTION OF AIR DRIER

(DESICCANT TYPE)
(IF EQUIPPED)
fl The air drier is installed at the rear of the left front

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

• Disassemble the air drier and replace the des-
iccant, oil filter, filter, and all the rubber parts.
(See *1. Repair kit.)
• Check the metallic parts for rust and repair or
replace them, if necessary.
• Check the piping and wiring for abnormality.
HD255-5 20-140-1
(13)
TESTING AND ADJUSTING INSPECTION OF AIR DRIER (DESICCANT TYPE)
(*1) Repair kit

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

3 O-ring 1
4 O-ring 1
6 O-ring 1
7 Valve 1
11 O-ring 1
14 Oil filter 1
15 Gasket ring 1
16 Gasket ring 1
19 O-ring 1
21 Filter 2
22 Desiccant 1
24 O-ring 1
27 Check valve 1
30 O-ring 1
34 O-ring 1
20-140-2 HD255-5
(13)
TESTING AND ADJUSTING ADJUSTING HOIST LEVER LINKAGE
ADJUSTING HOIST LEVER

LINKAGE
fl Lock the control levers inside the cab in the HOLD
position with the lock plate on the console box.
fl Install and connect the push-pull cable so that
there is no twisting or slack.
1. Remove pin (1), then disconnect push-pull cable

(2) and hoist lever (3).
fl When push-pull cable (2) is disconnected,
hoist lever (3) is set to the HOLD position.
2. Remove pin (5) at the hoist control lever end of

push-pull cable (2), and disconnect from lever (6).
3. Use yoke (4) to adjust the length of the cable to

standard dimension [A]. Check the position of
the pin hole in hoist lever (3) and push-pull cable
(2), then connect them.
fl Standard dimension [A] : 209 mm
4. Use yoke (7) to adjust the position of the pin hole

of lever (6) and push-pull cable (2), then connect
them.
fl If the pin hole is not in position, carry out fine
adjustment with yoke (7) to align the pin holes.
fl Standard dimension [B] : 200 mm
5. After adjusting, release lock plate (8), operate the

hoist control lever to the RAISE position and check
that the RAISE stroke of the hoist valve is stan-
dard value [C].
fl Standard dimension [C]: 12.9 mm
HD255-5 20-141
(10)
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER
ADJUSTING BODY POSITIONER

1. Adjust push cable (1) to standard length a.
fl Standard length a : 176 mm
2. With the dump body raised to a point 50 mm be-

fore the end of the hoist cylinder stroke, adjust
plate (2) so that the hoist valve lever is released
from the detent.
fl Reference dimension b: 136 mm
20-142 HD255-5
(10)
TESTING AND ADJUSTING HYDRAULIC
TESTING AND ADJUSTING PRESSURE IN STEERING, HOIST CIRCUIT

Serial No. : 1001 – 1200
HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
¤ Lower the body to the frame, stop the engine,
then remove the cap from the hydraulic tank and
release the pressure inside the cylinder circuit.
1. Measuring hydraulic pressure in steering circuit

1) Raise the hydraulic oil temperature.
fl Oil temperature when measuring :
45 – 55˚C
2) Remove plug (1) and install tool C1 (39.2 MPa
Serial No. : 1201 and up
{400 kg/cm2}).
• Plug (PT1/8) Serial No.: 1001 – 1599
• Plug (10 x 1.5) Serial No.: 1601 and up
3) Operate the steering wheel fully to the left or
right, and measure the hydraulic pressure
when the circuit is relieved.
2. Adjusting hydraulic pressure in steering circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
• Steering pressure (adjust with demand valve)
1) Remove cap (1), then loosen locknut (3) and
turn adjustment screw (4) to adjust.
fl To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl One turn of the adjustment screw adjusts
by 2.5 MPa {25 kg/cm2}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap.
3) Check that the hydraulic pressure is within the
specified value.
For details, see Measuring pressure in steer-
ing circuit.
fl The pressure of crossover relief valve (5) can-
not be adjusted when it is installed on the
machine, so do not adjust the pressure.
HD255-5 20-143
(10)
3. Measuring steering valve discharge pressure

1) Remove plug (6) and install tool C1 (39.2 MPa
{400 kg/cm2}).
• Plug (PT1/8) Serial No.: 1001 – 1599
2) Measure in the same way as when measur-
ing the hydraulic pressure in the steering cir-
cuit.
4. Measuring hydraulic pressure in steering cylin-

der
1) Remove oil pressure measurement plug (7)
(PT 1/8) (when turning the steering to the left)
or oil pressure measurement plug (8) (when
turning the steering to the right), and install
tool C1 (39.2 MPa {400 kg/cm2}).
• Plug (PT1/8) Serial No.: 1001 – 1599
2) Measure in the same way as when measur-
ing the hydraulic pressure in the steering cir-
cuit.
5. Measuring hydraulic pressure in hoist circuit

Serial No. : 1001 – 1200
1) Raise the hydraulic oil temperature.
fl Oil temperature when measuring :
45 – 55˚C
2) Remove oil pressure measurement plug (1)
and install tool C1 (39.2 MPa {400 kg/cm2}).
• Plug (PT1/8) Serial No.: 1001 – 1599
3) Operate the hoist lever, and move the dump
body to the maximum dump position to re-
lieve the circuit, then measure the hydraulic
pressure with the engine at full throttle.
Serial No. : 1201 and up
20-144 HD255-5
(10)
6. Adjusting hydraulic pressure in hoist circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
Hoist cylinder pressure (adjust with hoist valve)
1) Remove cap (2), then loosen locknut (3) and
turn adjustment screw (4) to adjust.
fl To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl One turn of the adjustment screw adjusts
by 5.18 MPa {52.9 kg/cm2}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap.
3) Check that the hydraulic pressure is within the
specified value.
For details, see Measuring pressure in steer-
ing circuit.
HD255-5 20-145
(10)
BLEEDING AIR FROM HYDRAULIC CYLINDER
TESTING AND ADJUSTING (STEERING CYLINDER)
BLEEDING AIR FROM HYDRAULIC

CYLINDER (STEERING CYLINDER)
fl If the hydraulic cylinder or the hydraulic piping
have been removed, bleed the air from the hy-
draulic cylinder as follows.
1) Start the engine and run at low idling for
approx. 5 minutes.
2) Turn the steering wheel at approx. 30 rpm (one
turn every 2 seconds) to turn the steering to
the left and right to a point approx. 50 mm
before the end of the steering cylinder stroke.
Repeat this operation 10 times.
(This is to prevent damage to the piston seal
by dieseling of the steering cylinder.)
3) Turn the steering wheel at approx. 30 rpm to
the left and right to the end of the steering
cylinder stroke.
Repeat this operation 10 times.
4) Turn the steering wheel as fast as possible to
the left and right to the end of the steering
cylinder stroke. When the steering wheel
reaches the end of the stroke at the left or right
end, turn it immediately in the opposite di-
rection. Carry out this operation continuously.
Repeat this operation 10 times in each direc-
tion.
20-146 HD255-5
(10)
EMERGENCY TRAVEL WHEN THERE IS
TESTING AND ADJUSTING FAILURE IN ELECTRICAL SYSTEM
EMERGENCY TRAVEL WHEN THERE IS FAILURE IN

ELECTRICAL SYSTEM
1. Need for emergency travel
The following is an explanation of the action to take when it is impossible to drive the machine.
If the machine cannot be driven, a serious failure has occurred in the transmission control system,
so repairs are necessary.
Using the procedure given here, move the machine to a safe place and then carry out the repairs.
2. Self-diagnostics display and emergency travel method

1) When the starting switch is turned ON, if an abnormality occurs (for example, the automatic
gearshift (mechatronics) abnormal display lights up or the shift position display does not light up
and the engine does not start,) it is possible to start the engine as follows.
(With this action, the engine will start even if the gearshift lever is not at the N position, so be
extremely careful when starting.)
Automatic gearshift (mechatronics) Remove engine stop relay.

abnormal display lights up, shift po- • Serial No.: 1001 – 1200 Connector No. 121
sition display does not light up • Serial No.: 1201 and up Relay No. R14
HD255-5 20-147
(12)
METHOD FOR EMERGENCY ESCAPE WHEN
TESTING AND ADJUSTING THERE IS FAILURE IN ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE

IN ELECTRICAL SYSTEM
1. Need for emergency escape
The following explains the action to take if it becomes impossible to drive the machine.
If it becomes impossible to drive the machine, and a serious failure has occurred in the engine con-
trol or transmission control system, it is necessary to carry out repairs.
Use the procedure in this section to move the machine to a safe place in order to carry out repairs.
2. Self-diagnostic display and emergency escape method
1) Engine control system
a) If the engine stops when the machine is traveling and cannot be started again, use the flow-
chart below to decide the method for emergency escape.
1
When engine stalled, did engine Check fuel level (is there failure NO
NO
mechatronics caution display on moni- ➤ in engine mechatronics portion)?
tor panel flash?
➤
YES Tow
YES
2
➤
➤
Are power source abnormality service Does engine start again when
code (C010) and controller self-diagnos- YES NO
➤ fuse unit (FU:30A) and fuse II (BT-
tic display (E.↔1.0) displayed, or our all 2) A (10A) are replaced?
lamps OFF?
Make emergency escape in
NO this condition (turn all ex-
YES
➤ cept minimum necessary
power supply OFF)
3 ✩ Investigate cause later?
➤
Is controller abnormality service code

(C010) and controller self-diagnostic dis- YES NO If there is no controller
➤ Replace controller ➤
play (E.↔1.1) displayed? available, tow
NO
4
➤
Are both service codes (C01b, C01C) for

abnormality in engine speed sensor sys- YES NO If there is no sensor
tems A and B and controller self- diag- ➤ Replace sensor ➤ available, tow
nostic display (E.↔ 1.b, E↔ 1.C) dis-
played?
NO
5
➤
Are service code (C010) for abnormality If there is no solenoid avail-

in governor solenoid system and control- YES NO
ler self-diagnostic display (E. ↔ 1.4, ➤ Replace solenoid ➤ able or system does not re-
turn to normal after replac-
E↔1.5) displayed? ing, tow
NO
6
➤
Are service codes (C056, C057) for ab-

normality in solenoid power source sys- YES NO If there is no relay available
tem and controller self-diagnostic display ➤ Replace relay ➤ or system does not return to
(E.↔5.6, E↔5.7) displayed? normal after replacing, tow
NO
7
➤
Are service codes (C019, C01A) for ab-

normality in governor servo system and YES Carry out troubleshooting of
controller self-diagnostic display ➤ engine system (S Mode)
(E.↔1.9, E↔1.A) displayed?
NO
8
➤
Tow
20-148 HD255-5
(10)
1
When engine stalled, did engine Check fuel level (is there failure NO
NO
mechatronics caution display on moni- ➤ in engine mechatronics portion)?
tor panel flash?
➤
YES Tow
YES
2
➤
Are power source abnormality service Does engine start again when
code (C056) and controller self-diagnos- YES fuse unit (FU:30A), fuse (BT-2) [1] NO
➤ ➤ Replace relay
tic display (E.↔1.0) displayed, or our all (10A) and (BT-3) [1] (20A)are re-
lamps OFF? placed? NO
➤
NO YES If there is no relay available
or system does not return to
normal after replacing, tow
Make emergency escape in

this condition (turn all ex-
➤ cept minimum necessary
power supply OFF)
✩ Investigate cause later?
3
➤
Is controller abnormality service code

(C080) and controller self-diagnostic dis- YES NO If there is no controller
➤ Replace controller ➤
play (E.↔1.1) displayed? available, tow
NO
4
➤
Are abnormality service code (C01b,

C01c) and controller self-diagnostic dis- YES NO If there is no sensor
play (E.↔1.b, E↔1.C) displayed for both ➤ Replace sensor ➤ available, tow
NE sensor and G sensor (engine speed
sensor) systems?
NO
5
➤
Are service code (C07A, C07C) of com-

mon rail pressure abnormality (2nd level YES Carry out troubleshooting of
of control system) and controller self-di- ➤ engine system (S Mode)
agnostic display (E.↔7A, E.↔7C) dis-
played?
NO
6
➤
Tow
b) When the starting switch is turned ON, if the automatic shift (mechatronics related) abnor-
mality display is flashing or the shift position display does not light up, or if any other abnor-
mality occurs and the engine does not start, the engine can be started by taking the follow-
ing action.
(With this procedure, the engine will start even when the shift lever is not at the N position,
so be careful when starting.)
If automatic shift (mechatronics Remove transmission neutral

related) abnormality display is
➤ relay
flashing or shift position display Relay No.: R14
does not light up?
HD255-5 20-149
(10)
2) Transmission control system

• If the transmission suddenly returns to neutral when the machine is traveling and the ma-
chine does not move again, use the table below to decide the method for emergency escape.
• If the emergency escape cannot be performed when carrying out the re-starting operation
after taking the necessary action, the machine must be towed.
No. Emergency escape method Condition when failure occurs Service

code
1. Stop the machine, move the gearshift lever to the • Speed range remains fixed, and when machine is 10
neutral position, then operate the lever to start the started again, it does not change from speed
machine again. range in use when machine stopped. 11
(N → D.5 - 3.L or N → R) (Returns to neutral when lever is at N.)
12
Note: Remove your foot from your accelerator
pedal when operating the lever.
51
52
53
54
55
56
58
60
61
62
• Suddenly returned to neutral when machine was 21

traveling
22
23
31
32
33
34
35
36
38
41
42
43
44
45
46
48
71
72
73
74
75
76
78
20-150 HD255-5
(10)
• If there are multiple occurrences of abnormality No. 2, the combination of failures may make
it impossible to carry out the escape even when using the emergency escape method in the
table below. In such cases, do as follows.
(1) For past failures in the transmission that have already been reset, delete the failure (for
details of deleting the failure, see MONITOR PANEL USER CODE AND SERVICE MODE
FUNCTIONS), then carry out the escape operation again.
(2) If it is still impossible to escape using the procedure in Step (1) above, or there is an error
which cannot be restored, it is necessary to tow the machine.
Transmission controller . service code is 2 Speed range for starting after performing emergency
digits or less (controller LED display) escape operation (combination of clutches)
1.0 Disconnection in engine shaft speed sensor 1.0: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
system and start off in F2
1.1 Disconnection in transmission input shaft 1.1: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
speed sensor system and start off in F2
1.2 Disconnection in transmission intermediate 1.2: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
shaft speed sensor system and start off in F1
5.1 Failure in flow detection valve for L/U clutch 5.1: Operate lever N → R, or operate lever N → D.5 - 3.L and start off in F2
5.2 Failure in flow detection valve for H clutch 5.2: Operate lever N → R and start off in equivalent of R (R, High), or
operate lever N → D.5 - 3.L and start off in equivalent of F2
5.3 Failure in flow detection valve for L clutch 5.3: Operate lever N → R, or operate lever N → D.5 - 3.L and start off in F1
5.4 Failure in flow detection valve for 1st clutch 5.4: Operate lever N → D.5 - 3.L and start off in F1
5.5 Failure in flow detection valve for 2nd clutch 5.5: Operate lever N → D.5 - 3.L and start off in F3
5.6 Failure in flow detection valve for 3rd clutch 5.6: Operate lever N → D.5 - 3.L and start off in F5
5.8 Failure in flow detection valve for R clutch 5.8: Operate lever N → R and start off in R
6.0 Failure in engine speed sensor 6.0: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
and start off in F2
6.1 Failure in transmission input shaft speed 6.1: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
sensor system and start off in F2
6.2 Failure in transmission intermediate shaft 6.2: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
2.1 Failure in L/U clutch system 2.1: Operate lever N → R and start off in equivalent of R (R, High), or
operate lever N → D.5 - 3.L and start off in equivalent of F2 (1st, High)
2.2 Failure in H clutch system 2.2: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
and start off in F1
2.3 Failure in L clutch system 2.3: Operate lever N → R and start off in equivalent of R (R, High), or
operate lever N → D.5 - 3.L and start off in equivalent of F2 (1st, High)
3.1 Failure 1 in pressure control valve for L/U 3.1: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
clutch and start off in F2
3.2 Failure 1 in pressure control valve for H 3.2: Operate lever N → R and start off in equivalent of R (R ← High), or
clutch operate lever N → D.5 - 3.L and start off in F2 (1st, High)
3.3 Failure 1 in pressure control valve for L 3.3: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
3.4 Failure 1 in pressure control valve for 1st 3.4: Operate lever N → D.5 - 3.L and start off in F2
clutch
3.5 Failure 1 in pressure control valve for 2nd 3.5: Operate lever N → D.5 - 4.L and start off in F3
clutch
3.6 Failure 1 in pressure control valve for 3rd 3.6: Operate lever N → D.5 - 3.L and start off in F5
clutch
3.8 Failure 1 in pressure control valve for R 3.8: Operate lever N → R and start off in R
clutch
4.1 Failure 2 in pressure control valve for L/U 4.1: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
4.2 Failure 2 in pressure control valve for H 4.2: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
4.3 Failure 2 in pressure control valve for L 4.3: Operate lever N → R and start off in equivalent of R (R, High), or
clutch operate lever N → D.5 - 3.L and start off in F2
4.4 Failure 2 in pressure control valve for 1st 4.4: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
4.5 Failure 2 in pressure control valve for 2nd 4.5: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
4.6 Failure 2 in pressure control valve for 3rd 4.6: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
4.8 Failure 2 in pressure control valve for R 4.8: Operate lever N → D.5 - 3.L and start off in F2
clutch
7.1 Short circuit in lock-up solenoid output 7.1: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
circuit and start off in F2
7.2 Short circuit in H clutch solenoid output 7.2: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
circuit and start off in F1
7.3 Short circuit in L clutch solenoid output 7.3: Operate lever N → R and start off in equivalent of R (R → High), or
circuit operate lever N → D.5 - 3.L and start off in F2
7.4 Short circuit in 1st clutch solenoid output 7.4: Operate lever N → R and start off in R
circuit
7.5 Short circuit in 2nd clutch solenoid output 7.5: Operate lever N → D.5 - 3.L and start off in F2
circuit
7.6 Short circuit in 3rd clutch solenoid output 7.6: Operate lever N → R and start off in R
circuit
7.8 Short circuit in R clutch solenoid output 7.8: Operate lever N → D.5 - 3.L and start off in F2
circuit
HD255-5 20-151
(10)
No. Emergency escape method Condition when failure occurs
2. Stop the machine, move the gearshift lever to the • Speed range remains fixed and when machine is started
neutral position, then remove and insert the again, it does not change from speed range in use when
emergency escape connectors (A1, A2). (Leave the machine stopped.
starting switch ON.) (Returns to neutral when lever is at N, but remains in
After doing this, operate the lever to start the neutral.)
machine again. (N → D.5 - 3.L or N → R)
Note: Remove your foot from your accelerator
pedal when operating the lever. • Suddenly returned to neutral when machine was traveling
Keep the machine in the emergency escape mode • After machine stops, transmission remains in neutral even
until you turn the starting switch OFF. when lever is operated, and machine does not start
3. Check for blown fuse (FB2 [8], [10]), check circuit

breaker (80A), or replace controller
4. Replace transmission cut relay (R20)
5. Use modulation checker
• After machine stops, transmission remains in neutral even

when lever is operated, and machine does not start
6. Tow • Suddenly returned to neutral when machine was traveling

• After machine stops, transmission remains in neutral even
when lever is operated, and machine does not start
20-152 HD255-5
(10)
Transmission controller . service code is 2 Speed range for starting after performing emergency
digits or less (controller LED display) escape operation (combination of clutches)
9.8 Disconnection solenoid system for R clutch 9.8: Operate lever N → D.5 - 3.L and start off in F2
pressure control
1.3 Disconnection in transmission output shaft 1.3: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
6.3 Failure in transmission output shaft speed 6.3: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
sensor system and start off in F2
2.4 Failure in 1st clutch system 2.4: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
and start off in F3
2.5 Failure in 2nd clutch system 2.5: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
and start off in F2
2.6 Failure in 3rd clutch system 2.6: Operate lever N → R and start off in R, or operate lever N → D.5 - 3.L
and start off in F2
2.8 Failure in R clutch system 2.8: Operate lever N → D.5 - 3.L and start off in F2
. Abnormality in power source voltage or Normal travel possible in R, F1 - F6 if controller returns to normal display
failure in controller (After 0.1 failure is reset, stays in neutral until lever is returned to N)
0.1 Drop in power source voltage
0.2 Abnormality in solenoid power source

system
0.5 Failure in transmission cut relay system
0.7 Failure in 12V output system Travel possible in desired speed range using modulation checker (but auto
1.5 Failure A in lever signal system lock-up does not work)
1.6 Failure B in lever signal system
1.4 Failure in machine model selection signal

system
A.1 Abnormality in machine model selection
B.1 Abnormality in connector connection
0.5 Double meshing detected
HD255-5 20-153
(10)
PROCEDURE FOR MOVING MACHINE WHEN
TESTING AND ADJUSTING TRANSMISSION VALVE FAILS
PROCEDURE FOR MOVING MA-

CHINE WHEN TRANSMISSION
VALVE FAILS
fl If the machine cannot be moved because of a fail-
ure in any part of the transmission valve system
(electrical system, solenoid valves, spools, etc.),
it is possible to move the machine by installing
plate S.
¤ Plate S is only for emergency use when the
machine cannot be moved by any other means
because of a failure in the transmission control
valve system. Do not install plate S to the ECMV
except when there has been a failure and it is
necessary to move the machine from a dan-
gerous working area to a safe place for repairs.
¤ When carrying out this operation, keep strictly
to the procedure and pay careful attention to
safety when moving the machine.
¤ To prevent the machine from moving, apply the
¤ Carry out the operation with the engine stopped.
¤ Be careful not to burn yourself if the oil is hot.
1. Remove valve cover (1).

fl Wash the area around the ECMV clean and
remove all dirt and mud.
2. Disconnect 14 wiring connectors (2) – (15).

fl For details of precautions when removing the
wiring connectors, see DISASSEMBLY AND
ASSEMBLY, REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY.
20-154 HD255-5
(10)
PROCEDURE FOR MOVING MACHINE WHEN
TESTING AND ADJUSTING TRANSMISSION VALVE FAILS
3. Depending on the direction for moving the ma-

chine (forward or reverse), remove the following
2 ECMV solenoids (14) and install plate S.
• FORWARD: Hi solenoid and 1st solenoid
• REVERSE : Lo solenoid and R solenoid
fl If there is any mistake in the selection of the
solenoid to remove, there is danger that the
transmission may be damaged.
fl Install plate S with the protruding surface fac-
ing the ECMV. Check also that there is an O-
ring installed to the mating surface.
fl Be careful not to let any dirt or mud get in-
side the removed solenoid or valve.
4. Depress the brake pedal securely.
5. Start the engine, release the parking brake, then

release the brake pedal gradually to allow the
machine to start, then move the machine.
¤ Remove the blocks under the tires.
¤ When the engine is started, the transmission
is also engaged to start the machine. To en-
sure safety when starting the engine, check
carefully that the direction of travel and area
around the machine are safe, and always
keep the brake pedal depressed when start-
ing.
¤ After moving the machine, stop the engine,
apply the parking brake, and put blocks un-
der the tires.
HD255-5 20-155
(10)
PROCEDURE FOR FLUSHING TORQUE CONVERTER,
TESTING AND ADJUSTING TRANSMISSION HYDRAULIC CIRCUIT
PROCEDURE FOR FLUSHING

TORQUE CONVERTER,
TRANSMISSION HYDRAULIC 5. Replace the flushing element.
CIRCUIT 1) Using the procedure in Step 2-1), replace
the flushing element with the standard el-
fl Metal particles and other dirt in the torque con- ement (424-16-11140).
verter and transmission hydraulic circuit will
reduce the life of the torque converter and
¤ If the flushing element is used for a
long time, there will be premature
transmission, and will cause internal breakage.
clogging, so always replace the flush-
To prevent this, carry out flushing to remove
ing element with the standard ele-
the dirt in the hydraulic circuit.
ment.
1. Flush the circuit if the following conditions ap- 2) Add oil and check the level again.
ply.
1) If there has been any damage to the torque 6. Replace the transmission fail-safe filter.
converter, transmission, or hydraulic 1) Use a wrench to turn portion A of fail-safe
equipment, and metal particles are circu- filter case (1) to remove it.
lating in the hydraulic circuit. fl If there is any dirt inside the filter case,
2) When the torque converter and transmis- wash the case.
sion have been overhauled or repaired. 2) Remove element (2) and replace it with a
new element.
2. Install the flushing element. 3) Install new O-ring (3) to the outside circum-
1) Drain the oil from the filter case. ference of the case.
2) Remove the transmission oil filter, then in- fl Coat the outside circumference of the
stall a flushing element (561-15-55670). O-ring with a small amount of grease.
fl After flushing the system, assemble 4) Install the case.
the parts that were removed and the 9 Case :
parts inside the case. 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3. Fill the transmission case with oil.

• Add fresh oil through the oil filler port to
the specified level, and run the engine to
circulate the oil through the system. Then
check the level again.
5 Transmission case: 100 ¬
4. Carry out flushing as follows.

1) After starting the engine, run the engine
for approx. 20 minutes at low idling with-
out operating the speed lever or directional
lever.
fl From time to time, raise the engine
speed to approx. 1500 rpm.
fl If the ambient temperature is low and
the engine water temperature gauge
does not enter the green range, con-
tinue the warming-up operation
longer.
2) Travel or carry out actual operations for at
least 20 minutes.
fl Use all the speed ranges (FORWARD
1st – 4th).
3) Repeat the procedure in 4-1) and run the
engine at low idling for approx. 20 min-
utes.
20-156 HD255-5
(10)
TESTING AND ADJUSTING Pm CLINIC CHECK SHEET
Pm CLINIC CHECK SHEET HD255-5 1001 and up

Machine Serial No. #
HOUR INSPECTION Engine Serial No. SA6D125E-2G#
WORK No. DATE SERVICE METER NAME OF INSPECTOR

Year Month Day
hrs
QUESTIONS TO OPERATOR AND INSPECTION AROUND THE MACHINE
Were there any problems before start of inspection? Ambient Temperature
.............................................................................................................................................................................................................................................
Max. ˚C (˚F)
............................................................................................................................................................................................................................................. Min. ˚C (˚F)
.............................................................................................................................................................................................................................................
Altitude m
Coolant tmperature maximum level? Torque converter, transmission oil tempe- Retarder oil temperature maximum
(during operation) rature maximum level? (during operation) level? (during operation)
White Green Green Green Green Red Red White Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
AFTER STARTING ENGINE! [ ] : Referance value
MEASUREMENT ITEM MEASUREMENT CONDITION UNIT STD. PMS. RESULT Sat Us

Engine low idling 755 – 805 755 – 805
Engine speed Engine full throttle rpm 2,400 – 2,500 2,400 – 2,500
Torque converter stall 1,815 – 1,965 1,815 – 1,965
kPa [Max. 1.47] [Max. 2.94]
Blow-by pressure Torque converter stall {mmAq} {(Max. 150)} {(Max. 300)}
0.34 – 0.49 Min. 0.20
Engine full throttle
ENGIINE
{3.5 – 5.0} {Min. 2.0}

SAE30
Min. 0.15 Min. 0.07
Engine low idling {Min. 1.5} {Min. 0.7}
Engine MPa
{kg/cm2} 0.25 – 0.44 MIn. 0.18
oil pressure Engine full throttle {2.5 – 4.5} {Min. 1.8}
SAE10W
Engine low idle Min. 0.1 Min. 0.07
{Min. 1.0} {Min. 0.7}
kPa Min. 140 Min. 113
Boost pressure Torque converter stall
{mmAq} {Min. 1,050} {Min. 850}
Exhaust Ambient temperature -–- -–-
temperature ˚C
Torque converter stall Max. 700 Max. 700
3.33 – 3.53 3.33 – 3.53

Engine low idling
Main relief {34.0 – 36.0} {34.0 – 36.0}
pressure 3.33 – 3.53 3.33 – 3.53
{34.0 – 36.0} {34.0 – 36.0}
Torque converter 0.75 – 0.94 0.75 – 0.94
Engine full throttle {7.6 – 9.6} {7.6 – 9.6}
inlet port pressure
outlet port pressure Engine full throttle {6.8 – 9.2} {6.8 – 9.2}
Torque converter 1.72 – 2.01 1.72– 2.01
T/C • T/M
lock-up pressure {17.5 – 20.5} {17.5 – 20.5}

MPa 2.70 – 2.99 2.70 – 2.99
1 st clutch {kg/cm2} {27.5 – 30.5} {27.5 – 30.5}
1.52 – 1.81 1.52 – 1.81
2 nd clutch {15.5 – 18.5} {15.5 – 18.5}
Engine full 1.67 – 1.96 1.67 – 1.96
Transmission 3 rd clutch {17.0 – 20.0} {17.0 – 20.0}
Oil temperature:
clutch pressure 1.52 – 1.81 1.52 – 1.81
60 – 80˚C H clutch {15.5 – 18.5} {15.5 – 18.5}
1.72 – 2.01 1.72 – 2.01
L clutch
{17.5 – 20.5} {17.5 – 20.5}
2.99 – 3.29 2.99 – 3.29
R clutch
{30.5 – 33.5} {30.5 – 33.5}
CHANGE OIL, CLEAN INSIDE OF TRANSMISSION CASE AND STRAINER AT EVERY 1000 HOURS SERVICE
Must be no excessive metallic
T/M Visual check of transmission strainer
particles or Rayflex (black power)
HD255-5 20-157
(12)
HD255-5 1001 and up

Engine Serial No. SA6D125E-2G2#
[ ] : Referance value

Hydraulic oil
temperature Oil temperature: 45 – 55˚C ˚C -–- -–-
STEERING&HYDRAULIC
Steering relief MPa 17.2 – 17.7 17.2 – 17.7

pressure Engine full throttle {kg/cm2} {175 – 180} {175 – 180}
EQUIPMENT
Low idling, right → Left Max. 3.0 Max. 5.0

Steering time sec
lock to lock Low idling, Left → right Max. 3.0 Max. 5.0
Hoist relief MPa 20.1 – 21.1 20.1 – 21.1
Dump body raise Engine full throttle 5.5 – 8.5 5.5 – 8.5
time sec
0.66 – 0.72 0.66 – 0.72

Cut-in {6.7 – 7.3} {6.7 – 7.3}
Air governor set MPa
pressure Engine full throttle {kg/cm2} 0.78 – 0.84 0.78 – 0.84
Cut-out
BRAKES
{8.0 – 8.6} {8.0 – 8.6}

Service brake Min. 1,350 Min. 1,350
Apply brake, set gearshift lever to"D",
Parking brake gradually raise engine speed, and measure Min. 1,250 Min. 1,250
engine speed when machine starts to move rpm
Retarder brake Min. 1,250 Min. 1,250
Emergency brake Full Full
SET DUMP BODY AND STOP ENGINE!

Hydraulic oil -–-
temperature ˚C
Hydraulic drift of hoist Set dump body with No. 2 cylinder extended mm/
cylinder 200 mm. 5 min. Max. 30 Max. 60
REPLACE DRAIN PLUG WITH SPARE PLUG!

Visual check of There must be no excessive
differential drain plug Stop engine -–- metal powder
Visual check of final Left There must be no excessive

drive drain plug -–- metal powder
Right
EVERY 1000 HOURS SERVICE!

Left 15.6 (Initial 2.0
Front brake
BRAKES
(pad thickness) Right dimensions) 2.0

mm
Left [+6.0 (Initial Wear limit
Rear brake
Right dimensions)] Wear limit
Suspension cylinder length mm 341 – 361 341 – 361

Left front
SUSPENSION CYLINDER
suspension Oil, gas leakage There must be no leakage

-–-
Right front
suspension Oil, gas leakage -–- There must be no leakage
Left rear
Right rear
MEMO: Write any data or phenomena that you notice during today's check.
......................................................................................................................................................................................................................................................................................
............................................................................................................................... ............................................................................................................................... .......................
20-158 HD255-5
(12)
HD255-5 1601 and up

HOUR INSPECTION Engine Serial No. SAA6D125E-3
WORK No. DATE SERVICE METER NAME OF INSPECTOR

Year Month Day
hrs
QUESTIONS TO OPERATOR AND INSPECTION AROUND THE MACHINE
Was there any abnormality before start of inspection? Ambient Temperature
.............................................................................................................................................................................................................................................
Max. ˚C (˚F)
............................................................................................................................................................................................................................................. Min. ˚C (˚F)
.............................................................................................................................................................................................................................................
Altitude m
Coolant tmperature maximum level? Torque converter, transmission oil tempe- Retarder oil temperature maximum
(during operation) rature maximum level? (during operation) level? (during operation)
White Green Green Green Green Red Red White Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
AFTER STARTING ENGINE! [ ] : Referance value

Engine low idring 700 – 800 700 – 800
Engine speed Engine full throttle rpm 2,400 – 2,500 2,400 – 2,500
Torque converter stall 1,815 – 1,965 1,815 – 1,965
kPa [Max. 1.47] [Max. 2.94]
Blow-by pressure Torque converter stall {mmAq} {(Max. 150)} {(Max. 300)}
0.34 – 0.49 Min. 0.20
ENGIINE
{3.5 – 5.0} {Min. 2.0}

SAE30
Min. 0.15 Min. 0.07
Engine low idling {Min. 1.5} {Min. 0.7}
Engine MPa
{kg/cm2} 0.25 – 0.44 MIn. 0.18
oil pressure Engine full throttle {2.5 – 4.5} {Min. 1.8}
SAE10W
Engine low idle Min. 0.1 Min. 0.07
{Min. 1.0} {Min. 0.7}
kPa Min. 140 Min. 113
Boost pressure Torque converter stall
{mmAq} {Min. 1,050} {Min. 850}
Exhaust Ambient temperature -–- -–-
temperature ˚C
Torque converter stall Max. 650 Max. 700
3.33 – 3.53 3.33 – 3.53

Engine low idling
Main relief {34.0 – 36.0} {34.0 – 36.0}
pressure 3.33 – 3.53 3.33 – 3.53
{34.0 – 36.0} {34.0 – 36.0}
Engine full throttle {7.6 – 9.6} {7.6 – 9.6}
inlet port pressure
outlet port pressure Engine full throttle {6.8 – 9.2} {6.8 – 9.2}
Torque converter 1.72 – 2.01 1.72– 2.01
T/C • T/M
lock-up pressure {17.5 – 20.5} {17.5 – 20.5}

MPa 2.70 – 2.99 2.70 – 2.99
1 st clutch {kg/cm2} {27.5 – 30.5} {27.5 – 30.5}
1.52 – 1.81 1.52 – 1.81
2 nd clutch {15.5 – 18.5} {15.5 – 18.5}
Engine full 1.67 – 1.96 1.67 – 1.96
Transmission 3 rd clutch {17.0 – 20.0} {17.0 – 20.0}
Oil temperature:
clutch pressure 1.52 – 1.81 1.52 – 1.81
60 – 80˚C H clutch {15.5 – 18.5} {15.5 – 18.5}
1.72 – 2.01 1.72 – 2.01
L clutch
{17.5 – 20.5} {17.5 – 20.5}
2.99 – 3.29 2.99 – 3.29
R clutch
{30.5 – 33.5} {30.5 – 33.5}
CHANGE OIL, CLEAN INSIDE OF TRANSMISSION CASE AND STRAINER AT EVERY 1000 HOURS SERVICE
Must be no excessive metallic
T/M Visual check of transmission strainer
particles or Rayflex (black power)
HD255-5 20-159
(10)
HD255-5 1601 and up

Engine Serial No. SAA6D125E-3
[ ] : Referance value

Hydraulic oil
temperature Oil temperature: 45 – 55˚C ˚C -–- -–-
STEERING&HYDRAULIC
Steering relief MPa 17.2 – 17.7 17.2 – 17.7

EQUIPMENT
Low idring, right → Left Max. 3.0 Max. 5.0

Steering time sec
lock to lock Low idring, Left → right Max. 3.0 Max. 5.0
Hoist relief MPa 20.1 – 21.1 20.1 – 21.1
Dump body raise Engine full throttle 5.5 – 8.5 5.5 – 8.5
time sec
0.66 – 0.72 0.66 – 0.72

Cut-in {6.7 – 7.3} {6.7 – 7.3}
Air governor set MPa
pressure Engine full throttle {kg/cm2} 0.78 – 0.84 0.78 – 0.84
Cut-out
BRAKES
{8.0 – 8.6} {8.0 – 8.6}

Service brake Min. 1,350 Min. 1,350
Apply brake, set gearshift lever to"D",
Parking brake gradually raise engine speed, and measure Min. 1,250 Min. 1,250
engine speed when machine starts to move rpm
Retarder brake Min. 1,250 Min. 1,250
Emergency brake Full Full
SET DUMP BODY AND STOP ENGINE!

Hydraulic oil -–-
temperature ˚C
Hydraulic drift of hoist Set dump body with No. 2 cylinder extended mm/
cylinder 200 mm. 5 min. Max. 30 Max. 60
REPLACE DRAIN PLUG WITH SPARE PLUG!

Visual check of There must be no excessive
differential drain plug Stop engine -–- metal powder
Visual check of final Left There must be no excessive

drive drain plug -–- metal powder
Right
EVERY 1000 HOURS SERVICE!

Left 15.6 (Initial 2.0
Front brake
BRAKES
(pad thickness) Right dimensions) 2.0

mm
Left [+6.0 (Initial Wear limit
Rear brake
Right dimensions)] Wear limit

Left front
SUSPENSION CYLINDER
suspension Oil, gas leakage There must be no leakage

-–-
Right front
Left rear
Right rear
MEMO: Write any data or phenomena that you notice during today's check.
......................................................................................................................................................................................................................................................................................
............................................................................................................................... ............................................................................................................................... .......................
20-160 HD255-5
(10)
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 20-202

Sequence of events in troubleshooting ................................................................................................ 20-203
Points to remember when carrying out maintenance ......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Type of connector and position of installation (Serial No. 1001 – 1200) ............................................ 20-214
Connector pin arrangement diagram (Serial No. 1001 – 1200) ........................................................... 20-218
Type of connector and position of installation (Serial No. 1201 – 1599) ......................................... 20-219-3
Connector pin arrangement diagram (Serial No. 1201 – 1599) ........................................................ 20-219-7
Type of connector and position of installation (Serial No. 1601 and up) ...................................... 20-219-11
Connector pin arrangement diagram (Serial No. 1601 and up) ..................................................... 20-219-15
Connection table for connector pin numbers ....................................................................................... 20-220
Method of using judgement table ......................................................................................................... 20-231
Method of using troubleshooting charts ............................................................................................... 20-232
Method of LED display for transmission controller ............................................................................. 20-234
Action taken by transmission controller and problems on machine .................................................. 20-238
Troubleshooting of engine system (D mode) ....................................................................................... 20-301
Troubleshooting of engine controller system (G mode) ...................................................................... 20-351
Troubleshooting of engine electrical system for START/ STOP system (ENG mode) .................. 20-400-11
Troubleshooting of transmission controller system (A mode) ............................................................ 20-401
Troubleshooting of meter panel system (E mode) ............................................................................... 20-471
Troubleshooting of pilot lamp system (F mode) .................................................................................. 20-501
Troubleshooting of machine air compressor air system (C mode) ..................................................... 20-551
Troubleshooting of hydraulic, mechanical system (H mode) .............................................................. 20-601
Troubleshooting of ARSC [automatic retarder speed controller] system (R mode) .......................... 20-701
HD255-5 20-201
(10)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure
and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 2) Check for any external leakage of oil from
hurry to disassemble the components. the piping or hydraulic equipment.
If components are disassembled immediately 3) Check the travel of the control levers.
any failure occurs: 4) Check the stroke of the control valve
• Parts that have no connection with the fail- spool.
ure or other unnecessary parts will be dis- 5) Other maintenance items can be checked
assembled. externally, so check any item that is con-
• It will become impossible to find the cause sidered to be necessary.
of the failure. 4. Confirming failure
It will also cause a waste of manhours, parts, Confirm the extent of the failure yourself,
or oil or grease, and at the same time, will also and judge whether to handle it as a real fail-
lose the confidence of the user or operator. ure or as a problem with the method of op-
For this reason, when carrying out trouble- eration, etc.
shooting, it is necessary to carry out through fl When operating the machine to reenact
prior investigation and to carry out trouble- the troubleshooting symptoms, do not
shooting in accordance with the fixed proce- carry out any investigation or measure-
dure. ment that may make the problem worse.
2. Points to ask user or operator 5. Troubleshooting
1) Have any other problems occured apart Use the results of the investigation and in-
from the problem that had been reported? spection in Items 2 - 4 to narrow down the
2) Was there anything strange about the ma- causes of failure, then use the troubleshoot-
chine before tha failure occurred? ing flowchart to locate the position of the
3) Did the failure occur suddenly, or were failure exactly.
there problems with the machine condition fl The basic procedure for troubleshooting
before this? is as follows.
4) Under what conditions did the failure oc- 1) Start from the simple points.
cur? 2) Start from the most likely points.
5) Had any repairs been carried out before the 3) Investigate other related parts or in-
failure? formation.
When were these repairs carried out? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred be- Even if the dailure is repaired, if the root
fore? cause of the failure is not repaired, the same
3. Check before troubleshooting failure will occur again.
1) Check the oil level. To prevent this, always investigate why the
problem occureed. Then, remove the root
cause.
20-202 HD255-5
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points. Ring Ring
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown
Step 2
Determining probable location of cause TEW00183
1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
TEW00184 It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
Step 8 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
Repair at workshop that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Machine
volume Re-enacting failure
• Drive and operate the machine to confirm

Shop manual the condition and judge if there is really a
failure.
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
HD255-5 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204 HD255-5
(10)
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
(4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
HD255-5 20-205
(10)
2) Removing, installing, and drying connectors and

wiring harnesses
‡ Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
fl Never pull with one hand.
(2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
Catches
(3) Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-206 HD255-5
(10)
‡ Connecting connectors
(1) Check the connector visually.
i) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
ii) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
iii) Check that there is no damage or break-
age to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
(2) Fix the connector securely.

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

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

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

Since the DT 8-pole and 12-pole DT type connec-
tors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
HD255-5 20-207
(10)
‡ 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 wa-
ter 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 com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a 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 connec-
tor.
TEW00202
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 HD255-5
(10)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box
unless necessary.
TEW00204
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
(5) Never touch the connector contacts with your
hand.
(6) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
TEW00205
(7) Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
(8) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
HD255-5 20-209
(10)
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

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

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-210 HD255-5
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Item Judgement value Action

Hydraulic, mecha-
nical equipment
31. Check for abnormal noise, smell — Repair

32. Check for oil leakage — Repair
33. Carry out air bleeding — Bleed air
34. Check battery voltage (engine stopped) 24V Charge or replace

Other check items
35. Check battery electrolyte level — Add electrolyte

Electrics, electrical equipment
36. Check for discolored, burnt, exposed wiring — Replace

2 37. Check for missing wiring clamps, hanging wiring — Repair
38. Check for water leaking on wiring
(pay particularly careful attention to water — Dry
leaking on connectors or terminals)
39. Check for blown, corroded fuses — Replace

40. Check alternator voltage After running for several
(engine running at 1/2 throttle or above) minutes: 27.5 – 29.5 V Replace
41. Check operating sound of battery relay

(starting switch ON, OFF) — Replace
HD255-5 20-213
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

Serial No.: 1001 – 1200
Con- No. Con- No.

nector Connec-
tor type of Place of use
Add- nector Connec-
Add-
No. ress No. ress
pins pins
11 Socket 5 Engine starting relay P-4 AC1 — 1 Air conditioner O-7
12 Socket 5 Neutral safety relay P-4 ACC1 Terminal 1 Starting switch (ACC) P-9
13 Socket 6 Parking, dump caution relay P-4 ACRD — 1 Air conditioner (pressure switch) D-1
14 Socket 5 Parking relay P-3 ACU — 1 Air conditioner compressor V-6
15 Socket 6 Rear brake pilot relay P-2 AD1 — 1 Air dryer H-9
16 Socket 5 Service brake relay P-2 AG — 1 Air gauge P-7
17 Socket 5 Backup alarm relay R-3 AR1 Terminal 1 Alternator (R) A-4
18 Socket 5 Transmission cut relay R-2 AR2 Terminal 1 Alternator (R) A-4
19 Socket 5 Oil filter caution relay R-2 AR3 Terminal 1 Alternator (R) A-3
20 Socket 5 Brake oil level relay R-2 ARS1 — 1 Auto retarder SOL X-9
21 Socket 5 Rear brake stroke relay R-2 ARS2 — 1 Auto retarder SOL X-9
101 Shinagawa 4 Fuse Q-5 B1 KES 1 1 Failure mode cancel switch B-2
102 SWP 8 Fuse Q-5 B1 Terminal 1 Starting switch (B) P-9
103 SWP 14 Fuse Q-5 B2 KES 1 1 Failure mode cancel switch B-2
104 X 4 Fuse R-3 B2 Terminal 1 Starting switch (B) P-9
105 SWP 12 Fuse Q-5 BA — 1 Backup alarm L-9
106 SWP 6 Fuse R-3 BCG Terminal 1 GND (rear brake stroke sensor) E-9
110 SWP 8 Intermediate connector W-4 BCS1 X 2 Rear brake stroke sensor F-9
(shift indicator)
111 X 4 Intermediate connector W-4 BCS2 X 2 Rear brake stroke sensor H-9
(shift indicator)
112 SWP 8 Intermediate connector W-4 BEA M 2 Beacon lamp switch U-5
(shift indicator)
Intermediate connector BL Terminal 1 Backup lamp L-8
113 SWP 12 (shift indicator) X-3
114 SWP 14 Intermediate connector X-2 BL4 — 1 Beacon lamp A-4
(shift indicator)
115 SWP 12 Intermediate connector V-7 BNC Terminal 1 Battery relay (BR) C-8
(shift indicator)
116 SWP 12 Intermediate connector I-9 BR Terminal 1 Starting switch (BR) P-9
121 Socket 5 Engine stop relay S-3 BR Terminal 1 Battery relay (BR) C-9
301 SWP 6 Rear combination lamp (L.H.) L-6 BRM Terminal 1 Battery relay (M) C-9
302 SWP 6 Intermediate connector (rear lamp) K-9 BRN Terminal 1 Battery relay (M) C-9
303 SWP 6 Rear combination lamp (R.H.) J-9 BS — 1 Speedometer, tachometer (lighting) M-7
1.PS Mitsubishi 2 1st clutch SOL O-4 BZ1 M 2 Buzzer Q-1
1.SW X 1 1st fill switch O-4 C Terminal 1 Starting switch (C) O-9
2.PS Mitsubishi 2 2nd clutch SOL N-4 C/V.T X 2 Transmission oil temperature sensor O-3
2.S X 1 2nd fill switch O-4 C1 SWP 14 Shift controller indicator U-7
3.PS Mitsubishi 2 3rd clutch SOL N-4 C2 SWP 14 Shift controller indicator U-8
3.SW X 1 3rd fill switch O-4 C3 SWP 14 Shift controller indicator U-8
A1 KES 1 1 Emergency travel switch E-1 CG1 — 1 Cigar lighter P-7
A2 KES 1 1 Emergency travel switch E-1 CG2 — 1 Cigar lighter Q-6
AB1 Terminal 1 Alternator (B) A-4 CN1 MIC 17 Transmission controller C-1
20-214 HD255-5
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
CN1 S 10 Pilot lamp (ass’y) R-7 EBS. X 2 Emergency brake switch (OP) X-9
CN2 MIC 21 Transmission controller B-2 EMP1 — 1 Emergency Steering pilot lamp Q-9
CN2 Socket 5 Fog lamp relay S-4 EMP2 — 1 Emergency Steering pilot lamp Q-9
CN3 Socket 5 Battery charge relay S-3 ENS SWP 8 Engine stop motor A-3
CN31 AMP040 20 Transmission controller B-2 EOP Terminal 1 Engine oil pressure switch C-2
CN32 AMP040 16 Transmission controller C-1 ESW X 2 Auto emergency steering switch J-2
CN4 PA 7 Fog lamp switch S-5 EW1 Terminal 1 Engine water temperature gauge (B) N-6
CN5 M 3 Timer (Preheating) W-4 EW2 Terminal 1 Engine water temperature gauge (T) N-5
Engine water temperature
CN51 AMP040 20 Transmission controller A-2 EW3 Terminal 1 gauge (lighting) O-7
CN52 AMP040 16 Transmission controller B-2 EWTS — 1 Engine water temperature sensor A-6
CN6 KES 1 6 Pilot lamp (combination) N-7 EXH1 X 2 Exhaust brake solenoid E-9
CN7 Socket 6 Marker lamp relay S-3 EXH2 Terminal 1 Ground connection (exhaust E-9
brake solenoid)
CN8 M 2 Central warning lamp P-7 EXH6 PA 7 Exhaust brake switch S-5
CN9 S 8 Light combination switch J-1 FB1 — Fuse P-3
CNA Socket 6 Head lamp relay V-5 FB2 — Fuse P-2

CNB Socket 6 Head lamp relay (Hi) V-4 FBT X 2 Brake oil level sensor F-9
CNC Socket 6 Head lamp relay (Lo) V-4 FC — 1 Oil filter caution T-5
CND Socket 5 Head lamp relay S-3 FG1 — 1 Fog lamp A-4
CNE Socket 5 Marker lamp relay S-3 FG1 — 1 Fuel gauge L-4
D01 KES 1 2 Diode (parking, dump relay) P-4 FG2 — 1 Fog lamp E-1
D010 KES 1 2 Diode (battery relay) B-8 FG2 — 1 Fuel gauge L-3
D02 KES 1 2 Diode (parking, dump relay) P-4 FGS Terminal 1 Fuel gauge (S) M-7
D03 KES 1 2 Diode (horn valve) C-1 FSW1 — 1 Steering, hoist fill sensor K-2
D04 KES 1 2 Diode (AUT.EM steering) Q-2 FSW2 — 1 Steering, hoist fill sensor K-2
D05 KES 1 2 Diode (brake oil level relay) R-2 FU KES 1 2 Fuse unit C-9
D06 KES 1 2 Diode (service brake relay) R-3 FUB — 1 Flasher unit W-1
D07 KES 1 2 Diode R-1 FUL — 1 Flasher unit W-1
D08 KES 1 2 Diode (auto retarder SOL) V-9 G1 Terminal 1 Ground connection (cab front face) S-4
D09 KES 1 2 Diode (exhaust brake solenoid) E-9 G2 Terminal 1 GND P-2
D11 KES 1 2 Diode (engine starting relay) R-4 G3 Terminal 1 Tachometer N-6
D12 KES 1 2 Diode (rear brake stroke relay) R-1 GND Terminal 1 Ground connection (wiper switch) J-2
D13 KES 1 2 Diode (marker lamp relay) T-2 GND1 Terminal 1 GND (rear lamp) L-7
D14 KES 1 2 Diode (marker lamp relay) T-2 GND2 Terminal 1 GND (fuel gauge) L-3
DB1 — 1 Dump buzzer P-3 GND3 Terminal 1 Ground connection (battery relay) B-8
DB2 — 1 Dump buzzer P-3 GND4 Terminal 1 GND (brake oil level sensor) G-9
E Terminal 1 Battery relay (E) B-8 GND5 Terminal 1 GND (engine stop motor) A-3
E12 X 1 Engine output shaft speed sensor A-2 GND6 Terminal 1 GND (tachograph)(opt) X-6
HD255-5 20-215
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
H.PS Mitsubishi 2 H clutch SOL M-4 RA7 — 1 Speaker L-3
H.SW X 1 H fill switch M-4 RA8 Terminal 1 Ground connection (radio) S-5
HAZ Socket 5 Hazard relay T-2 RE1 — 1 Resistor (central warning lamp) U-1
HAZ1 Socket 5 Hazard relay R.H. S-4 RE2 — 1 Resistor (central warning lamp) U-2
HAZ2 Socket 5 Hazard relay L.H. S-4 RE3 — 1 Resistor (head lamp) U-2
HAZ3 Terminal 1 Hazard switch U-5 RE4 — 1 Resistor (head lamp) T-2
HAZ4 Terminal 1 Hazard switch U-5 RE5 — 1 Resistor (lamp) V-1
HD1 SWP 6 Intermediate connector A-5 RE6 — 1 Resistor (lamp) V-1
(head lamp R.H.)
Intermediate connector
HD2 SWP 6 (head lamp L.H.) E-1 RE7 — 1 Resistor (Hi beam) V-1
HD3 AMP 3 Head lamp F-1 RE8 — 1 Resistor (Hi beam) U-1
HN1 — 1 Horn valve D-1 RH1 Terminal 1 Retarder oil temperature gauge (B) B-5
HN2 — 1 Horn valve D-1 RH1 Terminal 1 Electrical intake air heater relay (B) D-9
HS — 1 Horn button K-2 RH2 Terminal 1 Retarder oil temperature gauge (T) O-5
R-8
LPS Mitsubishi 2 L clutch SOL N-4 RH2 Terminal 1 Electrical intake air heater relay (SW) D-9
LSW X 1 L fill switch N-4 RH3 — 1 Retarder oil temperature gauge O-7
(lighting)
L/C.PS Mitsubishi 2 Torque converter lock-up SOL O-3 RH3 Terminal 1 Electrical intake air heater relay (C) O-9
L/C.SW X 1 Torque converter lock-up switch M-4 RL1 — 1 Fuse R-4
LPS X 1 Low-pressure switch V-8 RLS X 1 Retarder lamp pressure switch X-8
Retarder oil temperature alarm
MNO Terminal 1 Circuit breaker A-7 ROTA — 1 sensor A-5
MNP Terminal 1 Circuit breaker A-7 ROTS — 1 Retarder oil temperature sensor A-5
N1 X 2 Input shaft speed sensor N-1 RT2 Terminal 1 AUT.EM steering relay (opt) Q-1
N2 X 2 Intermediate shaft speed sensor O-1 RT6 — 1 AUT.EM steering (opt) P-2
N3 X 2 Output shaft speed sensor O-3 RT7 Terminal 1 AUT.EM steering relay (opt) Q-1
PBS X 2 Parking pressure switch X-7 RT8 Terminal 1 AUT.EM steering relay (opt) Q-1
PH PA 7 Preheating switch P-9 S1 SWP 14 Shift indicator M-6

PM1 — 1 Payload meter P-4 SB1 Terminal 1 Starting motor A-5
PM2 — 1 Payload meter P-5 SER1 Terminal 1 Emergency steering relay (BR) A-7
PM3 — 1 Payload meter R-4 SER2 Terminal 1 Emergency steering relay (BR) B-8
PM4 — 1 Payload meter R-4 SBS X 2 Foot brake pressure switch X-8
R.PS Mitsubishi 2 R clutch SOL N-4 SE1 Terminal 1 EM.ST relay A-6
R.SW X 1 R fill switch O-4 SE2 Terminal 1 Emergency steering relay (E) B-8
R1-1 Terminal 1 Starting switch (R1) P-9 SF S 12 Transmission shift lever U-9
R1-2 Terminal 1 Starting switch (R1) P-9 SLL — 1 Side lamp H-9
RA1 — 1 Radio O-8 SLR. — 1 Side lamp I-9

RA2 — 1 Radio N-8 SM1 Terminal 1 Emergency steering relay (M) A-7
RA3 PA 9 Radio N-8 SMR — 1 Service meter R-7
RA5 — 1 Speaker K-3 SP1 — 1 Fuse M-7
20-216 HD255-5
4
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
HD255-5 20-219-2
4

Serial No.: 1201 – 1599
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
100 Shinagawa 4 Intermediate connector S-7 ACP1 AMP 16 Air conditioner control panel —
101 SWP 16 Intermediate connector S-8 ACP2 AMP 12 Air conditioner control panel —
102 SWP 16 Intermediate connector S-8 ACPS Sumitomo 2 Air conditioner pressure switch R-7
103 SWP 16 Intermediate connector T-8 ACR1 AMP 4 Air conditioner blower main relay R-7
104 SWP 16 Intermediate connector T-9 ACR2 AMP 4 Air conditioner blower Hi relay R-7
105 M 3 Timer S-7 ACR3 AMP 4 Air conditioner blower M2 relay R-7
108 SWP 8 Intermediate connector E-1, Air conditioner blower M1 relay R-6
D-9 ACR4 AMP 4
109 SWP 16 Intermediate connector E-1, Air conditioner compressor relay R-6
D-9 ACR5 AMP 4
111 SWP 12 Intermediate connector F-1, Air conditioner pressure switch D-1
Q-9 ACRD SWP 2
112 M 2 Buzzer Q-4 ACRE AMP 4 Air conditioner blower resistor Q-8
113 M 2 Central warning lamp Q-4 ACTH AMP 2 Air conditioner thermistor R-8
114 S 10 Pilot lamp group O-3 1-pin Air dryer D-9

AD1 connector 1
115 KES1 6 Turn signal pilot lamp P-3 AE1 Terminal 1 Alternator (Terminal E) A-3
116 S 8 Light combination switch R-5 AE2 Terminal 1 Chassis ground B-2
117 — 7 Preheater switch M-5 1-pin Air pressure gauge P-2

AP1 connector 1
118 — 7 Exhaust brake switch M-5 AP2 Terminal 1 Air pressure gauge Q-2
119 — 7 Fog lamp switch N-4 AR1 Terminal 1 Alternator (Terminal R) A-3
120 — 7 Beacon lamp switch O-3 AR2 Terminal 1 Alternator (Terminal R) A-3
121 — 7 Hazard lamp switch N-6 AR3 Terminal 1 Alternator (Terminal R) A-3
301 SWP 6 Rear combination lamp (L.H.) L-6 ARS X 2 Auto-retarder solenoid valve F-9
302 SWP 6 Intermediate connector J-9 1-pin Intermediate connector —

ACU connector 1
303 SWP 6 Rear combination lamp (R.H.) J-9 B1 Terminal 1 Starting switch (Terminal B) M-7
1.PS Mitsubishi 2 Transmission 1st clutch solenoid W-4 B1 KES1 1 Failure mode memory cancel switch V-5
1.SW X 1 Transmission 1st clutch fill switch X-4 B2 KES1 1 Failure mode memory cancel switch W-5
2.PS Mitsubishi 2 Transmission 2nd clutch solenoid W-4 B2 Terminal 1 Starting switch (Terminal B) M-7
2.SW X 1 Transmission 2nd clutch fill switch X-4 1-pin Backup alarm K-9
BA connector 1
3.PS Mitsubishi 2 Transmission 3rd clutch solenoid W-4 BCG Terminal 1 Chassis ground C-9
3.SW X 1 Transmission 3rd clutch fill switch X-3 BCS1 X 2 Rear brake chamber stroke sensor C-9
A1 KES1 1 Emergency travel switch V-4 BCS2 X 2 Rear brake chamber stroke sensor C-9
A2 KES1 1 Emergency travel switch W-5 BL Terminal 1 Back-up lamp K-8

AB1 Terminal 1 Alternator (Terminal B) A-3 1-pin Beacon lamp A-4
BL4 connector 1
1-pin
AC1 connector 1 Intermediate connector M-6 BNC Terminal 1 Battery relay (Terminal B) B-8
ACBM Yazaki 2 Blower motor Q-8 BR Terminal 1 Starting switch (Terminal BR) M-7
ACC1 Terminal 1 Starting switch (ACC terminal) M-7 BR Terminal 1 Battery relay (Terminal BR) A-7
Air conditioner servo motor
ACM1 AMP 2 (for adjusting temperature) R-7 BRM Terminal 1 Battery relay (Terminal M) A-8
Air conditioner servo motor
ACM2 — 5 (for selecting vent mode) — BRN Terminal 1 Battery relay (Terminal M) A-8
Air conditioner servo motor 1-pin
ACM3 AMP 5 (for selecting FRESH/RECIRC) R-6 BS connector 1 Intermediate connector O-3
20-219-3 HD255-5
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
HD3 AMP 3 Head lamp D-1 R13 Socket 5 Engine starting relay X-8
1-pin
HN1 connector 1 Horn valve C-1 R14 Socket 5 Neutral caution detection relay X-8
1-pin
HN2 connector 1 Horn valve C-1 R15 Socket 6 Parking caution, dump caution relay X-8
1-pin
HS connector 1 Horn switch O-9 R16 Socket 5 Parking relay W-9
H.PS Mitsubishi 2 Transmission Hi clutch solenoid V-4 R17 Socket 6 Rear brake pilot relay X-9
H.SW X 1 Transmission Hi clutch fill switch V-3 R18 Socket 5 Service brake relay X-8
LPS X 2 Low-pressure switch F-9 R19 Socket 5 Back alarm relay X-8
L.PS Mitsubishi 2 Transmission Lo clutch solenoid W-4 R20 Socket 5 Transmission cut relay X-8
Rear brake chamber stroke
L.SW X 1 Transmission Lo clutch fill switch V-4 R21 Socket 5 sensor relay V-8
L/C.PS Mitsubishi 2 Torque converter lock-up solenoid X-3 R22 Socket 5 Brake oil level relay V-8
L/C.SW X 1 Torque converter lock-up fill switch V-4 R23 Socket 5 Hydraulic filter caution relay V-8
MNO Terminal 1 Circuit breaker A-6 R24 Socket 5 Beacon lamp relay V-8
1-pin
MNP Terminal 1 Circuit breaker A-6 RA1 connector 1 Intermediate connector M-6
1-pin
N1 X 2 Input shaft speed sensor W-1 RA2 connector 1 Intermediate connector M-6
N2 X 2 Intermediate shaft speed sensor W-1 RA3 PA 9 Radio M-7

1-pin
N3 X 2 Output shaft speed sensor X-3 RA4 connector 1 Right speaker P-9
1-pin
PBS X 2 Parking brake pressure switch H-9 RA5 connector 1 Left speaker —
1-pin Intermediate connector 1-pin
PM1 connector 1 (for payload meter) — RA6 connector 1 Right speaker P-9
PM2 connector 1 (for payload meter) — RA7 connector 1 Left speaker —
1-pin Intermediate connector
PM3 connector 1 (for payload meter) — RA8 Terminal 1 Chassis ground —
PM4 connector 1 (for payload meter) — RA10 connector 1 Left speaker R-5
1-pin
R.PS Mitsubishi 2 Transmission R clutch solenoid W-4 RA11 connector 1 Left speaker R-5
R.SW X 1 Transmission R clutch fill switch X-4 RE1 Terminal 1 Resistor (150 Ω) P-4
R1-1 Terminal 1 Starting switch (Terminal R1) M-7 RE2 Terminal 1 Resistor (150 Ω) P-4
R1-2 Terminal 1 Starting switch (Terminal R1) M-7 RE3 Terminal 1 Resistor (13 Ω) S-7
R01 Socket 5 Engine stop relay W-8 RE4 Terminal 1 Resistor (13 Ω) S-7
R02 Socket 6 Head lamp relay W-8 RE5 Terminal 1 Resistor (117 Ω) S-6
R03 Socket 6 Head lamp relay (Hi) W-8 RE6 Terminal 1 Resistor (117 Ω) S-6
R04 Socket 6 Head lamp relay (Lo) W-8 RE7 Terminal 1 Resistor (117 Ω) S-6
R05 Socket 5 Battery charge relay X-8 RE8 Terminal 1 Resistor (117 Ω) S-6
R06 Socket 5 Head lamp relay W-8 RH1 Terminal 1 Retarder oil temperature gauge O-1
Electrical intake air heater relay
R07 Socket 6 Marker lamp relay W-8 RH1 Terminal 1 (Terminal B) A-6
R08 Socket 5 Marker lamp relay W-8 RH2 Terminal 1 Retarder oil temperature gauge P-1
R09 Socket 5 Hazard lamp relay X-8 RH2 Terminal 1 (Terminal SW) A-8
1-pin
R10 Socket 5 Fog lamp relay X-8 RH3 connector 1 Retarder oil temperature gauge Q-2
R11 Socket 5 Hazard lamp relay (R.H.) W-9 RH3 Terminal 1 (Terminal C) A-6
R12 Socket 5 Hazard lamp relay (L.H.) W-8 RH4 Terminal 1 Retarder oil temperature gauge O-1
20-219-5 HD255-5
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
1-pin
RJ1 Hiyoshi 8 Joint connector H-9 ST2 connector 1 Emergency steering switch U-1
1-pin
RJ2 Hiyoshi 8 Joint connector N-3 ST3 connector 1 Emergency steering switch U-1
RJ3 Hiyoshi 8 Joint connector Q-4 ST7 Terminal 1 Emergency steering switch —
1-pin
RJ4 Hiyoshi 8 Joint connector Q-5 TAC1 connector 1 Tachograph M-8
1-pin
RJ5 Hiyoshi 8 Joint connector N-5 TAC2 connector 1 Tachograph M-8
1-pin
RJ6 Hiyoshi 8 Joint connector O-3 TAC3 connector 1 Tachograph M-8
RJ7 Hiyoshi 8 Joint connector Q-5 TAC4 Terminal 1 Starting swich (Terminal B) M-8
Torque converter oil temperature
RJ8 Hiyoshi 8 Joint connector M-5 TC1 Terminal 1 gauge Q-1
RJ9 Hiyoshi 8 Joint connector N-4 TC2 Terminal 1 gauge Q-1
1-pin Torque converter oil temperature
RJ10 Hiyoshi 8 Joint connector M-4 TC3 connector 1 gauge Q-1
RJ11 Hiyoshi 8 Joint connector M-4 TC4 Terminal 1 gauge Q-2
RJ12 Hiyoshi 8 Joint connector H-9 TC.SE Terminal 1 sensor U-3
Torque converter inlet oil
RJ13 Hiyoshi 8 Joint connector A-5 T/C IN X 3 pressure sensor X-1
Torque converter outlet oil
RJ14 Hiyoshi 8 Joint connector A-5 T/C OUT X 3 pressure sensor X-2
RJ15 Hiyoshi 8 Joint connector — TM2 SWP 14 Intermediate connector V-1

RJ16 Hiyoshi 8 Joint connector B-3 TM3 SWP 14 Intermediate connector U-2
RJ17 Hiyoshi 8 Joint connector E-1 TM4 SWP 14 Intermediate connector U-2
1-pin
RL1 connector 1 Intermediate connector O-3 TMA — 16 Intermediate connector T-9
E-1
RLS X 2 Retarder lamp switch E-9 TMB SWP 16 Intermediate connector Q-9
RM1 Terminal 1 Tachometer N-1 WP1 S 8 Wiper switch O-9
1-pin Retarder oil temperature sensor
ROTA connector 1 A-4 WP2 KES1 6 Wiper motor M-5
(for alarm)
ROTS Terminal 1 Retarder oil temperature sensor A-4 WP3 KES0 6 Intermittent wiper relay Q-4
RT Terminal 8 Auto emergency steering relay U-8 WP4 Yazaki 2 Window washer motor S-2
S1 SWP 14 Shift indicator N-2

SB1 Terminal 1 Starting motor (Terminal B) A-3
SBR1 Terminal 1 Emergency steering unit L-4
SBS X 2 Foot brake switch F-9
SF S 12 Transmission shift lever U-3
1-pin
SLL connector 1 Side lamp (L.H.) C-9
1-pin
SLR connector 1 Side lamp (R.H.) B-8
SM1 Terminal 1 Speedometer O-1
SM1 Terminal 1 Emergency steering unit K-4
1-pin
SMR connector 1 Service meter N-8
1-pin
SP1 connector 1 Service power source N-2
SR1 X 3 Accelerator sensor N-4
SR1 X 3 Starting motor (Terminals S, R) A-5
1-pin
ST1 connector 1 Emergency steering switch U-2
HD255-5 20-219-6
4
CONNECTOR PIN ARRANGEMENT DIAGRAM

Serial No.: 1201 – 1599
20-219-7 HD255-5
(10)
HD255-5 20-219-8
4
Serial No.: 1201 – 1599
20-219-9 HD255-5
(10)
HD255-5 20-219-10
4

Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
1-pin
100 L 2 Intermediate connector S-8 AP1 connector 1 Air pressure gauge R-3
101 SWP 16 Intermediate connector S-9 AP2 Terminal 1 Air pressure gauge R-2
102 SWP 16 Intermediate connector S-9 APS — 2 Engine overrun protection solenoid —
103 SWP 16 Intermediate connector S-9 AR1 Terminal 1 Alternator (terminal R) A-3
104 SWP 16 Intermediate connector T-9 AR2 Terminal 1 Alternator (terminal R) A-3
108 SWP 16 Intermediate connector N-4 AR3 Terminal 1 Alternator (terminal R) A-3
109 SWP 16 Intermediate connector Q-3 ARS X 2 Auto-retarder solenoid valve F-9
111 SWP 12 Intermediate connector F-1 B79 Terminal 1 Intake air heater AD-6
112 M 2 Buzzer Q-4 B1 Terminal 1 Starting switch (terminal B) M-1

113 M 2 Centralized caution lamp Q-4 B1 KES1 1 Error mode memory cancel switch V-9
114 S 10 Pilot lamp group Q-8 B2 KES1 1 Error mode memory cancel switch V-8
115 KES 6 Turn signal pilot lamp Q-3 B2 Terminal 1 Starting switch (terminal B) M-1
116 S 8 Light combination switch P-9 1-pin Backup alarm K-8
BA connector 1
118 — 7 Exhaust brake switch O-2 BCG Terminal 1 Chassis ground C-9
119 — 7 Fog lamp switch Q-9 BCS1 X 2 Rear brake chamber stroke sensor C-9
120 — 7 Beacon lamp switch Q-9 BCS2 X 2 Rear brake chamber stroke sensor C-9
121 — 7 Hazard lamp switch M-3 BL Terminal 1 Backup lamp K-8
122 X 4 Intermediate connector S-8 1-pin Beacon lamp (If equipped) A-4
BL4 connector 1
301 SWP 6 Combination lamp (left) L-6 BNC Terminal 1 Battery relay (terminal B) B-8
302 SWP 6 Intermediate connector J-9 BR Terminal 1 Starting switch (terminal BR) M-1
303 SWP 6 Combination lamp (right) J-9 BR Terminal 1 Battery relay (terminal BR) A-7
1.PS Mitsubishi 2 Transmission 1st clutch solenoid W-4 BRM Terminal 1 Battery relay (terminal M) A-8
1.SW X 1 Transmission 1st clutch fill switch X-4 BRN Terminal 1 Battery relay (terminal M) A-8
2.PS Mitsubishi 2 Transmission 2nd clutch solenoid W-4 1-pin Intermediate connector Q-3
BS connector 2
2.SW X 1 Transmission 2nd clutch fill switch X-4 C Terminal 1 Starting switch (terminal C) M-1
3.PS Mitsubishi 2 Transmission 3rd clutch solenoid W-4 C1 SWP 14 Shift indicator controller U-2
3.SW X 1 Transmission 3rd clutch fill switch X-3 C2 SWP 14 Shift indicator controller U-2
A1 KES1 1 Emergency escape switch V-9 C3 SWP 14 Shift indicator controller U-2
A2 KES1 1 Emergency escape switch V-9 C23 Terminal 1 Intake air heater AC-7
AB1 Terminal 1 Alternator (terminal B) A-3 1-pin Cigarette lighter Q-4

CG1 connector 1
Intermediate connector 1-pin
AC1 — 18 (air conditioner) R-8 CG2 connector 1 Cigarette lighter Q-4
AC2 — 8 Air conditioner panel M-6 CN1 MIC 17 Transmission controller W-8
ACC1 Terminal 1 Starting switch (terminal ACC) M-1 CN2 MIC 21 Transmission controller W-7
ACRD SWP 2 Air conditioner pressure switch P-1 CN31 AMP040 20 Transmission controller V-8
1-pin
AD1 connector 1 Air drier D-9 CN32 AMP040 16 Transmission controller V-8
AE1 Terminal 1 Alternator (terminal E) A-3 CN51 AMP040 20 Transmission controller W-8
AE2 Terminal 1 Chassis ground (alternator) B-2 CN52 AMP040 16 Transmission controller W-8
20-219-11 HD255-5
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
CN1 AMP070 12 Engine controller T-9 ESW X 2 Auto-emergency steering flow switch H-2
CN2 AMP070 18 Engine controller U-9 EW1 Terminal 1 Engine coolant temperature gauge P-1
CN4 AMP070 20 Engine controller U-9 EW2 Terminal 1 Engine coolant temperature gauge Q-1
1-pin
CN6 AMP070 10 Engine controller U-9 EW3 connector 1 Engine coolant temperature gauge R-3
CN7 AMP070 14 Engine controller T-9 EW4 Terminal 1 Engine coolant temperature gauge Q-3
CN1 DT 2 Injector A Z-6 EWTS Terminal 1 Engine coolant temperature gauge sensor A-5
CN2 DT 2 Injector E Z-7 EXH1 X 2 Exhaust brake solenoid valve B-8
CN3 DT 2 Injector C AA-7 EXH2 Terminal 1 Chassis ground B-8
CN4 DT 2 Injector F AA-7 FB1 — Fuse box U-9

CN5 DT 2 Injector B AB-7 FB2 — Fuse box T-9
CN6 DT 2 Injector D AC-7 FBT X 2 Brake fluid level sensor D-9
COMP SWP 1 Air conditioner compressor C-2 FG1 Terminal 1 Fuel gauge P-2
1-pin
C/V.T X 2 Transmission oil temperature sensor X-3 FG1 connector 1 Right fog lamp A-4
D01 KES1 2 Diode X-9 FG1 Terminal 1 Fuel level sensor J-3
D02 KES1 2 Diode X-8 FG2 Terminal 1 Fuel level sensor K-3
1-pin
D03 KES1 2 Diode C-2 FG2 connector 1 Left fog lamp D-1
D04 KES1 2 Diode — FG2 Terminal 1 Fuel level gauge P-2
D05 KES1 2 Diode X-9 FG3 1-pin 1 Fuel gauge P-3

connector
D06 KES1 2 Diode X-8 FG4 Terminal 1 Fuel gauge P-3
D07 KES1 2 Diode X-9 FU KES1 2 Fuse unit B-8
1-pin
D10 KES1 2 Diode B-2 FUB connector 1 Flasher unit P-4
1-pin
D11 KES1 2 Diode W-8 FUL connector 1 Flasher unit P-4
D12 KES1 2 Diode W-9 G — 2 G sensor AB-2
D13 KES1 2 Diode W-8 G1 Terminal 1 Chassis ground M-3

D14 KES1 2 Diode W-9 G2 Terminal 1 Chassis ground S-7
D010 KES1 2 Diode A-7 G3 Terminal 1 Chassis ground M-3
1-pin
DB1 connector 1 Dump buzzer switch (If equipped) S-7 GND Terminal 1 Chassis ground E-1
1-pin
DB2 connector 1 Dump buzzer switch (If equipped) S-7 GND Terminal 1 Chassis ground A-5
E Terminal 1 Battery relay (terminal E) A-7 GND1 Terminal 1 Chassis ground L-7
E12 X 2 Engine speed sensor AD-5 GND2 Terminal 1 Chassis ground I-2
EBS X 2 Emergency brake switch E-9 GND3 Terminal 1 Chassis ground A-7
ECA S 16 Intermediate connector R-5 GND4 Terminal 1 Chassis ground D-9
ECB SWP 6 Intermediate connector S-8, GND6 Terminal 1 Chassis ground N-8
R-5
ECC X 4 Intermediate connector Q-8 GND7 Terminal 1 Chassis ground E-9
1-pin
EG1 connector 1 Engine caution lamp P-2 HD1 SWP 6 Intermediate connector A-4
1-pin
EG2 connector 1 Engine caution lamp P-2 HD2 SWP 6 Intermediate connector D-1
EMP1 — 1 Emergency steering pilot lamp M-2 HD3 AMP 3 Head lamp A-5
1-pin
EMP2 connector 1 Emergency steering pilot lamp M-2 HD3 AMP 3 Head lamp D-1
ER2 HD24 31 (Controller - Engine) AC-7 HEAT1 connector 1 Pre-heater pilot lamp N-1
ER3 HD24 31 (Controller - Engine) AD-6 HEAT2 connector 1 Pre-heater pilot lamp N-1
HD255-5 20-219-12
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
HN1 — 2 Horn valve C-2 R04 Relay 6 Headlamp relay W-5
HN2 — 2 Horn valve C-1 R05 Relay 5 Battery charge relay W-5
H.PS Mitsubishi 2 Transmission Hi clutch solenoid valve V-3 R06 Relay 5 Headlamp relay W-5
H.SW X 1 Transmission Hi clutch fill switch V-3 R07 Relay 6 Marker lamp relay W-5
1-pin
HS connector 1 Horn switch O-9 R08 Relay 5 Marker lamp relay W-5
JCE DT-T 8 Joint connector — R09 Relay 5 Hazard lamp relay W-5
LPS X 2 Low pressure switch F-9 R10 Relay 5 Fog lamp relay (If equipped) X-5
L.PS Mitsubishi 2 Transmission Lo clutch solenoid valve W-4 R11 Relay 5 Hazard relay (R) (If equipped) W-5
L.SW X 1 Transmission Lo clutch fill switch V-4 R12 Relay 5 Hazard relay (L) (If equipped) W-5
Torque converter lockup clutch
L/C.PS Mitsubishi 2 solenoid valve X-3 R13 Relay 5 Engine starting relay X-5
L/C.SW X 2 Torque converter lockup clutch fill switch V-4 R14 Relay 5 Neutral caution detection relay X-5
MC1-F M 1 Memory cancel connector T-6 R15 Relay 6 Parking caution and dump caution relay X-5
MC2-M M 1 Memory cancel connector T-6 R16 Relay 5 Parking brake relay W-5
MNO Terminal 1 Circuit breaker A-6 R17 Relay 6 Rear brake pilot relay W-5
MNP Terminal 1 Circuit breaker A-6 R18 Relay 5 Service brake relay X-5
MS11-F M 1 Model selection T-5 R19 Relay 5 Backup alarm relay X-5
MS12-M M 1 Model selection T-5 R20 Relay 5 Transmission cutout relay X-5
MS21-F M 1 Model selection U-5 R21 Relay 5 Rear brake chamber stroke sensor X-5
MS22-M M 1 Model selection U-5 R22 Relay 5 Brake fluid level relay X-5
MS31-F M 1 Model selection T-5 R23 Relay 5 Power supply relay X-5
MS32-M M 1 Model selection T-5 R24 Relay 5 Beacon lamp relay (If equipped) X-4
N1 X 2 Transmission input shaft speed sensor W-1 R25 Relay 5 Pre-heater relay X-4
Transmission intermediate shaft
N2 X 2 speed sensor W-1 R26 Relay 5 Transmission filter clogging sensor relay X-5
Transmission output shaft speed sensor X-3 1-pin
N3 X 2 RA1 connector 1 Intermediate connector M-6
NE sensor 1-pin
NE — 2 AD-4 RA2 connector 1 Intermediate connector M-6
PBS X 2 Parking brake switch H-9 RA3 PA 9 Radio M-6
PCV1 DENSO 2 Supply pump 1 AB-2 RA4 1-pin 1 Right speaker P-9
connector
PCV2 DENSO 2 Supply pump 2 AB-3 RA5 1-pin 1 Left speaker R-6
connector
PFUEL — 3 Common rail pressure sensor AD-4 RA6 1-pin 1 Right speaker P-9
connector
PIM DENSO 3 Boost pressure sensor AD-6 RA7 1-pin 1 Left speaker R-6
connector
PLS — 2 Retarder lamp switch — RE1 Terminal 1 Resistor (150 Ω) P-4
1-pin Intermediate connector
PM1 connector 1 (for payload meter) — RE2 Terminal 1 Resistor (150 Ω) P-4
PM2 connector 1 (for payload meter) — RE3 connector 1 Resistor (13 Ω) T-6
PM3 connector 1 (for payload meter) — RE4 connector 1 Resistor (13 Ω) S-6
PM4 connector 1 (for payload meter) — RE5 connector 1 Resistor (117 Ω) S-6
1-pin 1-pin
PSH connector 1 Oil pressure switch Hi AA-2 RE6 connector 1 Resistor (117 Ω) S-6
1-pin 1-pin
PSL connector 1 Oil pressure switch Lo Z-2 RE7 connector 1 Resistor (117 Ω) S-6
1-pin
R01 Relay 5 Horn relay W-5 RE8 connector 1 Resistor (117 Ω) S-6
R02 Relay 6 Headlamp relay W-5 RH1 Terminal 1 Retarder oil temperature gauge Q-1
R03 Relay 6 Headlamp relay W-5 RH1 Terminal 1 Intake air heater relay (terminal B) A-6
20-219-13 HD255-5
(10)
Con- No. Con- No.

nector Connec-
Add- nector Connec-
Add-
No. ress No. ress
pins pins
1-pin
RH2 Terminal 1 Retarder oil temperature gauge Q-1 SP1 connector 1 Service power supply S-6
1-pin
RH3 connector 1 Retarder oil temperature gauge R-2 SR DT 2 Safety relay A-5
RH4 Terminal 1 Retarder oil temperature gauge Q-1 ST4 Terminal 1 Emergency steering switch N-3
1-pin
RJ1 S 8 Joint connector H-9 ST5 connector 1 Emergency steering switch N-3
RJ1 SWP 16 Joint connector N-4 ST5 Terminal 1 Emergency steering switch N-3
RJ2 S 8 Joint connector O-3 ST6 Terminal 1 Emergency steering switch N-3
RJ3 S 8 Joint connector Q-5 ST7 Terminal 1 Emergency steering switch N-3
RJ4 S 8 Joint connector R-5 SW22 Terminal 1 Intake air heater relay (Inlet of coil) AC-7
1-pin
RJ5 S 8 Joint connector O-3 TAC1 connector 1 Tachograph M-8
1-pin
RJ6 S 8 Joint connector O-3 TAC2 connector 1 Tachograph M-8
1-pin
RJ7 S 8 Joint connector R-5 TAC3 connector 1 Tachograph N-8
RJ8 S 8 Joint connector M-5 TAC4 Terminal 1 Starting switch (terminal B) M-1
RJ9 S 8 Joint connector N-4 TC1 Terminal 1 Torque converter oil temperature gauge R-1
RJ10 SWP 16 Joint connector M-5 TC2 Terminal 1 Torque converter oil temperature gauge R-1
1-pin
RJ11 SWP 16 Joint connector M-5 TC3 connector 1 Torque converter oil temperature gauge R-1
RJ12 SWP 16 Joint connector E-9 TC4 Terminal 1 Torque converter oil temperature gauge R-2
RJ13 SWP 16 Joint connector A-5 TC.SE Terminal 1 Torque converter oil temperature sensor U-3
RJ14 SWP 16 Joint connector A-5 T/C IN X 1 Torque converter oil temperature sensor X-1
RJ15 SWP 16 Joint connector A-6 T/C OUT X 3 Torque converter X-2
RJ16 SWP 16 Joint connector B-3 THL DT 3 Fuel temperature sensor AD-4
RJ17 S 8 Joint connector E-1 TM2 SWP 14 Intermediate connector V-1

RJM S 8 Joint connector R-6 TM3 SWP 14 Intermediate connector U-2
1-pin
RL1 connector 1 Intermediate connector (Room lamp) P-3 TM4 SWP 14 Intermediate connector U-2
RLS X 2 Retarder lamp switch E-9 TMA SWP 16 Intermediate connector S-8
RM1 — 3 Tachometer P-2 TMB SWP 16 Intermediate connector R-5
1-pin Retarder oil temperature sensor
ROTA connector 1 (for alarm) A-4 TMF X 2 Transmission filter clogging sensor I-2
Coolant temperature sensor
ROTS Terminal 1 Retarder oil temperature sensor A-5 TWH DT-T 2 (for high temperature) Y-6
Coolant temperature sensor
R.PS Mitsubishi 2 Transmission R clutch solenoid W-4 TWL DT-T 2 (for low temperature) AB-8
R.SW X 1 Transmission R clutch fill switch X-4 WAS1 DT-T 6 Acceleration sensor N-4
RT — 8 Emergency steering timer — WAS2 DT-T 3 Acceleration sensor N-4

S1 SWP 14 Shift indicator P-2 WP1 S 8 Wiper switch O-9
SB1 Terminal 1 Starting motor (terminal B) A-3 WP2 KES1 6 Wiper motor N-2
SBR1 Terminal 1 Emergency steering unit L-4 WP3 KES0 6 Intermittent wiper relay P-3
SBS X 2 Foot brake switch F-9 WP4 Yazaki 2 Windshield washer motor S-2
SF S 12 Transmission shift lever U-3
SH — 7 Shift limit switch M-2

1-pin
SLL connector 1 Side lamp (left) C-9
1-pin
SLR connector 1 Side lamp (right) C-8
SM1 Terminal 1 Speedometer P-1

SM1 Terminal 1 Emergency steering unit K-4
HD255-5 20-219-14
(10)
CONNECTOR PIN ARRANGEMENT DIAGRAM

20-219-15 HD255-5
(10)
HD255-5 20-219-16
(10)
20-219-17 HD255-5
(10)
HD255-5 20-219-18
(10)
20-219-19 HD255-5
(10)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
Num- X-Type Connector

ber of T-adapter Part
Pins Male (Female Housing) Female (Male Housing)
Number
1 Part Number: 08055-00181 Part Number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part Number: 08055-00282 Part Number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Grommet: black • Grommet: black
• Quantity: 20 pieces • Quantity: 20 pieces
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-220 HD255-5
(10)
Num- SWP-Type Connector

Number
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
HD255-5 20-221
(10)
Num- SWP-Type Connector

Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-222 HD255-5
(10)
Num- M-Type Connector

Number
1 Part Number: 08056-00171 Part Number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
3 BWP04719 BWP04720 799-601-7110
4 BWP04721 BWP04722 799-601-7120
6 BWP04723 BWP04724 799-601-7130
8 799-601-7340
BWP04725 BWP04726
HD255-5 20-223
(10)
Num- S-Type Connector

Number
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
(White) 799-601-7150
12 BWP04731 BWP04732 799-601-7350

(White)
16 BWP04733 BWP04734 799-601-7330

(White)
20-224 HD255-5
(10)
Num- S-Type Connector

Number
BWP04736
10 BWP04735 —
(Blue)
— —
12 BWP04737 BWP04738
(Blue) 799-601-7160
16 BWP04739 BWP04740 799-601-7170

(Blue)
HD255-5 20-225
(10)
Num- MIC-Type Connector

Number
Body Part Number: 79A-222-2640 Body Part Number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces) —
11 Body Part Number: 79A-222-2680 Body Part Number: 79A-222-2670 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-226 HD255-5
(10)
Num- MIC-Type Connector

Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

—
HD255-5 20-227
(10)
Num- AMP040-Type Connector

Number
BWP04752
BWP04751
8 799-601-7180
Housing Part Number:

—
79A-222-3430 (Quantity : 5 pieces)
BWP04753 BWP047544
12 799-601-7190

—
BWP04755 BWP04756
16 799-601-7210

—
BWP04757 BWP04758
20 799-601-7220

—
a Terminal Part Number: 79A-222-3470 (For all numbers of pins.)
20-228 HD255-5
(10)
AMP070-Type Connector
Num-
ber of
Pins T-adapter Part
Male (Female Housing) Female (Male Housing)
Number
BWP04760
10 BWP04759 799-601-7510
— Part Number: 08195-10210
BWP04761 BWP04762
12 799-601-7520
— Part Number: 08195-12210
BWP04763 BWP04764
14 799-601-7530
— Part Number: 08195-14210
18 BWP04765 BWP04766 799-601-7540
— Part Number: 08195-18210
BWP04767 BWP04768
20 799-601-7550
— Part Number: 08195-20210
HD255-5 20-229
(10)
Num- L-Type Connector

Number
BWP04770
2 BWP04769
— — —
Num- PA-Type Connector

Pins Male (Female Housing) Female (Male Housing) Number
BWP04772
9 BWP04771
— —
Num- BENDIX MS-Type Connector

Number
BWP04774
10 BWP04773 799-601-3460
— —
20-230 HD255-5
(10)
Num- KES1 Automobile-Type Connector

Number
BWP04776
BWP04775
2 —
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
HD255-5 20-230-1
(10)
Num- KES1 Automobile-Type Connector

Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
20-230-2 HD255-5
(10)
Num- Socket-Type Connector for Relay

Number
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
HD255-5 20-230-3
(10)
Num- F-Type Connector

Number
BWP04786
BWP04785
4 —
— —
20-230-4 HD255-5
(10)
The pin number is also marked on the connector (Electric wire insertion end).
Type HD30 Series Connector

(Shell
Size T-adapter Part
Body (Plug) Body (Receptacle)
Code) Number
Pin (Male Terminal) Pin (Female Terminal)
Part Number: 08191-11201, 08191-11202, Part Number: 08191-14101, 08191-14102,

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8
Pin (Female Terminal) Pin (Male Terminal) 799-601-9210
(1)

08191-12205, 08191-12206 08191-13105, 08191-13106

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
(2) Pin (Female Terminal) Pin (Male Terminal)
Part Number: 08191-22201, 08191-22202 Part Number: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
HD255-5 20-230-5
(10)

(Shell
Size T-adapter Part
Code) Number
18-20 Part Number: 08191-31201, 08191-31202 Part Number: 08191-34101, 08191-34102

(3) 799-601-9230
Pin (Female Terminal) Pin (Male Terminal)
Part Number: 08191-32201, 08191-32202 Part Number: 08191-33101, 08191-33102

18-21 Part Number: 08191-41201, 08191-42202 Part Number: 08191-44101, 08191-44102

799-601-9240
20-230-6 HD255-5
(10)

(Shell
Size T-adapter Part
Code) Number

24-9 (5) 799-601-9250
Pin (Female Terminal) Pin (Male Terminal)


24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
HD255-5 20-230-7
(10)

(Shell
Size T-adapter Part
Code) Number

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
Part Number: 08191-81201, 08191-81202, 08191- Part Number: 08191-84101, 08191-84102, 08191-
24-23 81203, 08191-81204, 08191-81205, 08191-81206 84103, 08191-84104, 08191-84105, 08191-84106
799-601-9280
Part Number: 08191-82201, 08191-82202, 08191- Part Number: 08191-83101, 08191-83102, 08191-
82203, 08191-82204, 08191-82205, 08191-82206 83103, 08191-83104, 08191-83105, 08191-83106
20-230-8 HD255-5
(10)

(Shell
Size T-adapter Part
Code) Number

24-31 08191-91205, 08191-91206 08191-94105,08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
HD255-5 20-230-9
(10)
No. DT Series Connector

of T-adapter Part
Pins Body (Plug) Body (Receptacle)
Number
2 799-601-9020
Part Number: 08192-12200 (Normal type) Part Number: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-230-10 HD255-5
(10)
No. DT Series Connector

of T-adapter Part
Number
8GR:799-601-9060
8B:799-601-9070
8
8G:799-601-9080
8BR:799-601-9080
Part Number: 08192-1820T (Normal type) Part Number: 08192-1810T (Normal type)
08192-2820T (Fine wire type) 08192-2810T (Fine wire type)
12GR:799-601-9110
12B:799-601-9120
12 12G:799-601-9130
12BR:799-601-9140
Part Number: 08192-1920T (Normal type) Part Number: 08192-1910T (Normal type)
08192-2920T (Fine wire type) 08192-2910T (Fine wire type)
HD255-5 20-230-11
(10)
No. DTM Series Connector

of T-adapter Part
Number
2 799-601-9000
No. DTHD Series Connector

of T-adapter Part
Number
Part Number: 08192-31200 (Contact size #12) Part Number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-230-12 HD255-5
(10)
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality
in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are
then used to decide which troubleshooting table (D-cc, G-cc, A-cc, E-cc, F-cc, C-cc, H-cc) matches
the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
1. When using judgement table for transmission controller and transmission related parts
• If an abnormality display is given on the self-diagnostic display, go to the troubleshooting code at
the bottom of the judgement table (A-cc).
(A b mark is put at the places where the failure mode and self-diagnostic display match.)
• If a problem has appeared but no abnormality display is given on the self-diagnostic display,
check for a point where the warning lamp (point with a c mark) matches the failure mode on the
judgement table.
If the display is normal, go to the troubleshooting code on the right side (D-cc or H-cc)
If the display is abnormal, go to the troubleshooting code at the bottom (A-cc or F-cc)
<Example>
Failure mode “Machine does not start”.
Procedure: Check if an abnormality display is given on the self-diagnostic display or if the num-
ber at the top of the controller is lighted up.
Judgement table for transmission controller and transmission related parts
(Hyou)
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,
TRANSMISSION RELATED PARTS
Self-diagnostic display (abnormal display) Panel
Power Neu- Con- T/M cut Rear Ex- Speed Clutch Model Trans- Accel- T/M Pres- Flow Pres- Pres-
source tral troller relay brake haust sensor slip selec- mis- erator valve sure detec- sure sure
Check item
sys- safety box system sole- brake system speed tor sion signal oil control tor control sensor
tem system noid sole- sensor signal shift system tem- valve valve sole- system
system noid system system lever pera- system system noid Re-
system system system Troubleshoot-
ture Shift tarder
system indica- brake ing code when
tor warn- no abnormal
1.0
. 0.3 . 0.6 0.8 0.9 1.1 2. A.1 0.7 1.7 1.9 3. 5. 7. 8. ing
display is given
0.1 0.4 1.2
1.3 ↑ 1.5 3. ↑ 9. ↑ lamp
0.2 0.5 6.0 1– 6,8 1.6 ↑ 1– 6,8 ↑ 1–4
6.1
No. Category Failure mode 6.2 1– 6,8 1– 6,8
6.3
1 Engine does not start (1) Engine does not start b b b D-2
(1) Does not start in any speed range b b b b b b b
Machine does not (2) Cannot start in R or D – L b bª b H-1
2 start
(3) After stopping and placing in N, it is impossible to start again b b
(1) Travels forward even when lever is at N b
—
Movement of ma- (2) Travel forward when lever is in R b
3 chine is abnormal
when starting (3) Starting shock is abnormally large b b b H-4
(4) Starts in F3 or above (starting when machine is stoppd) b —
(1) Suddenly shifts down b —
(2) Repeatedly shifts between certain speed ranges b b b H-2
(3) Will not shift from a certain speed range when traveling b b c —
(4) Engine stalls b H-3
Movement of ma-
4 chine is abnormal (5) Transmission shock is abnormally large b b b b H-4
during travel
(6) Brake is applied when traveling b b
(7) Abnormal display given when overrun speed is reached b —
(8) Retarder is being operated, but transmission im- c
mediately shifts up
(1) Transmission shifts to neutral when traveling, but it is
possible to start again with transmission shift lever at N b
Suddenly returns
5 to neutral when (2) Shifts to neutral when traveling, but impossible —
to start again b b b b b bª b
traveling
(3) Shifts to N when about to lock up b
Long time taken to (1) Shift up speed is too high

6 shift up H-5
(2) Long time taken to lock up b
(1) Lack of power at all speed ranges
7 No power (2) Lack of power at certain speed range b b H-6
(3) Does not lock up b
(1) Time lag is excessive when starting b
8 Excessive time lag (2) Takes time to shift gear b b H-7
(3) Takes time to shift from FORWARD to REVERSE b
Defective shift in- (1) Gearshifting is normal, but E display is given c

9 —
dicator display (2) Gearshifting is normal, but display is wrong c
Defective actua- (1) Exhaust brake does not work b

10 tion of exhaust Operation of exhaust brake and movement of ma- —
brake (2) b c
chine do not match
11
temperature is high (1) Torque converter oil temperature is high b H-8
Troubleshooting code when abnormal display is given A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13 A-14 A-15 A-16 A-13 F-1
A-14
In the case of [] display, for the display if A-13 b) only, measure the oil pressure of the clutch
ª – first, and if the oil pressure is normal, carry out troubleshooting of the electrical system.
, (The probability of the clutch slipping is high)
[Judgement]
If an abnormality display ( ) is given on the self-diagnostic display
... go to troubleshooting A-2 for the electrical system.
If no abnormality display is given on the self-diagnostic display, and the machine does not start:
• Check the warning lamp display — Go to troubleshooting H-1 of hydraulic system
HD255-5 20-231
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component

D-cc Troubleshooting of engine
G-cc Troubleshooting of engine controller system
ENG-cc Troubleshooting of engine electrical system
A-cc Troubleshooting of transmission controller system
E -cc Troubleshooting of meter panel system
F -cc Troubleshooting of pilot lamp system
C -cc Troubleshooting of machine air compressor air system
H-cc Troubleshooting of hydraulic, mechanical system
R -cc Troubleshooting of automatic speed controller system
2. Method of using troubleshooting table for each troubleshooting mode

(1) Troubleshooting code number and problem (for (1) - (4), see the examples on the next page.)
The title at the top of the troubleshooting chart gives the troubleshooting code and failure mode
(problem with the machine).
(2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according
to the model, component, or problem. In such cases, the failure mode (problem) is further di-
vided into sections marked with small letters (for example, a)), so go to the appropriate section to
carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item in the failure mode.
(3) Method of following troubleshooting chartYES
• Check or measure the item inside NO
, and according to the answer follow either the YES
line or the NO line to go to the next . (Note: The number written at the top right corner
of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy col-
umn on the right.
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
(4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when carrying
out the check inside the .
(5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
(6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin num-
ber. When carrying out troubleshooting, see this chart for details of the location for inspection
and measurement of the wiring connector CNcc appearing in the troubleshooting flow chart
for each failure mode (problem).
20-232 HD255-5
(10)
ACTION TAKEN BY TRANSMISSION CONTROLLER
TROUBLESHOOTING AND PROBLEMS ON MACHINE
Action of control- Symptoms that appear in ma-

Condition when normal : Check with tester chine when there is abnormal- Trouble-
ler when abnor- ity. Mechatronics abnormality shoot-
Voltage (V), current (A), resistance value Ω mality is detected display given, warning actuated ing code
1. CN1 (9), (17) – (8), (16) (V) : 20 – 30V Cannot control Suddenly shifts to
2. TMA (6), (8) – TMB (4) (V) : 20 – 30V  transmission neutral when trav-
 returns to  eling and cannot
3. 101 (1), (4) – TMB (4) (V) : 20 – 30V  neutral  start again
4. Fuse FB2 (14), (15) is not blown A-1a
Normal display of controller : 0.0 or 0.C Cannot control Suddenly shifts to

 transmission neutral when trav-
 returns to  eling and cannot A-1a
 neutral  start again
1. CN1 (9), (17) – (8), (16) (V) : 20 – 30V Places in neu- Suddenly shifts to
2. TMA (6), (8) – TMB (4) (V) : 20 – 30V tral neutral when trav-
eling and cannot
3. 101 (1), (4) – TMB (4) (V) : 20 – 30V start again
4. No looseness of terminals: alternator B, battery relay M, B, A-1b
battery (+)
1. Between CN2 (1),(12) - chassis : 20 – 30 V Places in neu- Suddenly shifts to

2. Between TMA (4) - chassis : 20 – 30 V tral neutral when trav-
eling and cannot A-1c
3. Between 18 (5) - chassis : 20 – 30 V start again
4. Between 18 (3) - chassis : 20 – 30 V
1. Starting switch at ON and transmission shift lever at N Places in neu- Sometimes re-
2. Connectors 101, TMA are securely inserted tral turns to neutral
when traveling,
but if transmission
shift lever is re-
turned to neutral, it A-2
is possible to start
again.
Normal display of controller: 0.0 or 0.C Places in neu- Suddenly shifts to

tral neutral when trav-
eling and cannot A-3a
start again
Transmission shift lever at N, and condition as in table below Ω Actuates trans- Suddenly shifts to
mission cut re- neutral when trav-
H.SW male – chassis TM3 male (3) – chassis CN51 female (12) – chassis lay and returns eling and cannot
Over 1
L.SW male – chassis TM3 male (6) – chassis CN51 female (10) – chassis MΩ or to neutral start again
over 1
R.SW male – chassis TM3 male (9) – chassis CN51 female (16) – chassis MΩ A-3b
1.SW male – chassis TM4 male (3) – chassis CN51 female (13) – chassis be-
tween
2.SW male – chassis TM4 male (6) – chassis CN51 female (14) – chassis termi-
nals
3.SW male – chassis TM4 male (9) – chassis CN51 female (15) – chassis
Places in neu- Suddenly shifts to

CN1 TMA 18 (V) Ω tral neutral when trav-
(15) – chassis (3) – chassis (1) – chassis 20 – 30 V — eling and cannot
start again A-4
Relay
— — (1) – (2) — 100 – 500Ω
HD255-5 20-239
(10)
Details of abnormality Check the wiring harnesses and equipment

Display Abnormal system given below : Disconnection, short circuit in wiring harness
code fl Judgment conditions
(+): Positive, (–): Negative
0.7 12V output circuit short cir- 1. (+) CN2 (14) – SF (1)
cuiting with ground
(shift lever power source) 2. Defective voltage circuit inside controller
fl 12V output terminal volt-
age: Below 6V
0.8 Automatic retarder solenoid 1. (+) CN1 (13) – TMB (6) – 115 (8) – ARS1
disconnection, short circuit, 2. (–) ARS2 – 115 (9) – 106 (3) – GND G2
short circuit with ground
fl Automatic retarder 3. (+) CN1 (4) – TMA (6), (8) – fuse FB2 (14), (15)
When operated: 4. Defective automatic retarder solenoid
Above 11V
When not operated:
Below 11V
0.9 Rear brake solenoid discon- 1. (+) CN1 (14) – TMB (5) – EXH1 (2)
nection, short circuit, short 2. (–) EXH (1) – GND EXH2
circuit with ground
fl Rear brake 3. (+) CN1 (5) – TMA (6), (8) – fuse FB2 (14), (15)
When operated: 4. Defective exhaust brake solenoid
Above 11V
When not operated:
Below 11V
1.0 Defective engine speed sen- 1. Defective engine speed sensor system
sor output 1) E12 (1) – TMB (1) – CN31 (13)
flWhen engine speed is
less than 350 rpm, trans- 2) E12 (2) – TMB (2) – CN31 (14)
mission speed continues 2. Defective engine speed sensor system
at more than 500 rpm for
10 seconds
1.1 Disconnection in transmis- 1. Input shaft speed sensor system

sion input shaft speed sensor 1) N1 (1) – TM2 (3) – CN31 (2)
flWhen disconnection de-
tector is actuated and 2) N1 (2) – TM2 (4) – CN31 (14)
there is no sensor signal 2. Defective input shaft speed sensor
1.2 Disconnection in transmis- 1. Intermediate shaft speed sensor system

sion intermediate shaft speed 1) N2 (1) – TM2 (3) – CN31 (12)
sensor
flWhen disconnection de- 2) N2 (2) – TM2 (4) – CN31 (14)
tector is actuated and 2. Defective intermediate shaft speed sensor
there is no sensor signal
1.3 Disconnection in transmis- 1. Output shaft speed sensor system

sion output shaft speed sen- 1) N3 (1) – TM2 (5) – CN31 (3)
sor
tector is actuated and 2. Defective output shaft speed sensor
A-1 Defective model selection 1. CN52 (30), (31), (32) – TMB (4) – GND terminal 3
signal 2. Defective contact of connector CN52
flAfter starting switch is
turned ON, model selec-
tion signal from wiring
harness does not match
20-240 HD255-5
4

Set in order of 1. Shifts to speed

Shift lever priority range higher than
position CN52 SF (V)
If it is together position set by
with R, it is transmission shift A-10b
R (22) – chassis (3) – (2) lever.
N (23) – chassis (4) – (2) taken as N 2. Stays at neutral
and machine
D (24) – chassis (5) – (2)
cannot start
5 (25) – chassis (6) – (2) Below 1.0V
4 (26) – chassis (7) – (2) Position before 1. Shifts to speed
signal stopped range higher than
3 (27) – chassis (8) – (2) is held position set by
L (28) – chassis (9) – (2) transmission shift
lever.
When lever is not set to above positions 2. Stays at neutral
Between above terminals Over 15V and machine A-10c
cannot start
3. Impossible to shift
between FOR-
WARD and RE-
VERSE
1. 1. A u t o m a t i c 1. Transmission
CN32 SR1 (V) gearshifting shock becomes
(31) – chassis (2) – (3) 4.75 V is carried out large.
with normal
mode 2. Immediately
2. Adjustment of clearance of accelerator sensor mount 2. Control of shifts up when
clutch oil traveling down- A-11
Clearance between sensor lever and sensor stopper bolt hill
pressure is
• Low idling: 0.8 ± 0.1 mm carried out as
• High idling: 2.5 ± 0.1 mm for when ac-
celerator is
fully depressed
Clutch oil pres- Transmission

CN32 female TM4 female C/V.T male Ω sure is con- shock becomes
(16) – (29) (13) – (14) (1) – (2) trolled at low large.
1 KΩ – 500 KΩ tem per atur e A-12
(29) – chassis (13) – chassis (1) – chassis
mode
1. CN31 female Ω Places in 1. Suddenly shifts to

neutral neutral when trav-
(12) – (14) eling and cannot
start again
(12) – (14) 500 – 1,000 Ω 2. Power is lost
(3) – (14) when traveling, —
and transmission
Each terminal – chassis Over 1 M Ω repeatedly shifts
when traveling up-
2. See TESTING AND ADJUSTING OF TRANSMISSION hill
3. Transmission oil is not black enough to indicate abnormality
Normal display of controller: 0.0 or 0.C Places in Suddenly shifts to

start again
1. CN31 female (2) – (14): 500 – 1,000 Ω Places in See display code
2. See TESTING AND ADJUSTING OF TRANSMISSION, H clutch neutral Item 2.
Note: The problem in A-8b
Item 3 does not occur
2. See TESTING AND ADJUSTING OF TRANSMISSION, L clutch neutral Item 2.
Note: The problem in A-8c
2. See TESTING AND ADJUSTING OF TRANSMISSION, 1st clutch neutral Item 2. A-8c
HD255-5 20-243
(10)

2.5 Defective 2nd clutch or out- See display code Item 2.
put shaft speed sensor sys-
tem
2.6 Defective 3rd clutch or output See display code Item 2.

shaft speed sensor system
2.8 Defective R clutch or output See display code Item 2.

3. Defective pressure control 1. Dirt or dust caught in pressure control spool

valve system I
↑ fl When it is tried to disen-
2. Fill sensor switch system contact with ground, short circuit
1 – 6, 8 gage the clutch, the con- 1) H.SW – TM3 (3) – CN51 (12)
troller issues the com- 2) L.SW – TM3 (6) – CN51 (10)
mand, but the fill sensor 3) R.SW – TM3 (9) – CN51 (16)
signal is still given (clutch
engaged) 4) 1.SW – TM4 (3) – CN51 (13)
5) 2.SW – TM4 (6) – CN51 (14)
6) 3.SW – TM4 (9) – CN51 (15)
7) Lock-up SW – TH3 (10) – CN51 (17)
3.1 Defective lock-up clutch pres- 1) Dirt or dust caught in lock-up clutch pressure control spool
sure control valve system 2) Lock-up SW – TM3 (10) – CN51 (17)
3.2 Defective H clutch pressure 1) Dirt or dust caught in H clutch pressure control spool
control valve system 2) H.SW – TM3 (3) – CN51 (12)
3.3 Defective L clutch pressure 1) Dirt or dust caught in L clutch pressure control spool
control valve system 2) L.SW – TM3 (6) – CN51 (10)
3.4 Defective 1st clutch pressure 1) Dirt or dust caught in 1st clutch pressure control spool
control valve system 2) 1.SW – TM4 (3) – CN51 (13)
3.5 Defective 2nd clutch pressure 1) Dirt or dust caught in 2nd clutch pressure control spool
3.6 Defective 3rd clutch pressure 1) Dirt or dust caught in 3rd clutch pressure control spool
3.8 Defective R clutch pressure 1) Dirt or dust caught in R clutch pressure control spool
control valve system 2) R.SW – TM3 (9) – CN51 (16)
4. Defective pressure control Pressure control spool was stuck at side where clutch was disengaged
valve system II
↑ fl When it is tried to engage
1 – 6, 8 the clutch, the controller
issues the command, but
the fill sensor signal is not
given, and the clutch is
not engaged
20-244 HD255-5
(10)

1. T/C IN (1) – (2) (V) : 20 – 30 V Only gives self- Transmission

2. T/C IN (1) – (3) (V) : 0.5 – 4.5 V diagnostic dis- shock becomes
play; does not larger
take any action
1. T/C OUT (1) – (2) (V) : 20 – 30 V Only gives self- Transmission

diagnostic dis- shock becomes
2. T/C OUT (1) – (3) (V) : 0.5 – 4.5 V play; does not larger
take any action
—
When each speed range is engaged using the shift checker, the fill Even when a 1. Power is lost
sensor signal is given with the combinations shown in disconnection when traveling,
is detected, it and when shift-
Table 2 Solenoid valve check tries to send ing up, transmis-
Female CN2 Female CN2 Ω current to the sion immedi-
solenoid ately shifts down
(9) – (10) 30 – 80 Ω • This is be- again
(9) – (10) (2) – (13) cause there is • This frequently
(4) – (15)
no danger of happens when
damage to traveling uphill —
(3) – (13) 5 – 25 Ω the controller loaded
(5) – (15) even if there 2. Shift indicator
(7) – (17)
is a discon- display shows
nection “E”.
Resistance value between each terminal Over 1 MΩ
Each terminal – chassis Over 1 MΩ
Check with display code Item 9. in Table 2 See display See display code A-15
code Item 9. Item 9.
HD255-5 20-253
Serial No.: 1201 – 1599

. Defective controller power 1. Battery (+) – circuit breaker
source
fl Input voltage: Below 12V 2. Circuit breaker – 101 (1), (4)
Above 37V 3. (+) 100(1), (4) – FB2(14), (15) – TMA(6), (8)
fl Voltage of power source 4. (+) TMA(6), (8) – CN1(9), (17)
inside controller
5. (–) CN1 (8), (16) – TMB (4) – chassis ground
6. Defective alternator regulator
7. Defective power source circuit inside controller
. Controller box system Defective controller box

fl Watch dog timer actuated
0.1 Drop in controller voltage When controller power source has become weak
fl Input voltage: 1. Defective generation of electricity by alternator
Below 19.5V
2. Battery tends to become discharged
3. Defective charging circuit
1) Alternator terminal B – battery relay terminal M, B – battery (+)
2) Alternator terminal E – chassis
0.2 Drop in solenoid powersource Defective solenoid power source circuit

voltage 1. Defective transmission cut relay
fl Solenoid power source in-
put voltage: Below 19.5V 2. CN2 (1), (12) – TMA (4) – R20 (5), (3) (transmission cut relay) – fuse FB2
(15)
0.3 Neutral safety 1. Defective handling of machine

fl With starting switch ON 2. Defective controller power source system
shift lever at position
other than N 1) Defective insertion of circuit breaker, fuse FB2 (14), (15)
 There may also be sudden 2) Defective contact of connectors 100 (1),(4) and TMA (6), (8)
 there is defective contact
cut in power source [when
 of control power source
 and power is momentarily
 cut and comes on again 
0.4 Data error Defective controller box
fl Content of data has
changed
0.5 Double meshing of clutch 1. Defective control box

fl With double meshing of 2. Defective fill sensor switch
clutch, input of fill sensor
signal was detected 3. H.SW – TM3 (3) – CN51 (12)
• Actuated for 0.8 – 3.5 sec L.SW – TM3 (6) – CN51 (10)
R.SW – TM3 (9) – CN51 (16)
1.SW – TM4 (3) – CN51 (13)
2.SW – TM4 (6) – CN51 (14)
3.SW – TM4 (9) – CN51 (15)
0.6 Transmission cut relay discon- 1. Defective transmission cut relay R20
nection, short circuit, short cir- 2. CN1 (15) – TMA (3) – R20 (2), (1) (transmission cut relay) – fuse FB2 (10)
cuit with ground
fl Voltage at output terminal
of transmission cut relay
• When actuated: Above 11V
• When not actuated: Below 11V
20-254 HD255-5
(10)

3. 101 (1), (4) – TMB (4) (V) : 20 – 30V  returns to  eling and cannot

eling and cannot
 returns to  start again
A-1a
 neutral 
eling and cannot
3. 101 (1), (4) – TMB (4) (V) : 20 – 30V start again
battery (+)

3. Between R20 (5) - chassis : 20 – 30 V start again
4. Between R20 (3) - chassis : 20 – 30 V
when traveling,
but if transmission
shift lever is re-
again.

start again
Over 1
over 1
tween
nals

CN1 TMA R20 (V) Ω tral neutral when trav-
start again A-4
Relay
— — (1) – (2) — 100 – 500Ω
HD255-5 20-255
(10)

cuiting with ground
age: Below 6V
0.8 Automatic retarder solenoid 1. (+) CN1 (13) – TMB (6) – RJ2 (3), (2) – ARS(1)
disconnection, short circuit, 2. (–) ARS(2) – RJ1 (12), (15) – GND (1)
Above 11V
When not operated:
Below 11V
0.9 Rear brake solenoid discon- 1. (+) CN1 (14) – TMB (5) – RJ5 (15), (13) – EXH1 (2)
nection, short circuit, short 2. (–) EXH1 (1) – RJ5 (9), (10) – GND
circuit with ground
Above 11V
When not operated:
Below 11V
10 seconds


sensor

sor
A-1 Defective model selection 1. CN52 (30), (31), (32) – TMB (4) – GND
20-256 HD255-5
(10)


R (22) – chassis (3) – (2) lever.
N (23) – chassis (4) – (2) taken as N 2. Stays at neutral
and machine
D (24) – chassis (5) – (2)
cannot start
5 (25) – chassis (6) – (2) Below 1.0V
4 (26) – chassis (7) – (2) Position before 1. Shifts to speed
lever.
Between above terminals Over 15V and machine A-10c
cannot start
between FOR-
WARD and RE-
VERSE
CN32 SR1 (V) gearshifting shock becomes
with normal
mode 2. Immediately
Clearance between sensor lever and sensor stopper bolt hill
pressure is
celerator is
fully depressed

mode

start again
(12) – (14) 500 – 1,000 Ω 2. Power is lost
and transmission
when traveling up-

start again
HD255-5 20-259
(10)

tem



valve system I
engaged) 4) 1.SW – TM4 (3) – CN51 (13)
5) 2.SW – TM4 (6) – CN51 (14)
6) 3.SW – TM4 (9) – CN51 (15)
7) Lock-up SW – TH3 (10) – CN51 (17)
valve system II
not engaged
20-260 HD255-5
(10)

. Defective controller power 1. Battery relay (+) – circuit breaker
source
fl Input voltage: Below 12V 2. Circuit breaker – 100 (1)
Above 37V 3. (+) 100(1) – FB2 (8), (10) – TMA(6), (8)
fl Voltage of power source 4. (+) TMA(6), (8) – CN1(9), (17)
inside controller
5. (–) CN1 (8), (16) – TMB – (4) – RJ16 (5), (8)– chassis ground
6. Defective alternator regulator
7. Defective power source circuit inside controller
. Controller box system Defective controller box

fl Watch dog timer actuated
0.1 Drop in controller voltage When controller power source has become weak
fl Input voltage: 1. Defective generation of electricity by alternator
Below 19.5V
2. Battery tends to become discharged
3. Defective charging circuit
1) Alternator terminal B – battery relay terminal M, B – battery (+)
2) Alternator terminal E – chassis
0.2 Drop in solenoid powersource Defective solenoid power source circuit

voltage 1. Defective transmission cut relay
fl Solenoid power source in-
put voltage: Below 19.5V 2. CN2 (1), (12) – TMA (4) – R20 (5), (3) (transmission cut relay) – fuse FB2
(8), (10)
0.3 Neutral safety 1. Defective handling of machine

fl With starting switch ON 2. Defective controller power source system
shift lever at position
other than N 1) Defective insertion of circuit breaker, fuse FB2 (8), (10)
 There may also be sudden 2) Defective contact of connectors 100 (1) and TMA (6), (8)
 cut in power source [when
 there
of control power source
is defective contact
 and power is momentarily
 cut and comes on again 
0.4 Data error Defective controller box
fl Content of data has
changed
0.5 Double meshing of clutch 1. Defective control box

fl With double meshing of 2. Defective fill sensor switch
clutch, input of fill sensor
signal was detected 3. H.SW – TM3 (3) – CN51 (12)
• Actuated for 0.8 – 3.5 sec L.SW – TM3 (6) – CN51 (10)
R.SW – TM3 (9) – CN51 (16)
1.SW – TM4 (3) – CN51 (13)
2.SW – TM4 (6) – CN51 (14)
3.SW – TM4 (9) – CN51 (15)
0.6 Transmission cut relay discon- 1. Defective transmission cut relay R20
nection, short circuit, short cir- 2. CN1 (15) – TMA (3) – R20 (2), (1) (transmission cut relay) – fuse FB2 (8),
cuit with ground (10)
fl Voltage at output terminal
of transmission cut relay
• When actuated: Above 11V
• When not actuated: Below 11V
20-270 HD255-5
(10)

3. 100 (1) – TMB (4) (V) : 20 – 30V  returns to  eling and cannot

eling and cannot
 returns to  start again
A-1a
 neutral 
eling and cannot
3. 100 (1) – TMB (4) (V) : 20 – 30V start again
battery (+)

3. Between R20 (5) - chassis : 20 – 30 V start again
4. Between R20 (3) - chassis : 20 – 30 V
when traveling,
but if transmission
shift lever is re-
again.

start again
Over 1
over 1
tween
nals

CN1 TMA R20 (V) Ω tral neutral when trav-
start again A-4
Relay
— — (1) – (2) — 100 – 500Ω
HD255-5 20-271
(10)

cuiting with ground
age: Below 6V
0.8 Automatic retarder solenoid 1. (+) CN1 (13) – TMB (6) – ARS(1)
disconnection, short circuit, 2. (–) ARS(2) – RJ12 (12), (15) – GND (7)
Above 11V
When not operated:
Below 11V
0.9 Rear brake solenoid discon- 1. (+) CN1 (14) – TMB (5) – RJ5 (15), (13) – EXH (1)
nection, short circuit, short 2. (–) EXH1 (2) – RJ5 (9), (10) – GND
circuit with ground
Above 11V
When not operated:
Below 11V
10 seconds


sensor

sor
A-1 Defective model selection 1. CN52 (30), (31), (32) – TMB (4) – RJ16 (5), (8) – GND3
20-272 HD255-5
(10)

1. CN2 (14) – chassis : 12V 12V output cir- Suddenly shifts to

cuit OFF (does neutral when trav-
2. SF (1) – (2) : 12V not give +12V) eling and cannot A-10a
3. CN2 (14), SF (1) terminals -– chassis : Over 1 MΩ start again
1. CN1 (13) – chassis : 20 – 60 Ω Operation of Even when engine

2. ARS male (1) – (2) : 20 – 60 Ω overrun pre- speed exceeds
vention func- 2500 rpm and en-
3. CN1 (4) – CN1 (13) : 20 – 30 V tion stopped gine overruns,
brake to prevent A-5
overrun is not actu-
ated
1. CN1 (female) (14) – chassis : 20 – 60 Ω Operation of Even when accel-

2. EXH1 male (1) – (2) : 20 – 60 Ω exhaust brake erator pedal is re-
function stop- leased and retarder
3. CN1 (5) – CN1 (14) : 20 – 30 V ped lever is operated,
exhaust brake is A-6
not actuated.
1. CN31 female (13) – (14) : 500 – 1,000 Ω Holds the speed 1. Tr a n s m i s s i o n

2. CN31 female (13) – chassis : Over 1 MΩ range being does not shift.
used for travel 2. If transmission
3. E12 male (1) – (2) : 500 – 1,000 Ω When transmis- shift lever is re-
4. E12 male (1) – chassis : Over 1 MΩ sion shift lever turned to neu- A-7a
is at N, it holds tral, it is impos-
transmission at sible to start
neutral again.
3. Tachometer
stops.

used for travel 2. If transmission A-7b
3. N1 male (1) – (2) : 500 - 1,000 Ω When transmis- shift lever is re-
4. N1 male (1) – chassis : Over 1 MΩ sion shift lever turned to neu-
neutral again.

used for travel 2. If transmission A-7c
3. N2 male (1) – (2) : 500 – 1,000 Ω When transmis- shift lever is re-
4. N2 male (1) – chassis : Over 1 MΩ sion shift lever turned to neu-
neutral again.
1. CN31 female (3) – (14) : 500 – 1,000 Ω Holds the speed 1. If transmission
2. CN31 female (3) – chassis : Over 1 MΩ range being shift lever is re-
used for travel turned to neu- A-7d
3. N3 male (1) – (2) : 500 – 1,000 Ω When transmis- tral, it is impos-
4. N3 male (1) – chassis : Over 1 MΩ sion shift lever sible to start
is at N, it holds again.
transmission at
neutral
1. CN52 (30) – chassis : Max. 15 V If there is ab- When starting

2. CN52 (31) – chassis : Max. 15 V normality switch is turned
when starting ON, machine can- A-9
3. CN52 (32) – chassis : Max. 15 V switch is at not be started even
4. Connectors CN52 is inserted securely ON, transmis- when transmission
sion is held at is operated
neutral
HD255-5 20-273
(10)

1.5 Short circuit, short circuit 1. R CN52 (22) – SF (3)
with ground in lever signal
system N CN52 (23) – SF (4)
fl When two or more lever D CN52 (24) – SF (5)
signals are generated, 5 CN52 (25) – SF (6)
and this continues for 3
seconds 4 CN52 (26) – SF (7)
3 CN52 (27) – SF (8)
1.6 Disconnection in lever signal L CN52 (28) – SF (9)
system
fl When there is no lever GND CN31 (16) – SF (2)
signal for 3 seconds 2. Defective shift lever
1.7 Accelerator signal system 1. CN32 (31) – WAS2 (2)

Disconnection, defective ad- 2. Defective adjustment and clearance at sensor mount
justment of mount, link out of
position 3. Accelerator pedal, link damaged
fl Voltage between CN32 4. Defective accelerator sensor
(31) and chassis 5. Defective power source circuit for engine controller, accelerator
• Above 4.75 ± 0.1 V sensor
• Below 0.6 ± 0.1 V
1.9 Short circuit of transmission 1. (+) CN32 (29) – TM4 (13) – C/V.T (1)
valve oil temperature sensor 2. (–) CN32 (16) – TM4 (14) – C/V.T (2)
with ground
fl When transmission oil 3. Defective transmission valve oil temperature sensor
temperature sensor sig-
nal is more than 150˚C
2. Clutch slipping or defective 1. Input shaft speed sensor 1) N1 (1) – TM2 (1) – CN31 (2)
transmission speed sensor
↑ system
2) N1 (2) – TM2 (2) – CN31 (14)
1 – 6, 8 fl When the input shaft 2. Output shaft speed sensor 1) N3 (1) – TM2 (5) – CN31 (3)
speed, intermediate shaft 2) N3 (2) – TM2 (6) – CN31 (14)
speed, output shaft speed 3. One of following clutches worn or damaged: H, L, 1st, 2nd, 3rd, R
are converted and it is
found that there is an ab-
normality with the HL
clutch or speed clutch.
2.1 Defective lock-up clutch sys- 1) When display codes 6.0, 6.1, 6.2, 6.3 are displayed, see appropriate
tem display code
2) When display code is other than those in Item 1), see H-6.b (Defec-
tive torque converter lock-up)
2.2 Defective H clutch or input See display code Item 2.

2.3 Defective L clutch or input See display code Item 2.

2.4 Defective 1st clutch or output See display code Item 2.

20-274 HD255-5
(10)


R (22) – chassis (3) – (2) lever.
N (23) – chassis (4) – (2)
taken as N 2. Stays at neutral
and machine
D (24) – chassis (5) – (2) cannot start
5 (25) – chassis (6) – (2) Below 1.0V
4 (26) – chassis (7) – (2)
Position before 1. Shifts to speed
lever.
Between above terminals Over 15V A-10c
and machine
cannot start
between FOR-
WARD and RE-
VERSE
CN32 WAS2 (V) gearshifting shock becomes
with normal
mode 2. Immediately
Clearance between sensor lever and sensor stopper bolt
pressure is hill
celerator is
fully depressed

mode

start again
(12) – (14) 500 – 1,000 Ω 2. Power is lost
and transmission
when traveling up-

start again
HD255-5 20-275
(10)

tem



valve system I
engaged) 4) 1.SW – TM4 (3) – CN51 (13)
5) 2.SW – TM4 (6) – CN51 (14)
6) 3.SW – TM4 (9) – CN51 (15)
7) Lock-up SW – TH3 (10) – CN51 (17)
valve system II
not engaged
20-276 HD255-5
(10)

neutral Item 2. A-8c
2. See TESTING AND ADJUSTING OF TRANSMISSION, 2nd clutch
2. See TESTING AND ADJUSTING OF TRANSMISSION, 3rd clutch neutral Item 2. A-8c
2. See TESTING AND ADJUSTING OF TRANSMISSION, R clutch neutral Item 2. A-8c
Shift lever at N and condition as shown in table below Ω Places in Suddenly shifts to
H.SW male – chassis TM3 male (3) – chassis CN51 female (12) – chassis eling and cannot
L.SW male – chassis TM3 male (6) – chassis CN51 female (10) – chassis Over 1 start again
MΩ or
R.SW male – chassis TM3 male (9) – chassis CN51 female (16) – chassis over 1
1.SW male – chassis TM4 male (3) – chassis CN51 female (13) – chassis MΩ —
be-
2.SW male – chassis TM4 male (6) – chassis CN51 female (14) – chassis tween
termi-
3.SW male – chassis TM4 male (9) – chassis CN51 female (15) – chassis nals
L/C.SW male – chassis TM3 male (10) – chassis CN51 female (17) – chassis
Over 1 MΩ or Places in Suddenly shifts to

L/U.SW male – chassis TM3 male (10) – chassis CN51 female (17) – chassis over 1 MΩ neutral neutral when trav- A-13a
between each eling and cannot
terminal
start again

H.SW male – chassis TM3 male (3) – chassis CN51 female (12) – chassis over 1 MΩ neutral neutral when trav- A-13a
terminal
start again

L.SW male – chassis TM3 male (6) – chassis CN51 female (10) – chassis over 1 MΩ neutral neutral when trav- A-13a
terminal
start again

1.SW male – chassis TM4 male (3) – chassis CN51 female (13) – chassis over 1 MΩ neutral neutral when trav- A-13a
terminal start again

terminal
start again

terminal start again

R.SW male – chassis TM3 male (9) – chassis CN51 female (16) – chassis over 1 MΩ neutral neutral when trav- A-13a
terminal
start again
Controller normal display: 0.0 or 0.C Places in Suddenly shifts to

eling and cannot
start again
—
HD255-5 20-277
(10)

4.1 Defective lock-up clutch pres- Pressure control spool was stuck at side where clutch was disengaged
sure control valve system
4.2 Defective H clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
4.3 Defective L clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
4.4 Defective 1st clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
4.5 Defective 2nd clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
4.6 Defective 3rd clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
4.8 Defective R clutch pressure Pressure control spool was stuck at side where clutch was disengaged
control valve
5. Disconnection in flow detec- 1. Disconnection in fill sensor switch system

↑ tion valve system 1) H.SW – TM3 (3) – CN51 (12)
fl When it is tried to engage
1 – 6, 8 the clutch, the controller 2) L.SW – TM3 (6) – CN51 (10)
issues the command, but 3) R.SW – TM3 (9) – CN51 (16)
the fill sensor signal is 4) 1.SW – TM4 (3) – CN51 (13)
not given. However, the
clutch is engaged. 5) 2.SW – TM4 (6) – CN51 (14)
6) 3.SW – TM4 (9) – CN51 (15)
7) L/C.SW – TM3 (10) – CN51 (17)
2. Defective fill sensor switch
5.1 Defective lock-up clutch flow 1. lock-up SW – TM3 (10) – CN51 (17)
control valve system 2. Defective lock-up clutch fill sensor switch
5.2 Defective H clutch flow con- 1. H.SW – TM3 (3) – CN51 (12)
trol valve system 2. Defective H clutch fill sensor switch
20-278 HD255-5
(10)


eling and cannot A-13b
start again

start again

start again

start again

start again

start again

start again
When each speed range is engaged using the shift checker, the fill Holds the 1. Tr a n s m i s s i o n
sensor signal is given with the combinations shown in Table 1 speed range does not shift
Table 1 Relationship between speed range being used for when traveling.
and fill sensor signal travel. 2. If transmission
When transmi- shift lever is re-
H L 1 2 3 R ssion shift le- turned to neu-
R c c ver is at N, it tral, it is impos-
F1 c c holds transmi- sible to start
ssion at neutral again. —
F2 c c
F3 c c
F4 c c
F5 c c
F6 c c
Controller normal display: 0.0 or 0.C Holds the speed 1. Transmission does
ra n g e b e i n g not shift when
used for travel traveling.
When transmis- 2. If transmission A-14
sion shift lever is shift lever is re-
at N, it holds turned to neutral, it
transmission at is impossible to
neutral start again.
When each speed range is engaged using the shift checker, the fill See display 1. Transmission does
sensor signal is given with the combinations shown in Table 1 code Item 5. not shift when
traveling.
2. If transmission
shift lever is re- A-14
turned to neutral, it
is impossible to
start again.
HD255-5 20-279
(10)

5.3 Defective L clutch flow con- 1. L.SW – TM3 (6) – CN51 (10)
trol valve system
2. Defective L clutch fill sensor switch
5.4 Defective 1st clutch flow con- 1. 1.SW – TM4 (3) – CN51 (13)
trol valve system 2. Defective 1st clutch fill sensor switch
5.5 Defective 2nd clutch flow 1. 2.SW – TM4 (6) – CN51 (14)
control valve system 2. Defective 2nd clutch fill sensor switch
5.6 Defective 3rd clutch flow con- 1. 3.SW – TM4 (9) – CN51 (15)
trol valve system 2. Defective 3rd clutch fill sensor switch
5.8 Defective R clutch flow con- 1. R.SW – TM3 (9) – CN51 (16)
trol valve system 2. Defective R clutch fill sensor switch
6.0 Defective engine speed sen- 1. Engine speed sensor system

fl When it is found that
there is abnormality in 2) E12 (2) – TMB (2) – CN31 (14)
engine speed, torque 2. Defective engine speed sensor
converter inlet port pres-
sure, outlet port pressure
6.1 Defective transmission input 1. Input shaft speed sensor system
shaft speed sensor output 1) N1 (1) – TM2 (1) – CN31 (2)
flWhen the engine speed,
input shaft speed, and in- 2) N1 (2) – TM2 (2) – CN31 (14)
termediate shaft speed 2. Defective input shaft speed sensor
are converted and it is
found that there is abnor-
mality in lock-up clutch
and HL clutch
6.2 Defective output of transmis- 1. Intermediate shaft speed sensor system
sensor
flWhen the input shaft 2) N2 (2) – TM2 (4) – CN31 (14)
speed, intermediate shaft 2. Defective intermediate shaft speed sensor
speed, and output shaft
speed are converted and
it is found that there is
abnormality in HL clutch
and speed clutch
20-280 HD255-5
(10)

traveling.
2. If transmission
is impossible to
start again.
traveling.
2. If transmission
is impossible to
start again.
traveling.
2. If transmission
is impossible to
start again.
traveling.
2. If transmission
is impossible to
start again.
traveling.
2. If transmission
is impossible to
start again.
1. CN31 female (13) – (14) : 500 – 1,000 Ω Holds the speed 1. Transmission does
range being not shift.
2. CN31 female (13) – chassis : Over 1 MΩ used for travel 2. If transmission
3. E12 male (1) – (2) : 500 – 1,000 Ω When transmis- shift lever is re- A-7a
sion shift lever is turned to neutral, it
4. E12 male (1) – chassis : Over 1 MΩ at N, it holds is impossible to
transmission at start again.
neutral
1. CN31 female (2) – (14) : 500 – 1,000 Ω Holds the speed 1. Transmission does
4. N1 male (1) – chassis : Over 1 MΩ at N, it holds is impossible to A-7b
neutral
1. CN31 female (12) – (14) : 500 - 1,000 Ω Holds the speed 1. Transmission does
4. N2 male (1) – chassis : Over 1 MΩ at N, it holds is impossible to A-7c
neutral
HD255-5 20-281
(10)

6.3 Defective output of transmis- 1. Output shaft speed sensor system
sion output shaft speed sen-
sor 1) N3 (1) – TM2 (5) – CN31 (3)
flWhen the engine speed, 2) N3 (2) – TM2 (6) – CN31 (14)
input shaft speed, inter- 2. Defective output shaft speed sensor
mediate shaft speed, and
output shaft speed are
converted and it is found
that there is abnormality
7. Short circuit in pressure con- 1. 1) Lock-up (+) L/C.PS (1) – TM3 (13) – CN2 (10)
trol solenoid system
↑ flWhen it is tried to disen-
(–) L/C.PS (2) – TM3 (14) – CN2 (20)
1 – 6, 8 gage the clutch, 2) H clutch (+) H.PS (1) – TM3 (1) – CN2 (9)
The pressure control so- (–) H.PS (2) – TM3 (2) – CN2 (19)
lenoid output is turned 3) L clutch (+) L.PS (1) – TM3 (4) – CN2 (7)
OFF, but the solenoid cur-
rent still flows (–) L.PS (2) – TM3 (5) – CN2 (17)
or 4) 1st clutch (+) 1.PS (1) – TM4 (1) – CN2 (2)
• Excessive solenoid cur- (–) 1.PS (2) – TM4 (2) – CN2 (13)
rent flows
5) 2nd clutch (+) 2.PS (1) – TM4 (4) – CN2 (4)
(–) 2.PS (2) – TM4 (5) – CN2 (15)
6) 3rd clutch (+) 3.PS (1) – TM4 (7) – CN2 (3)
(–) 3.PS (2) – TM4 (8) – CN2 (13)
7) R clutch (+) R.PS (1) – TM3 (7) – CN2 (5)
(–) R.PS (2) – TM3 (8) – CN2 (15)
2. Defective pressure control solenoid
7.1 Short circuit in lock-up pres- See display code Item 7.

sure control solenoid system
7.2 Short circuit in H clutch pres- See display code Item 7.

7.3 Short circuit in L clutch pres- See display code Item 7.

7.4 Short circuit in 1st clutch See display code Item 7.

pressure control solenoid
system
7.5 Short circuit in 2nd clutch See display code Item 7.

system
7.6 Short circuit in 3rd clutch See display code Item 7.

system
7.8 Short circuit in R clutch pres- See display code Item 7.

20-282 HD255-5
(10)

1. CN31 female (3) – (14) : 500 – 1000 Ω Holds the speed 1. Transmission does
3. N3 male (1) – (2) : 500 – 1000 Ω When transmis- shift lever is re-
4. N3 male (1) – chassis : Over 1 MΩ at N, it holds is impossible to A-7d
neutral
Table 2 Solenoid valve check Places in Suddenly shifts to

female female Ω eling and cannot
(9) – (10) 30 – 80 Ω start again
(9) – (19) (2) – (13)
(4) – (13)
(3) – (15) 5 – 25 Ω
(5) – (15)
(7) – (17)
—
Check with display code Item 7. in Table 2 Places in Suddenly shifts to A-15
eling and cannot
start again
eling and cannot
start again
eling and cannot
start again
eling and cannot
start again
eling and cannot
start again
eling and cannot
start again
eling and cannot
start again
HD255-5 20-283
(10)

8.1 Defective output of torque 1. T/C IN (2) – TM2(8) – CN1(3)
• converter inlet port pressure 2. T/C IN (3) – TM2(9) – CN31(7)
8.3 sensor
fl Sensor output voltage is 3. Defective pressure sensor
less than 0.5 V or more
than 4.5 V.
flWhen there is found to be
abnormality in engine
speed, or torque con-
verter inlet port pressure
or outlet port pressure
8.2 Defective output of torque 1. T/C OUT (2) – TM2(11) – CN1(3)
• converter outlet port pres- 2. T/C OUT (3) – TM2(12) – CN31(8)
8.4 sure sensor
fl Sensor output voltage is 3. Defective pressure sensor
less than 0.5 V or more
than 4.5 V.
flWhen there is found to be
abnormality in engine
speed, or torque con-
verter inlet port pressure
or outlet port pressure
9. Disconnection in pressure 1. 1) Lock-up (+) L/C.PS (1) – TM3 (13) – CN2 (10)
control solenoid system
↑ flWhen it is tried to disen-
(–) L/C.PS (2) – TM3 (14) – CN2 (20)
1 – 6, 8 gage the clutch, the pres- 2) H clutch (+) H.PS (1) – TM3 (1) – CN2 (9)
sure control solenoid out- (–) H.PS (2) – TM3 (2) – CN2 (19)
put is turned ON, but the 3) L clutch (+) L.PS (1) – TM3 (4) – CN2 (7)
solenoid current does not
flow (–) L.PS (2) – TM3 (5) – CN2 (17)
4) 1st clutch (+) 1.PS (1) – TM4 (1) – CN2 (2)
(–) 1.PS (2) – TM4 (2) – CN2 (13)
5) 2nd clutch (+) 2.PS (1) – TM4 (4) – CN2 (4)
(–) 2.PS (2) – TM4 (5) – CN2 (15)
6) 3rd clutch (+) 3.PS (1) – TM4 (7) – CN2 (3)
(–) 3.PS (2) – TM4 (8) – CN2 (13)
7) R clutch (+) R.PS (1) – TM3 (7) – CN2 (5)
(–) R.PS (2) – TM3 (8) – CN2 (15)
2. Defective pressure control solenoid
9.1 Short circuit in lock-up pres- See display code Item 9.

9.2 Short circuit in H clutch pres- See display code Item 9.
9.3 Short circuit in L clutch pres- See display code Item 9.
9.4 Short circuit in 1st clutch See display code Item 9.
system
9.5 Short circuit in 2nd clutch See display code Item 9.
system
9.6 Short circuit in 3rd clutch See display code Item 9.
system
9.8 Short circuit in R clutch pres- See display code Item 9.
20-284 HD255-5
(10)

1. T/C IN (1) – (2) (V) : 20 – 30 V Only gives self- Transmission

2. T/C IN (1) – (3) (V) : 0.5 – 4.5 V diagnostic dis- shock becomes
take any action
1. T/C OUT (1) – (2) (V) : 20 – 30 V Only gives self- Transmission

2. T/C OUT (1) – (3) (V) : 0.5 – 4.5 V diagnostic dis- shock becomes
take any action
—
When each speed range is engaged using the shift checker, the fill Even when a 1. Power is lost
sensor signal is given with the combinations shown in disconnection when traveling,
is detected, it and when shift-
Table 2 Solenoid valve check tries to send ing up, transmis-
Female CN2 Female CN2 Ω current to the sion immedi-
solenoid ately shifts down
(9) – (10) 30 – 80 Ω • This is be- again
(9) – (10) (2) – (13) cause there is • This frequently
(4) – (13)
no danger of happens when
damage to traveling uphill —
(3) – (15) 5 – 25 Ω the controller loaded
(5) – (15) even if there 2. Shift indicator
(7) – (17)
is a discon- display shows
nection “E”.
HD255-5 20-285
(10)
TROUBLESHOOTING OF ENGINE SYSTEM
(D MODE)
Serial No.: 1001 – 1599

Method of using troubleshooting charts ............................................................................................... 20-302
D- 1 Starting performance is poor (starting always takes time) ....................................................... 20-306
D- 2 Engine does not start ................................................................................................................... 20-307
(1) Engine does not turn ............................................................................................................. 20-307
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-308
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected) ................. 20-309
D- 3 Engine does not pick up smoothly (follow-up is poor) ............................................................. 20-310
D- 4 Engine stops during operations .................................................................................................. 20-311
D- 5 Engine does not rotate smoothly (hunting) ............................................................................... 20-312
D- 6 Engine lacks output (no power) .................................................................................................. 20-313
D- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-314
D- 8 Oil consumption is excessive, or exhaust gas is blue ............................................................... 20-315
D- 9 Oil becomes contaminated quickly ............................................................................................. 20-316
D-10 Fuel consumption is excessive .................................................................................................... 20-317
D-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-318
D-12 Oil pressure caution lamp lights up (drop in oil pressure) ....................................................... 20-319
D-13 Oil level rises (water, fuel in oil) ................................................................................................. 20-320
D-14 Water temperature becomes too high (overheating) ................................................................ 20-321
D-15 Abnormal noise is made .............................................................................................................. 20-322
D-16 Vibration is excessive ................................................................................................................... 20-323
HD255-5 20-301
(10)
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in [B] are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the Causes
user and the results of [C] that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and (1) (2) (3)
[Check items].
(a) w
Questions
[A] (b) w
(c) w
(d) c
(e) c
Check items
[B]
[C]
i b
shooting
Trouble-
ii b
iii b
20-302 HD255-5
(10)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with c, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items] in
turn, and marked the c or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
ª1. For [Confirm recent repair history] in the Causes
[Questions] Section, ask the user, and mark
the Cause column with t to use as refer-
n)
ence for locating the cause of the failure.
ctio
However, do not use this when making cal-
inje
culations to narrow down the causes.
sive
e
ª2. Use the t in the Cause column as reference
renc
xces
zzle
for [Degree of use (Operated for long pe-
ent
n no
erfe
p (e
der
ing
lem
riod)] in the [Questions] section as reference.
, int
ctio
pum
cylin
m
er e
As a rule, do not use it when calculating the
i
rger
inje
on t
ion
,
lean
points for locating the cause, but it can be
ring
cha
ecti
zed
ject
included if necessary to determine the order
air c
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
ª1 Confirm recent repair history
ª2 Degree of use Operatred for long period
HD255-5 20-303
(10)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
D-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black Causes
• Insufficient intake of air
• Improper condition of fuel injection
d)
ead
n)
eize
• Excessive injection of fuel
ctio
nd h
er s
inje
er a
lung
at
sive
e se
harg
ck, p
elem rence
xces
n tim nozzle
valv
rboc
p (ra
ent
terfe
p (e
lve,
er
u
ing
ffler
e
n
pum
ranc
lind
ctio
pum
r, in
een
f va
u
y
dm
rope ized inje
clea
etw
n pis cleaner
arge
g, c
ion
o
rope jection
ctio
tact
e
ject
air b
n rin
lve
logg
Clog urboch
r inje
con
Legend
e in
r va
se
e in
air
o
e of
: Possible causes (judging from Questions and check items)
d, c
t
e
,
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
on reduced cylinders
When check is made using delivery method, injection timing

is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-304 HD255-5
TROUBLESHOOTING OF ENGINE SYSTEM
(D MODE)
Points to remember when troubleshooting.................................................................................................. 20-326

Method of using troubleshooting charts ...................................................................................................... 20-327
D-1 Starting performance is poor (starting always takes time) .............................................................. 20-330
D-2 Engine does not start ...................................................................................................................... 20-331
D-3 Engine does not pick up smoothly (follow-up is poor)..................................................................... 20-334
D-4 Engine stops during operations....................................................................................................... 20-335
D-5 Engine does not rotate smoothly (hunting) ..................................................................................... 20-336
D-6 Engine lacks output (or lacks power) .............................................................................................. 20-337
D-7 Exhaust smoke is black (incomplete combustion) .......................................................................... 20-338
D-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................... 20-339
D-9 Oil becomes contaminated quickly.................................................................................................. 20-340
D-10 Fuel consumption is excessive ....................................................................................................... 20-341
D-11 Oil is in cooling water (or water spurts back, or water level goes down)......................................... 20-342
D-12 Oil pressure caution lamp lights up (drop in oil pressure) ............................................................... 20-343
D-13 Oil level rises (water, fuel in oil)....................................................................................................... 20-344
D-14 Water temperature becomes too high (overheating)....................................................................... 20-345
D-15 Abnormal noise is made.................................................................................................................. 20-346
D-16 Vibration is excessive...................................................................................................................... 20-347
HD255-5 20-325
(10)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
parking brake is securely applied.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
allow any unauthorized person to come near.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
burns. Always wait for the water temperature to go down before removing the radiator cap.
k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the fail- 3) Carry out other checks if necessary.
ure or other unnecessary parts will be disas- 4) Other maintenance items can be checked
sembled externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior a problem with the method of operation, etc.
investigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the Use the results of the investigation and inspec-
machine before the failure occurred? tion in Items 2 - 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure
this? exactly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
20-326 HD255-5
(10)
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in [B] are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
[Causes]
The serviceman narrows down the causes from
information [A] that he has obtained from the
user and the results of [C] that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HD255-5 20-327
(10)
<Example of troubleshooting> Exhaust smoke is black
D-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
20-328 HD255-5
(10)
HD255-5 20-329
(10)
TROUBLESHOOTING D-1
D-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the

fuel injection timing is recognized electrically,
so even when the starting operation is carried
out, the engine may not start until the crank-
shaft has completed two rotations. However,
this does not indicate any abnormality.
20-330 HD255-5
(10)
TROUBLESHOOTING D-2
D-2 Engine does not start
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
a See "Engine stops during operations".
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
HD255-5 20-331
(10)
TROUBLESHOOTING D-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
20-332 HD255-5
(10)
TROUBLESHOOTING D-2
c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out but
engine does not start
• Lack of rotating force due to defective electrical
system
HD255-5 20-333
(10)
TROUBLESHOOTING D-3
D-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly

20-334 HD255-5
(10)
TROUBLESHOOTING D-4
D-4 Engine stops during operations
General causes why engine stops

• Internal part of engine seized
• Failure in power train
a Carry out troubleshooting of the machine.
HD255-5 20-335
(10)
TROUBLESHOOTING D-5
D-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
20-336 HD255-5
(10)
TROUBLESHOOTING D-6
D-6 Engine lacks output (or lacks power)
General causes why engine lacks output

HD255-5 20-337
(10)
TROUBLESHOOTING D-7
D-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• There is excessive fuel.
20-338 HD255-5
(10)
TROUBLESHOOTING D-8
D-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes con-
tinuous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
HD255-5 20-339
(10)
TROUBLESHOOTING D-9
D-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
20-340 HD255-5
(10)
TROUBLESHOOTING D-10
D-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
HD255-5 20-341
(10)
D-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
20-342 HD255-5
(10)
D-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
HD255-5 20-343
(10)
D-13 Oil level rises (water, fuel in oil)
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out troubleshooting

for "Oil is in cooling water".
20-344 HD255-5
(10)
D-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
HD255-5 20-345
(10)
D-15 Abnormal noise is made
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the engine sound
becomes slightly louder because it is operated in the low
temperature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration
mode and the engine noise is higher for 3 seconds, but this
is not an abnormality.
20-346 HD255-5
(10)
D-16 Vibration is excessive
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry

out troubleshooting also for "Abnormal noise is made".
HD255-5 20-347
(10)
TROUBLESHOOTING OF ENGINE CONTROLLER
SYSTEM (G MODE)
Error code displays and points to remember when troubleshooting .......................................................... 20-353
Action taken by controller and condition of machine when error code is displayed ................................... 20-356
Engine controller related judgement table.................................................................................................. 20-364
Electrical circuit diagram for engine controller system ............................................................................... 20-366
G-1 Error code [C01b] [Abnormality in Ne revolution sensor system] .................................................... 20-368
G-2 Error code [C01C] [Abnormality in G revolution sensor system] ...................................................... 20-369
G-3 Error code [C020] [Abnormality in model selection system] ............................................................ 20-370
G-4 Error code [C022] [Overrun]............................................................................................................. 20-371
G-5 Error code [C023] [Overheat]........................................................................................................... 20-371
G-6 Error code [C024] [Drop in oil pressure] .......................................................................................... 20-372
G-7 Error code [C030] [Abnormality in idling validation signal system] .................................................. 20-373
G-8 Error code [C031] [Abnormality in accelerator sensor system] ........................................................ 20-375
G-9 Error code [C034] [Abnormality in high engine coolant temperature sensor system] ...................... 20-377
G-10 Error code [C036] [Abnormality in oil pressure switch system] ........................................................ 20-378
G-11 Error code [C03C] [Abnormality in boost pressure sensor system] .................................................. 20-380
G-12 Error code [C03d] [Abnormality in fuel temperature sensor system ................................................ 20-381
G-13 Error code [C050] [Abnormality in preheating relay connecting point system] ................................ 20-382
G-14 Error code [C051] [Abnormality in preheating relay coil system] ..................................................... 20-383
G-15 Error code [C054] [Short circuit in starting switch C system] ........................................................... 20-384
G-16 Error code [C056] [Power source system abnormality 1]................................................................. 20-385
G-17 Error code [C057] [Power source system abnormality 2]................................................................. 20-387
G-18 Error code [C05A] [Abnormality in fuel injection quantity control switch signal] ............................... 20-388
G-19 Error code [C06A] [Abnormality in low engine coolant temperature sensor system ] ...................... 20-388
G-20 Error code [C070] [Excess current in fuel supply pump PCV1 system] ........................................... 20-389
G-21 Error code [C071] [Excess current in fuel supply pump PCV2 system] ........................................... 20-390
G-22 Error code [C074] [Disconnection in fuel supply pump PCV1 system] ............................................ 20-391
G-23 Error code [C075] [Disconnection in fuel supply pump PCV2 system] ............................................ 20-392
G-24 Error code [C077] [Abnormality in common rail fuel pressure sensor system] ................................ 20-393
G-25 Error code [C079] [Common rail high fuel pressure abnormality 1]
Error code [C07A] [Common rail high fuel pressure abnormality 2] ................................................. 20-394
G-26 Error code [C07b] [Fuel supply pump non-force feed 1]
Error code [C07C] [Fuel supply pump non-force feed 2] .................................................................. 20-395
a If the starting switch was turned OFF when an error occurred, turn it ON again and check that the error code
is displayed. (If the error code is not displayed, the error has been repaired.)
a Before carring out troubleshooting check that all the related connecror are properly inserted.
a Always coonnect disconnected connectors before going to the next step.
HD255-5 20-351
(10)
TROUBLESHOOTING
G-27 Error code [C07d] [Abnormality in common rail fuel pressure]......................................................... 20-397
G-28 Error code [C080] [Defective controller] ........................................................................................... 20-397
G-29 Error code [C081] [Disconnection in No. 1 fuel injector <A> system] .............................................. 20-398
G-30 Error code [C082] [Disconnection in No. 2 fuel injector <E> system] .............................................. 20-399
G-31 Error code [C083] [Disconnection in No. 3 fuel injector <C> system] .............................................. 20-400
G-32 Error code [C084] [Disconnection in No. 4 fuel injector <F> system]............................................ 20-400-1
G-33 Error code [C085] [Disconnection in No. 5 fuel injector system] ........................................... 20-400-2
G-34 Error code [C086] [Disconnection in No. 6 fuel injector <D> system] ........................................... 20-400-3
G-35 Error code [C08A] [Short circuit in No. 1 <A>, No. 2 <E>, No. 3 <C> fuel injector system] .......... 20-400-4
G-36 Error code [C08b] [Short circuit in No. 4 <F>, No. 5 , No. 6 <D> fuel injector system]........... 20-400-7
20-352 HD255-5
(10)
ERROR CODE DISPLAYS AND POINTS TO REMEMBER
TROUBLESHOOTING WHEN TROUBLESHOOTING
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN

TROUBLESHOOTING
1. Error code displays
a For the display method of the monitor panel,
see MONITOR PANEL USER CODES AND
SERVICE MODE in the introduction to the
troubleshooting.
• The engine controller displays the appropri-
ate error code for the abnormality in display
window (1) of the controller using seven seg-
ments with two alphanumeric digits.
• When the starting switch is turned ON, the
display check displays [88], then displays [E]
to show the occurrence of an error and a 2-
digit code repeatedly.
If there are multiple service codes in memo-
ry, the display returns to the first display after
completing all the displays.
• To prevent mistakes when reading, the nu-
merals and letters are displayed as follows.
Numerals: 0 1 2 3 4 5 6 7 8 9
Alphabet: A b C d E
• When re-enacting an abnormality or after
completion of repair of an abnormality, keep
the starting switch at the ON position and
connect the No. 4 pin circuit of connector (2)
CN4 to the ground.
HD255-5 20-353
(10)
ERROR CODE DISPLAYS AND POINNTS TO REMEMBER
TROUBLESHOOTING WHEN TROUBLESHOOTING
2. Points to remember when troubleshooting

1) Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and the
error code is no longer displayed, or the [E] for the error code is no longer displayed, the abnormality
has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to follow up
this problem carefully.
2) Handling error code:
When carry out troubleshooting after displaying the error codes, save all the errors that have been dis-
played, then delete them. Following this, try to re-enact the problem and carry out troubleshooting for
the error codes that are displayed.
a Among the error codes that are saved, there are some that were caused by mistaken operation or
when the connectors were disconnected, so re-enacting the failure prevents time from being wasted
on unnecessary checks.
After completing troubleshooting, erase all the error codes.
20-354 HD255-5
(10)
ACTION TAKEN BY CONTROLLER AND CONDITION OF
TROUBLESHOOTING MACHINE WHEN ERROR CODE IS DISPLAYED

MACHINE WHEN ERROR CODE IS DISPLAYED
Error System with
Nature of abnormality
code abnormality
1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside Ne
revolution sensor
Abnormality in 2. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
C01b Ne revolution ler CN1 (5) (+) and Ne revolution sensor NE (1)
sensor system 3. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
ler CN1 (12) (–) and Ne revolution sensor NE (2)
4. Defective engine controller
1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside G
revolution sensor
Abnormality in 2. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
C01C G revolution ler CN2 (1) (+) and G revolution sensor G (1)
sensor system 3. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
ler CN2 (9) (–) and G revolution sensor G (2)
1. Defective model selection connector
2. Disconnection in wiring harness between engine controller CN4 (13) and model selection connector
Abnormality in MS11 and ground
model 3. Short circuit with ground in wiring harness between engine controller CN4 (14) and model selection
C020
selection connector MS21 and ground
system 4. Short circuit with ground in wiring harness between engine controller CN4 (15) and model selection
connector MS31 and ground
1. Engine speed goes above operating range.
C022 Overrun
1. Engine water temperature goes above operating range.
C023 Overheat
1. Engine oil pressure goes below operating range.
2. Defective oil pressure low-pressure sensor
3. Defective oil pressure high-pressure sensor
4. Short circuit with chassis ground in wiring harness between engine controller CN4 (5) and oil pressure
Drop in oil low-pressure sensor PSL
C024
pressure 5. Short circuit with chassis ground in wiring harness between engine controller CN4 (6) and oil pressure
low-pressure sensor PSH
1. Defective accerelator sensor

2. Defective contact or disconnection in wiring harness between engine controller CN4 (female) (8) (GND)
Abnormality in and accerelator sensor WSI (female) (4)
idling 3. Defective contact, disconnection, or short circuit with ground in wiring harness between emgine control-
C030
validation ler CN4 (female) (11) (signal 2) and accerelator sensor WSI (female) (5)
signal system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
ler CN4 (female) (12) (signal 3) and accerelator sensor WSI (female) (6)
1. Defective accerelater sensor
2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1
(4) (power source) and throttle sensor WSI (3)
Abnormality in
C031 accerelator sensor
(6) (signal) and throttle sensor WSI (2)
system
(11) (GND) and throttle sensor WSI (1)
1. Defective engine water high-temperature sensor
2. Defective contact, disconnection, or short circuit with ground in wiring harness between engine control-
Abnormality in high
ler CN2 (4) (signal) and engine water high-temperature sensor TWH (1)
engine water tem-
C034 3. Defective contact or disconnection in wiring harness between engine controller CN2 (10) (GND) and
perature
engine water high-temperature sensor TWH (2)
sensor system
20-356 HD255-5
(10)
Condition when normal Action by controller Problem that appears on machine
• Sensor resistance value 1. Limits output for operation 1. Reduces output (when problem occurs
Between NE (1) and (2): 85 – 210 z (when problem occurs independently) independently)
2. Control of the system becomes impossi- 2. Engine stops during operation
ble (when C01C occurs at same time) (when C01C occurs at same time)
3. Engine cannot be started
(when C01C occurs at same time)
• Sensor resistance value 1. Limits output for operation 1. Output is reduced (when problem
Between G (1) and (2): (when problem occurs independently) occurs independently)
1,400 – 3,500 z 2. Control of the system becomes impossi- 2. Engine stops during operation
ble (when C01C occurs at same time) (when C01b occurs at same time)
3. Engine cannot be started
(when C01b occurs at same time)
• Resistance between CN4 (14), (15) 1. Carries out operation under normal con- 1. Carries out operation under normal con-
(female) and ground: Min. 1 Mz trol. trol.
• Resistance between CN4 (13) (female)
and ground: Max. 1 z
1. Stops fuel injection until engine speed 1. Engine speed varies abnormally.
goes down to operating range.
1. Limits fuel injection amount until temper- 1. Output is reduced
ature goes down to operating range.
• Low engine oil pressure switch resis- 1. Limits output for operation 1. Output is reduced
tance value
Between PSL and ground
Engine stopped: Max. 1 z
Engine above 600 rpm: Min. 1 Mz
• High engine oil pressure switch resis-
tance value
Between PSH and ground
Engine above 1,300 rpm: Min. 1 Mz
• Signal 2 voltage (between CN4 (11) 1. Carries out operation under normal con- 1. Operates normally.
and (8)) trol.
Accererator below 0.446 V: Max. 1 V
Accererator above 0.446 V: 15 – 30 V
• Signal 3 voltage (between CN4 (12)
and (8))
Accererator below 0.446 V: 15 – 30 V
Accererator above 0.446 V: Max. 1 V
• Sensor power source voltage 1. Carries out operation with idle valida- 1. If accelerator pedal is not pressed,
Between CN1 (4) and (11): 4.6 – 5.4 V tion. engine speed is fixed at low idling.
• Sensor signal voltage 2. If accelerator pedal is pressed, engine
Between CN1 (6) and (11): 0.3 – 4.5 V speed is fixed at medium level.
• Sensor resistance value (water temper- 1. Carries out operation under normal 1. Fixes water temperature signal output to
ature: 10 – 100ºC) control. machine at 90ºC
Between TWH (1) and (2): 3.5 k – 90 kz
HD255-5 20-357
(10)
Error System with

code abnormality
1. Defective oil pressure low engine oil pressure sensor
2. Defective oil pressure high engine oil pressure sensor
ler CN4 (5) and low engine oil pressure sensor PSL
4. Defective contact or disconnection in wiring harness between engine controller CN4 (6) and low engine
Abnormality in oil pressure sensor PSH
C036 oil pressure
switch system
1. Defective boost pressure sensor

(2) (power source) and boost pressure sensor PIM (3)
Abnormality in
C03C boost pressure
(3) (signal) and boost pressure sensor PIM (2)
sensor system
(10) (GND) and boost pressure sensor PIM (1)
1. Defective fuel temperature sensor
Abnormality in fuel
ler CN2 (11) (signal) and fuel temperature sensor THL (A)
C03d temperature
3. Defective contact or disconnection in wiring harness between engine controller CN2 (10) (GND) and
sensor system
fuel temperature sensor THL (B)
1. Defective heater relay
Abnormality in
2. Defective contact, disconnection, short circuit with ground, or short circuit with power source in wiring
C050 preheating relay
harness between engine controller CN4 (3) and heater relay C23
contact system
1. Defective preheating relay
Abnormality in
C051 preheating relay
ler CN2 (5) and preheating relay R25 (2)
coil system
1. Defective starting switch
Short circuit in
2. Short circuit with power source in wiring harness between controller CN4 (2) and starting switch termi-
C054 starting switch
nal C
C signal system
1. Defective power source relay
2. Defective contact, disconnection, or short circuit with ground in wiring harness between starting switch
terminal ACC and power source relay R23 (1)
Power source 3. Defective contact or disconnection in wiring harness between power source relay R23 (2) and ground
C056 system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between power source
abnormality 1 fuse and power source relay R23 (3)
(6)(14) and power source relay R23 (5)
1. Defective power source relay
Power source
2. Short circuit with power source in wiring harness between controller CN7 (6)(14) and power source
C057 system
relay (5)
abnormality 2
Abnormality in fuel 1. Defective setting of fuel injection quantity control switch
injection quantity 2. Defective engine controller
C05A
control switch
signal
1. Defective low engine water temperature sensor
Abnormality in low 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2
engine water tem- (3) (signal) and water temperature low-temperature sensor TWL (A)
C06A
perature 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and water
sensor system temperature low-temperature sensor TWL (B)
1. Defective fuel supply pump PCV1
Excess current in 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
C070 fuel supply pump CN7 (10) and solenoid PCV1 (1)
PCV1 system 3. Short circuit with power source in wiring harness between controller CN7 (11) and solenoid PCV1 (2)
20-358 HD255-5
(10)
• Low engine oil pressure switch resis- 1. Carries out operation under normal con- 1. Operates normally.
tance value trol.
Between PSL and ground
Engine above 600 rpm: Min. 1 Mz
[Engine oilpresssure:
0.07 MPa{0.7 kg/cm2} or above]
• High engne oil pressure switch resis-
tance value
Between PSH and ground
Engine above 1,300 rpm: Min. 1 Mz
[Engine oilpresssure:
0.17 MPa{1.7 kg/cm2} or above]
• Sensor power source voltage 1. Operates normally.
Between PIM (3) and (1): 4.6 – 5.4 V
• Sensor signal voltage
Between PIM (2) and (1): 0.3 – 4.7 V
—
• Sensor resistance value 1. Carries out operation under normal con- 1. Operates normally.
(fuel temperature: 10 – 100°C) trol.
Between THL (A) and (B): 0.3 k – 9 kz
• Preheating signal voltage 1. Carries out operation under normal con- 1. Starting ability in cold weather becomes
Between CN4 (3) and ground trol. worse.
Preheating not actuated: Max. 1 V
Preheating actuated: 20 – 30 V
• Preheating signal voltage 1. Carries out operation under normal con- 1. Starting ability in cold weather becomes
Between CN1 (5) and (6) trol. worse.
Preheating not actuated: 20 – 30 V
Preheating actuated: Max. 1 V
• Starting switch C signal voltage 1. Carries out operation under normal con- 1. Operates normally 10 seconds after
Between CN4 (2) and ground trol. engine starts.
Starting switch at ON: Max. 1 V
Starting switch at START: 20 – 30 V
• Power source voltage 1. Engine stops during operation.
Between CN7 (6), (14) and (5), (13) 2. Engine cannot be started.
Starting switch at ON: 20 – 30 V
• Power source voltage 1. Carries out operation under normal con- 1. Operates normally.
Between CN7 (6)(14) and (5)(13) trol.
Starting switch at OFF: Max. 8 V
• Either fuel injection quantity control 1. Carries out operation under normal con- 1. Fuel injection quantity control setting
switch 1 or 2 of controller is set to [F] trol. cannot be changed.
• Sensor resistance value (water temper- 1. Carries out operation under normal con- 1. Exhaust gas color at low temperatures is
ature: 10 – 100°C) trol. poor.
Between TWL (A) and (B): 0.3 k – 9 kz 2. Starting ability at low temperatures is
poor.
• Solenoid resistance value 1. Stops output to PCV1 (when problem 1. Operates normally (when problem
Between PCV1 (1) and (2): 2.3 – 5.3 z occurs independently) occurs independently)
2. Stops output to PCV1 and PCV2 (when 2. Stops engine (when C071 occurs at
C071 occurs at same time) same time)
HD255-5 20-359
(10)
Error System with

code abnormality
2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
Excess current in
CN7 (4) and solenoid PCV2 (1)
C071 fuel supply pump
3. Short circuit with power source in wiring harness between controller CN7 (12) and PCV2 solenoid
PCV2 system
PCV2 (2)
2. Defective contact or disconnection in wiring harness between controller CN7 (10) and solenoid PCV1
Disconnection in
(1)
C074 fuel supply pump
PCV1 system
(11) and solenoid PCV1 (2)
Disconnection in 2. Defective contact or disconnection in wiring harness between controller CN7 (4) and solenoid PCV2 (1)
C075 fuel supply pump 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN7
PCV2 system (12) and solenoid PCV2 (2)
1. Defective common rail fuel pressure sensor
Abnormality in (2) (power source) and fuel pressure sensor PFUEL (1)
common rail fuel 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1
C077
pressure sensor (1) (signal) and fuel pressure sensor PFUEL (2)
system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2
(10) (GND) and fuel pressure sensor PFUEL (3)
1. Viscosity of fuel is too high (unsuitable fuel)
Common rail high 2. Defective overflow valve
C079 fuel pressure 3. Defective pressure limiter
abnormality 1 4. Defective common rail fuel pressure sensor
5. Clogged overflow piping
Common rail high a See C079.
C07A fuel pressure
abnormality 2
1. Defective fuel low-pressure circuit (etc)
2. Defective fuel supply pump PCV
Supply pump
3. Defective pressure limiter
C07b non-force
4. Defective common rail fuel pressure sensor
feed abnormality 1
5. Defective fuel injector
6. Leakage from fuel high-pressure piping
Supply pump a See C07b.
C07C non-force feed
abnormality 2
a See C079.
Abnormality in
C07d common rail fuel
pressure
1. Defective contact or disconnection in wiring harness between controller CN7 (5)(13) and ground
Abnormality in
C080
controller
1. Defective No. 1 fuel injector <A>

2. Defective contact or disconnection in wiring harness between controller CN6 (7) (+) and No. 1 injector
Disconnection in
<A> connector CN1 (1)
C081 No. 1 fuel injector
3. Defective contact or disconnection in wiring harness between controller CN6 (8) (–) and No. 1 injector
<A> system
<A> connector CN1 (2)
1. Defective No. 2 fuel injector
Disconnection in
<E> connector CN2 (1)
<E> system
<E> connector CN2 (2)
20-360 HD255-5
(10)
• Sensor power source voltage 1. Limits output with open control. 1. Output is reduced
Between PFUEL (1) and (3):
4.6 – 5.4 V
• Sensor signal voltage
Between PFUEL (2) and (3):
0.3 – 4.7 V
1. Operation carried out with limited output 1. Output is reduced
1. Operation carried out with limited output 1. Output is reduced

—
1. Carries out operation under normal con- 1. Carries out operation under normal con-
trol. trol.
—
1. Carries out operation with limited output 1. Output and engine speed lower.
— and engine speed.
1. Carries out operation under normal con- 1. The engine does not run at high idling
trol. speed when there is no load
—
2. The engine stops when a large load is
applied
1. Operation carried out with limited output 1. The engine does not run at high idling
speed when there is no load
2. The engine stops when a large load is
—
applied
3. Engine stops during operation.
4. Engine cannot be started.
• No. 1 injector <A> resistance value 1. Stops output to No. 1 injector <A> (when 1. Output is reduced (when problem
Between No. 1 injector <A> connector problem occurs independently) occurs independently)
CN1 (1) and (2): 0.4 – 1.1 z 2. Stops output to fuel supply pump, all fuel 2. Engine stops (when C082 to C086 occur
injectors (when at same time in C082 to at same time)
C086)
• No. 2 injector <E> resistance value 1. Stops output to No. 2 injector <E> (when 1. Output is reduced (when problem
Between No. 2 injector <E> connector problem occurs independently) occurs independently)
injectors (when C081 to C086 occur at at same time)
same time)
HD255-5 20-361
(10)
Error System with

code abnormality
1. Defective No. 3 fuel injector <C>
Disconnection in
<C> connector CN3 (1)
<C> system
<C> connector CN3 (2)
1. Defective No. 4 fuel injector <F>
Disconnection in
<F> conector CN4 (1)
<F> system
<F> conector CN4 (2)
1. Defective No. 5 fuel injector 
Disconnection in
 conector CN5 (1)
 system
 conector CN5 (2)
1. Defective No. 6 fuel injector <D>
Disconnection in
<D> conector CN6 (1)
<D> system
<D> conector CN6 (2)
1. Defective No. 1 fuel injector <A>
2. Defective No. 2 fuel injector <E>
3. Defective No. 3 fuel injector <C>
CN6 (7) (+) and No. 1 injector <A> conector CN1 (1)
CN6 (8) (– ) and No. 1 injector <A> conector CN1 (2)
Short circuit in No.
1 <A>, No. 2 <E>,
C08A CN6 (4) (+) and No. 2 injector <E> conector CN2 (1)
No. 3 <C> fuel
injector system
CN6 (10) (–) and No. 2 injector <E> conector CN2 (2)
CN6 (3) (+) and No. 3 injector <C> conector CN3 (1)
CN6 (9) (– ) and No. 3 injector <C> conector CN3 (2)
1. Defective No. 4 fuel injector <F>
2. Defective No. 5 fuel injector 
3. Defective No. 6 fuel injector <D>
CN7 (3) (+) and No. 4 injector <F> conector CN4 (1)
CN7 (9) (– ) and No. 4 injector <F> conector CN4 (2)
Short circuit in No.
4 <F>, No. 5 ,
C08b CN7 (1) (+) and No. 5 injector conector CN5 (1)
No. 6 <D> fuel
injector system
CN7 (7) (– ) and No. 5 injector conector CN5 (2)
CN7 (2) (+) and No. 6 injector <D> conector CN6 (1)
CN7 (8) (– ) and No. 6 injector <D> conector CN6 (2)
20-362 HD255-5
(10)
• No. 3 injector <C> resistance value 1. Stops output to No. 3 injector <C> (when 1. Output is reduced (when problem
Between No. 3 injector <C> connector problem occurs independently) occurs independently)
same time)
• No. 4 injector <F> resistance value 1. Stops output to No. 4 injector <F> (when 1. Output is reduced (when problem
Between No. 4 injector <F> connector problem occurs independently) occurs independently)
same time)
• No. 5 injector resistance value 1. Stops output to No. 5 injector 1. Output is reduced (when problem
Between No. 5 injector connector (when problem occurs independently) occurs independently)
same time)
• No. 6 injector <D> resistance value 1. Stops output to No. 6 injector <D> (when 1. Output is reduced (when problem
Between No. 6 injector <D> connector problem occurs independently) occurs independently)
same time)
• No. 1 injector <A> resistance value 1. Stops output to No. 1 <A>, No. 2 <E>, 1. Output is greatly reduced (when prob-
Between No. 1 injector connector CN1 No. 3 <C> fuel injectors (when problem lem occurs independently)
(1) and (2): 0.4 – 1.1 z occurs independently) 2. Engine stops (when C08b occurs at
• No. 2 injector <E> resistance value 2. Stops output to fuel supply pump, all fuel same time)
Between No. 2 injector connector CN2 injectors (when C08b occurs at same
(1) and (2): 0.4 – 1.1 z time)
• No. 3 injector <C> resistance value
Between No. 3 injector connector CN3
(1) and (2): 0.4 – 1.1 z
• No. 4 injector <F> resistance value 1. Stops output to No. 4 <F>, No. 5 , 1. Output is greatly reduced (when prob-
Between No. 4 injector connector CN4 No. 6 <D> fuel injectors (when problem lem occurs independently)
(1) and (2): 0.4 – 1.1 z occurs independently) 2. Engine stops (when C08A occurs at
• No. 5 injector resistance value 2. Stops output to fuel supply pump, all fuel same time)
Between No. 5 injector connector CN5 injectors (when C08A occurs at same
(1) and (2): 0.4 – 1.1 z time)
• No. 6 injector <D> resistance value
Between No. 6 injector connector CN6
(1) and (2): 0.4 – 1.1 z
HD255-5 20-363
(10)
TROUBLESHOOTING ENGINE CONTROLLER RELATED JUDGEMENT TABLE
ENGINE CONTROLLER RELATED JUDGEMENT TABLE
Self-diagnostic display (Abnormal display)
Abnormality in high engine water temperature sensor system

Abnormality in engine oil pressure switch system
Abnormality in fuel temperature sensor system
Short circuit in starting switch C-signal system

Abnormality in preheater relay contact system
Abnormality in boost pressure sensor system
Abnormality in idle validation signal system
Abnormality in acceleration sensor system
Abnormality in preheater relay coil system

Abnormality in NE rotation sensor system
Abnormality in G rotation sensor system
Inspection item
Abnormality in model selection system
Abnormality in power supply system 1

Low oil pressure
Overheating
Overrun
Failure display 1b 1c 20 22 23 24 30 31 34 36 3C 3d 50 51 54 56
Panel display C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0
No. Classification Failure mode code 1b 1C 20 22 23 24 30 31 34 36 3C 3d 50 51 54 56
1 Engine does not start
(1) Exhaust smoke comes out but engine

2 Starting performance is poor does not start (easily)
(2) Exhaust smoke does not come out
3 Engine stops during operations
4 Engine lacks output
5 Engine does not pickup smoothly
Engine keeps at low idling and (1) Exhaust smoke is normal

6
does not follow up acceleratord (2) Exhaust smoke is very black
(1) Engine speed rises and abnormality is

displayed simultaneously
7 Engine speed rises to high idling
Engine speed rises while abnormality
(2) is displayed
Low idling is not adjusted as (1) Engine is not set to high-speed low idling
8 expected (2) Engine is not set to low-speed low idling
(1) Exhaust smoke is normal
9 Fuel consumption is excessive
(2) Exhaust smoke is very black
(1) Engine speed does not rise to high idling
10 Engine is not set to high idling
(2) Engine speed rises to high idling but
returns to low idling
11 Automatic warm-up operation is defective
(1) Engine speed keeps high
12 Engine does not stop (2) Engine keeps running at low idling after
key switch is turned off
13 Engine hunts (1) Engine does not rotate smoothly at low idling
14 Oil cooler is excessive (or exhaust smoke is blue)
15 Oil becomes contaminated quickly
16 Oil is mixed in cooling water
17 Oil pressure caution lamp lights up
18 Oil level rises
19 Water temperature becomes too high
20 Abnormal noise is made
21 Vibration is excessive
Diagnostic code when abnormality is displayed G-1 G-2 G-3 G-4 G-5 G-6 G-7 G-8 G-9 G-10 G-11 G-12 G-13 G-14 G-15 G-16
20-364 HD255-5
(10)
Abnormality in power supply system 2
Abnormality in Q adjustment switch signal
HD255-5
Abnormality in low water temperature sensor system
Overcurrent in fuel supply pump PCV1 system
Overcurrent in fuel supply pump PCV2 system
Disconnection in fuel supply pump PCV1 system
Disconnection in fuel supply pump PCV2 system
TROUBLESHOOTING
Abnormality in common rail fuel pressure sensor system

Abnormally high fuel pressure in common rail 1
Abnormally high fuel pressure in common rail 2
Supply of no fuel by fuel supply pump 1
Supply of no fuel by fuel supply pump 2
Abnormal fuel pressure in common rail
Defective controller
Disconnection in No. 1 fuel injector <A> system
Disconnection in No. 2 fuel injector <E>system
Disconnection in No. 3 fuel injector <C>ystem
Disconnection in No. 4 fuel injector <F> system
Disconnection in No. 5 fuel injector system
Disconnection in No. 6 fuel injector <D> system
57 5A 6A 70 71 74 75 77 79 7A 7b 7c 7d 80 81 82 83 84 85 86
57 5A 6A 70 71 74 75 77 79 7A 7b 7c 7d 80 81 82 83 84 85 86
C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0 C0
G-17 G-18 G-19 G-20 G-21 G-22 G-23 G-24 G-25 G-25 G-26 G-26 G-27 G-28 G-29 G-30 G-31 G-32 G33 G-34
Short circuit in No. 1 <A>, No. 2 <E>, No. 3 <C> fuel
Self-diagnostic display (Abnormal display)
C0
8A
G-35
8A
injector systems
Short circuit in No. 4, <F> No. 5 , No. 6 <D> fuel

8b
C0
G36
8b
injector systems
Diagnostic code when
abnormality is not displayed
As per Shop Manual for engine

(10)
20-365
ENGINE CCONTROLLER RELATED JUDGEMENT TABLE
ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING ENGINE CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER

SYSTEM
20-366 HD255-5
(10)
ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING ENGINE CONTROLLER SYSTEM
HD255-5 20-367
(10)
TROUBLESHOOTING G-1
G-1 Error code [C01b] [Abnormality in Ne revolution sensor system]
Cause Remedy
1
Is resistance between NE (male)
• Turn starting switch OFF. NO
(1) and (2), between (1)(2) and Defective Ne revolution sensor Replace
• Disconnect NE.
ground as shown in Table 1?
YES
2 Defective contact or
NO disconnection in wiring harness
• Turn starting switch OFF. Is resistance between CN2 Repair or
between CN2 (female) (5) and
• Disconnect CN2. (female) (5) and (12) 85 – 210 z? replace
NE (female) (2) or between
CN2 (female) (12) and NE
YES (female) (1)
3 Short circuit with chassis ground

Is resistance between CN2 NO in wiring harness between CN2
• Turn starting switch OFF. Repair or
(female) (5)(12) and ground more (female) (5) and NE (female)
• Disconnect CN2 and NE. replace
than 1 Mz? (2) or between CN2 (female)
(12) and NE (female) (1)
YES
Defective engine controller Replace
Table 1
NE (male) Resistance value
Between (1) and (2) 85 – 210
Between (1)(2) and ground Min. 1 Mz
G-1 Related electrical circuit diagram
20-368 HD255-5
(10)
TROUBLESHOOTING G-2
G-2 Error code [C01C] [Abnormality in G revolution sensor system]
Cause Remedy
1
Is resistance between G (male) NO
• Turn starting switch OFF.
(1) and (2), between (1)(2) and Defective G revolution sensor Replace
• Disconnect G.
YES
Is resistance between CN2 NO disconnection in wiring harness
(male) (1) and (9) between CN2 (female) (1) and
• Disconnect CN2. replace
1,400 – 3,500 z? G (female) (2) or between CN2
(female) (9) and G (female) (1)
YES
3 Short circuit with chassis ground

Is resistance between CN2 NO in wiring harness between CN2
(male) (1)(9) and ground more (female) (1) and G (female) (2)
• Disconnect CN2 and G replace
than 1 Mz? or between CN2 (female) (9) and
G (female) (1)
YES
Table 1
G (male) Resistance value
Between (1) and (2) 1,400 – 3,500 z
HD255-5 20-369
(10)
TROUBLESHOOTING G-3
G-3 Error code [C020] [Abnormality in model selection system]
Cause Remedy
1 • Disconnection or defective
contact in wiring harness
Is resistance between CN4 NO
• Turn starting switch OFF. between CN4 (female) (13) and
(female) (13), (14), (15) and chassis ground Repair or
• Disconnect CN4 and MSC.
ground more than 1 Mz? • Short circuit with chassis replace
ground in wiring harness
between CN4 (female) (14),
(15) and MS21 (F), MS31 (F)
YES
20-370 HD255-5
(10)
TROUBLESHOOTING G-4, G-5
G-4 Error code [C022] [Overrun]
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to trouble-
YES shooting for
---- error code
displayed
2
Was machine used in a way that NO
would cause engine to overrun?
Check cause
YES of problem
---- and repair
damage to
engine
3
Go to trouble-
Can engine speed be read NO shooting for
• Start engine. ----
correctly? error codes
[C01b], [C01C]
YES
G-5 Error code [C023] [Overheat]
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
---- error code
displayed
2
NO
Is engine overheating? Defective engine controller Replace
Check cause
YES of problem
---- and repair
damage to
engine
HD255-5 20-371
(10)
TROUBLESHOOTING G-6
G-6 Error code [C024] [Drop in oil pressure]
Cause Remedy
1
NO Check cause
• See the standard values
Is engine oil pressure normal? Drop in engine oil pressure of problem
table for engine.
and repair
YES damage to
engine
2
• Insert T-adapter to CN4. Is voltage between CN4 (5) and NO
• Engine at low idling. ground 20 – 30 V?
YES
3
Is resistance between CN4 NO Short circuit with chassis ground
(female) (5) and ground more in wiring harness between CN4 Repair or
• Disconnect CN4 and PSL. replace
than 1 Mz? (female) (5) and PSL
YES Defective engine oil pressure
Replace
low-pressure switch
4
• Insert T-adapter to CN4. NO
Is voltage between CN4 (6) and
• Engine at midrange
speed (Min. 1,300 rpm) ground 20 – 30 V?
YES
5
Is resistance between CN4 NO Short circuit with chassis ground
• Disconnect CN4 and PSH. (female) (6) and ground more in wiring harness between CN4 replace
than 1 Mz? (female) (6) and PSH.
YES Defective oil pressure Replace

high-pressure switch
20-372 HD255-5
(10)
TROUBLESHOOTING G-7
G-7 Error code [C030] [Abnormality in idling validation signal system]
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
----
error code
displayed
2
When accelerator pedal is
• Connect T-adapter to WAS1. operated, does voltage between NO
Defective accelerator sensor Replace
• Turn starting switch ON. WAS1 (5) and (4) (signal 2)
change as shown in Fig. 1?
YES
3
• Connect T-adapter to WAS1. operated, does voltage between NO
• Turn starting switch ON. WAS1 (6) and (4) (signal 3)
YES Defective contact, disconnection,

4 short circuit with ground, or short
When accelerator pedal is circuit with power source in
• Connect T-adapter to CN4. operated, does voltage between NO wiring harness between CN4 Repair or
• Turn starting switch ON. CN4 (11) and (8) (signal 2) (female) (11) and WAS1 (female) replace
change as shown in Fig. 1? (5) or between CN4 (female) (8)
and WAS1 (female) (4)
YES
5 Defective contact, disconnection,
short circuit with ground, or short
circuit with power source in
• Connect T-adapter to CN4. operated, does voltage between NO Repair or
wiring harness between CN4
• Turn starting switch ON. CN4 (12) and (8) (signal 3) replace
(female) (12) and WAS1 (female)
(6) or between CN4 (female) (8)
and WAS1 (female) (4)
YES
Fig. 1
HD255-5 20-373
(10)
TROUBLESHOOTING G-7
20-374 HD255-5
(10)
TROUBLESHOOTING G-8
G-8 Error code [C031] [Abnormality in accelerator sensor system]
Cause Remedy
1
• Insert T-adapter to WAS1. Is voltage between WAS1 (1) NO
• Turn starting switch ON. and (3) 4.6 – 5.4 V?
YES
2
• Insert T-adapter to CN1. Is voltage between E11 (4) and NO
(11) 4.6 – 5.4 V? Defective engine controller Replace
Defective contact, disconnection,
YES or short circuit with ground in
Repair or
replace
3 (1) or CN1 (female) (11) and
Is resistance between WAS1 WAS1(female) (3)
• Turn starting switch OFF. (male) (1) and (3), between (2) NO
• Disconnect WAS1. and (3), between (1)(2) and
ground as shown in Fig. 1?
YES
4
Is resistance between CN1
NO or short circuit with ground in
• Turn starting switch OFF. (female) (4) and (11), between Repair or
• Disconnect CN1. (5) and (11), between (4)(11) and replace
ground as shown in Fig. 1?
(2)
YES
Fig. 1 Fig. 2
HD255-5 20-375
(10)
TROUBLESHOOTING G-8
20-376 HD255-5
(10)
TROUBLESHOOTING G-9
G-9 Error code [C034] [Abnormality in high engine coolant temperature sensor system]
Cause Remedy
1
• Turn starting switch OFF. Is resistance between TWH
• Disconnect TWH. NO Defective water temperature
(male) (1) and (2), between (1) Replace
• Water temperature: high-temperature sensor
10 – 100ºC and ground as shown in Table 1?
YES
• Turn starting switch OFF. disconnection in wiring harness
• Disconnect CN2. between CN2 (female) (4) and Repair or
(female) (4) and (10)
• Water temperature: TWH (female) (1) or between replace
10 – 100ºC 3.5 – 90 kz?
CN2 (female) (10) and TWH
(female) (2)
YES
3
Short circuit with chassis ground
Is resistance between CN2 NO in wiring harness between CN2 Repair or
• Disconnect CN2 and TWH. (female) (4) and ground more (female) (4) and TWH (female) replace
than 1 Mz? (1)
YES
Table 1
TWH (male) Resistance value
Between (1) and (2) 3.5 k – 90 kz
Between (1) and ground Min. 1 Mz
HD255-5 20-377
(10)
TROUBLESHOOTING G-10
G-10 Error code [C036] [Abnormality in oil pressure switch system]
Cause Remedy
1
Is voltage between CN4 (5) and NO
• Insert T-adapter to CN4.
YES
2
Is resistance between PSL NO Defective oil pressure
• Disconnect PSL. (switch end) and ground as Replace
low engine oil pressure switch
shown in Table 2?
YES Defective contact, disconnection,
Repair or
or short circuit with ground in
replace
3 (female) (5) and PSL
• Insert T-adapter to CN4.
YES
4
Is resistance between PSH NO Defective oil pressure
• Disconnect PSH. (switch end) and ground as Replace
high engine oil pressure switch
shown in Table 4?
YES Defective contact or

disconnection in wiring harness Repair or
between CN4 (female) (5) and replace
PSL
Table 1 Table 2
Resistance
CN4 (male) Engine Voltage PSL Engine
value
When stopped, When stopped,
Max. 1 V Max. 1 z
starting switch ON starting switch ON
Between Between
At 600 rpm or more At 600 rpm or more
(5) PSL (switch)
[Engine oil pressure [Engine oil pressure
and ground 20 – 30 V and ground Min. 1 Mz
0.07 MPa {0.7 kg/cm2} 0.07 MPa {0.7 kg/cm2}
or more] or more]
Table 3 Table 4
CN4 Engine Resistance PSH Engine Resistance
When stopped, When stopped,
Max. 1 V Max. 1 z
starting switch ON Between starting switch ON
Between
At 1,300 rpm or more PSH At 1,300 rpm or more
(6) and
[Engine oil pressure (switch) and [Engine oil pressure
ground 20 – 30 V Min. 1 Mz
0.17 MPa {1.7 kg/cm2} ground 0.17 MPa {1.7 kg/cm2}
or more] or more]
20-378 HD255-5
(10)
HD255-5 20-379
(10)
G-11 Error code [C03C] [Abnormality in boost pressure sensor system]
Cause Remedy
1
• Connect T-adapter to CN2. Is voltage between CN2 (2) and NO
• Turn starting switch ON. (10) 4.6 – 5.4 V?
YES
2 wiring harness between CN2
NO (female) (2) and PIM (female) (3)
• Disconnect PIM. Is voltage between PIM (female) Repair or
or CN2 (female) (10) and PIM
• Turn starting switch ON. (3) and (1) 4.6 – 5.4 V? replace
(female) (1)
YES
Defective boost pressure sensor Replace
3
• Connect T-adapter to CN1 Is voltage between CN1 (3) and NO
and CN2.
CN2 (10) 0.3 – 4.7 V?
YES

• Disconnect CN1 and PIM. Is resistance between CN1 NO or short circuit with ground in Repair or
• Turn starting switch ON. (female) (3) and PIM (female) (2), wiring harness between CN1 replace
between CN1 (female) (3) and (female) (3) and PIM (female) (2)
YES
Defective boost pressure sensor Replace
Table 1
CN1, PIM (female) Resistance value
Between CN1 (3) and PIM (2) Max. 1 z
Between CN1 (3) and ground Min. 1 Mz
20-380 HD255-5
(10)
G-12 Error code [C03d] [Abnormality in fuel temperature sensor system
Cause Remedy
1
• Turn starting switch OFF. Is resistance between THL (male) NO
• Disconnect THL. Defective fuel temperature
(A) and (B), between (A) and Replace
• Fuel temperature: sensor
10 – 100ºC ground as shown in Table 1?
YES
• Turn starting switch OFF. Is resistance between CN2 disconnection in wiring harness
• Disconnect CN2. NO Repair or
(female) (11) and (10) between CN2 (female) (11) and
• Fuel temperature: replace
10 – 100ºC 3.5 - 90 kz? THL (female) (A) or CN2 (female)
(10) and THL (female) (B)
YES
3
• Turn starting switch OFF. in wiring harness between CN2 Repair or
(female) (11) and ground more
• Disconnect CN2 and THL. (female) (11) and THL (female) replace
than 1 Mz?
(A)
YES
Table 1
THL (Male) Resistance value
Between (A) and (B) 0.3 – 90 kz
Between (A) and ground Min. 1 Mz
HD255-5 20-381
(10)
G-13 Error code [C050] [Abnormality in preheating relay connecting point system]
a When error code <C051>, <C056> or <C057> is displayed, carry out this tuoubleshooting after carries out other
applicable troubleshooting
Cause Remedy
1
• Connect T-adapter to CN4. ground 20 – 30 V when
preheating is actuated?
YES
2
Is voltage between C23 (heater NO
• Disconnect C23.
end) and ground 20 – 30 V when Defective heater relay Replace
preheating is actuated?
YES short circuit with ground, or short
circuit with power source in Repair or
wiring harness between CN4 replace
(female) (3) and C23
20-382 HD255-5
(10)
G-14 Error code [C051] [Abnormality in preheating relay coil system]
Cause Remedy
1
• Turn starting switch OFF. Is resistance between R23 NO
Defective preheating relay Replace
• Disconnect R23. (male) (1) and (2) 200 – 900 z?
YES

Is voltage between CN2 (5) and NO or short circuit with ground in
• Connect T-adapter to CN2. Repair or
(10) 20 – 30 V when wiring harness between CN2
• Turn starting switch ON. replace
preheating is actuated? (female) (5) and R23 (female)
(1)
YES
HD255-5 20-383
(10)
G-15 Error code [C054] [Short circuit in starting switch C system]
Cause Remedy
1
• Turn starting switch ON. ground less than 1 V?
YES
2
• Disconnect starting switch Is voltage between starting NO
terminal C. switch terminal C and ground Defective starting switch Replace
• Turn starting switch ON. less than 1 V?
YES Short circuit with power source in

wiring harness between CN4 Repair or
(female) (2) and starting switch replace
terminal C
20-384 HD255-5
(10)
G-16 Error code [C056] [Power source system abnormality 1]
Cause Remedy
1
• Insert T-adapter to CN7. Is voltage between CN7 (6)(14) NO
• Turn starting switch ON. and (5)(13) 20 – 30 V?
YES
2
• Turn starting switch OFF. Is resistance between R23 NO Defective power source relay
Replace
• Disconnect R23. (male) (1) and (2) 200 – 400 z? R23 (coil end)
YES
Defective fuse or defective

3 contact, disconnection,
• Turn starting switch OFF. Is voltage between R23 (1) and NO or short circuit with ground in Repair or
• Insert T-adapter to R23. ground 20 – 30 V? wiring harness between starting replace
switch terminal ACC and R23
YES
(female) (1)
4
Defective contact or
Is resistance between R23 NO
• Turn starting switch OFF. disconnection in wiring harness Repair or
(female) (2) and ground less than
• Disconnect R23. between R23 (female) (2) and replace
1 z?
ground
YES
Defective power source fuse or

5 defective contact, disconnection,
• Insert T-adapter to R23. Is voltage between R23 (3) and NO or short circuit with ground in Repair or
• Turn starting switch ON. ground 20 – 30 V? wiring harness between power replace
source fuse and R23 (female)
YES (3)
6
• Turn starting switch OFF. Is voltage between R23 (5) and NO Defective power source relay
Replace
• Insert T-adapter to R23. ground 20 – 30 V? R23 (contact end)
YES
or short circuit with ground in Repair or
wiring harness between CN7 replace
(female) (6)(14) and R23
(female) (5)
HD255-5 20-385
(10)
20-386 HD255-5
(10)
G-17 Error code [C057] [Power source system abnormality 2]

Cause Remedy
1
• Turn starting switch OFF. Is voltage between CN7 (6)(14) NO
• Insert T-adapter to CN7. and (5)(13) less than 8 V?
YES
2
• Turn starting switch OFF. Short circuit with power source in
Is voltage between CN7 (6)(14) NO Repair or
• Disconnect R22. wiring harness between CN7
• Insert T-adapter to CN7. and (5)(13) less than 8 V? (female) (6)(14) and R22 replace
(female) (5)
YES
3
• Disconnect R22. Short circuit with power source in
Is voltage between CN4 (7), (18) NO Repair or
• Insert T-adapter in CN4. wiring harness between CN4
• Turn starting switch OFF. and (8), (19) below 8 V? replace
(7), (18) – R22 (1)
YES
Defective power source relay
Replace
R22 (contact end)
HD255-5 20-387
(10)
G-18 Error code [C05A] [Abnormality in fuel injection quantity control switch signal]
Cause Remedy
1
Are both fuel injection quantity NO
control switches 1 and 2 set to [F]?
YES
Defective fuel injection quantity Adjust again
control switch setting
G-19 Error code [C06A] [Abnormality in low engine coolant temperature sensor system ]
Table 1
TWL (male) Resistance value
Between (A) and (B) 0.3 – 9 kz
Between (A) and ground Min. 1 Mz
Cause Remedy
1
• Turn starting switch OFF. Is resistance between TWL
• Disconnect TWL. NO Defective water temperature
(male) (A) and (B), between (A) Replace
• Water temperature: low-temperature sensor
10 – 100ºC and ground as shown in Table 1?
YES
• Turn starting switch OFF. disconnection in wiring harness
• Disconnect CN2. between CN2 (female) (3) and Repair or
(female) (3) and (10)
• Water temperature: TWL (female) (A) or between replace
10 – 100ºC 0.3 – 9 kz?
CN2 (female) (10) and TWL
(female) (B)
YES
3
• Disconnect CN2 and TWL.
(female) (3) and ground more
(female) (3) and TWL (female) replace
than 1 Mz?
(A)
YES
20-388 HD255-5
(10)
G-20 Error code [C070] [Excess current in fuel supply pump PCV1 system]
Cause Remedy
1
Is resistance between PCV1 NO
(male) (1) and (2), between (1)(2) Defective fuel supply pump PCV1 Replace
• Disconnect PCV1.
and ground as shown in Table 1?
YES
Short circuit with chassis ground,
2
2 or short circuit with power source
(female) (10) and (11), (10)(11)
• Disconnect CN7. (female) (10) and PCV1 (female) replace
and PCV1 (female) (2)
YES
Table 1 Table 2
PCV1 (male) Resistance value CN7 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z Between (10) and (11) 2.3 – 5.3 z
Between (1)(2) and ground Min. 1 Mz Between (10)(11) and ground Min. 1 Mz
HD255-5 20-389
(10)
G-21 Error code [C071] [Excess current in fuel supply pump PCV2 system]
Cause Remedy
1
Is resistance between PCV2
• Turn starting switch OFF. NO Defective fuel supply pump
(male) (1) and (2), between (1)(2) Replace
• Disconnect PCV2. PCV2
YES
2 Short circuit with chassis ground,
or short circuit with power source
• Turn starting switch OFF. NO in wiring harness between CN7 Repair or
(female) (4) and (12), (4)(12)
YES
Table 1 Table 2
PCV2 (male) Resistance value CN7 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z Between (4) and (12) 2.3 – 5.3 z
Between (1)(2) and ground Min. 1 Mz Between (4)(12) and ground Min. 1 Mz
20-390 HD255-5
(10)
G-22 Error code [C074] [Disconnection in fuel supply pump PCV1 system]
Cause Remedy
1
• Turn starting switch OFF. Is resistance between PCV1 NO Defective fuel supply pump
Replace
• Disconnect PCV1. (male) (1) and (2) 2.3 – 5.3 z? PCV1
YES
2
• Turn starting switch OFF. wiring harness between CN7 Repair or
(female) (10) and (11), (11) and
YES
Table 1
CN7 (male) Resistance value
Between (10) and (11) 2.3 – 5.3 z
HD255-5 20-391
(10)
G-23 Error code [C075] [Disconnection in fuel supply pump PCV2 system]
Cause Remedy
1
• Turn starting switch OFF. Is resistance between PCV2 NO Defective fuel supply pump
Replace
• Disconnect PCV2. (male) (1) and (2) 2.3 – 5.3 z? PCV2
YES
2
• Turn starting switch OFF. wiring harness between CN7 Repair or
(female) (4) and (12), (12) and
YES
Table 1
CN7 (male) Resistance value
Between (4) and (12) 2.3 – 5.3 z
Between (12) and ground Min. 1 Mz
20-392 HD255-5
(10)
G-24 Error code [C077] [Abnormality in common rail fuel pressure sensor system]
1 Cause Remedy
• Turn starting switch ON. (10) 4.6 – 5.4 V?
YES
2 wiring harness between CN2
• Disconnect PFUEL. NO (female) (2) and PFUEL (female)
Is voltage between PFUEL Repair or
• Turn starting switch ON. (1) or between CN2 (female)
(female) (1) and (3) 4.6 – 5.4 V? replace
• See Note 1. (10) and PFUEL (female) (3)
YES
Defective common rail fuel
pressure sensor Replace
3
• Connect T-adapter to CN1 Is voltage between CN1 (1) and NO
and CN2.
CN2 (10) 0.3 – 4.7 V?
YES
4
• Disconnect CN1 and PIM. or short circuit with ground in Repair or
(female) (1) and PFUEL (female) NO
• Turn starting switch ON. wiring harness between CN1 replace
• See Note 1. (2), and between CN1 (female)
(female) (1) and PFUEL (female)
(1) and ground as shown in
(2)
Table 1?
YES
Replace
pressure sensor
Table 1
CN1, PFUEL (female) Resistance value
Between CN1 (1) and PFUEL (2) Max. 1 z
Between CN1 (1) and ground Min. 1 Mz
HD255-5 20-393
(10)
G-25 Error code [C079] [Common rail high fuel pressure abnormality 1]
Error code [C07A] [Common rail high fuel pressure abnormality 2]
Cause Remedy
1
at same time?
Go to troubl-
YES eshooting for
----
error code
displayed
2
Does fuel being used match NO
Unsuitable fuel being used Replace
ambient temperature?
YES
3
When priming pump is operated, NO
• Loosen joint of fuel supply
does fuel leak out from
pump overflow valve.
connection of joint?
YES
4
NO Go to Troub-
• Disassemble fuel supply In overflow valve, is spring
pump overflow valve. ---- leshooting
broken, seat worn, or ball stuck?
No. 7
YES
Defective overflow valve Replace
5
• Loosen joint of common When engine is started, does fuel NO
rail pressure limiter leak out from connection of joint?
YES
6
When troubleshooting for error
code [C077] is carried out, does NO
Defective pressure limiter Replace
any problem occur in electrical
system?
YES Defective electric system of
Clean or
common rail fuel pressure
replace
sensor
7
NO Defective mechanical system of
Is overflow pipe clogged? Replace
common rail fuel pressure sensor
YES
Clean or
Clogged overflow pipe
replace
20-394 HD255-5
(10)
G-26 Error code [C07b] [Fuel supply pump non-force feed 1]

Error code [C07C] [Fuel supply pump non-force feed 2]
Cause Remedy
1
at same time?
Go to troubl-
YES eshooting for
----
error code
displayed
2
Does fuel being used match NO
Unsuitable fuel being used Replace
ambient temperature?
YES
3
• Check visually with Is there any leakage of fuel from
engine stopped, then fuel pump, high- pressure NO
check visually with primary piping, common rail, or
engine at low idling. high-pressure secondary piping?
YES Fuel leakage in high-pressure Repair or

circuit. replace
4
• Measure fuel pressure Is fuel low pressure circuit
(see TESTING AND NO Defective equipment in Repair or
pressure 0.15 – 0.3 MPa
ADJUSTING). low-pressure circuit (See Note 1) replace
• Engine at high idling. {1.5 – 3.0 kg/cm 2 }?
YES
• Disconnect outlet piping 5

of common rail pressure Is drain amount from pressure NO
Defective pressure limiter Replace
limiter. limiter less than 10 cc/min?
• Start engine.
YES
6
• Disconnect pressure Does engine stop when PCV
compensation valve connector is disconnected from NO
connector on one side. one side of fuel pump and engine
• Start engine. is run on one lung?
YES Defective fuel pump PCV

(on bank where engine does Replace
not stop)
• Disconnect hose at
7
portion collecting spill Is spill flow from injector normal? NO
Defective fuel injector Replace
from injector. (See Note 2)
• Start engine.
YES
Replace
pressure sensor
HD255-5 20-395
(10)
Note 1: If the equipment in the low-pressure circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump, clogged filter
3) Leakage, clogged low-pressure fuel piping
4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig.1)
5) Clogged fuel filter
6) Fuel entering oil pan (fuel leakage inside head cover)
Note 2: Method of measuring amount of fuel spill flow

k The fuel in the spill line is at high temperature (up to 90°C), so be careful not to burn yourself during the
operation.
1) Disconnect the hose connected to the spill tube return collection portion (rear of engine).
2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container.
3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1 minute.
Limits for fuel spill amount (total for 6 cylinders)

Stall speed (rpm) Spill limit (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
20-396 HD255-5
(10)
G-27 Error code [C07d] [Abnormality in common rail fuel pressure]
a Go to Troubleshooting of error codes [C079] and [C07A].
G-28 Error code [C080] [Defective controller]
Cause Remedy
1
• Disconnect CN7.
(female) (5)(13) and ground less
between CN7 (female) (5)(13) replace
than 1 z?
and ground
YES
HD255-5 20-397
(10)
G-29 Error code [C081] [Disconnection in No. 1 fuel injector <A> system]
k A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution
or electric leakage. For details, see TESTING AND ADJUSTING,
Cause Remedy
1
• Turn starting switch OFF. Is resistance between No. 1 NO
Defective No. 1 fuel injector Replace
• Disconnect No.1 injector injector <A> connector CN1
<A> connector CN1. (male) (1) and (2) 0.4 – 1.1 z?
YES
disconnection in wiring harness
2 between CN6 (female) (7) and Repair or
• Turn starting switch OFF. Is resistance between CN6 NO No. 1 injector <A> connector replace
• Disconnect CN6. (female) (7) and (8) 0.4 – 1.1 z? CN1 (female) (1) or between
CN6 (female) (8) and No. 1
injector <A> connector CN1 Replace
YES (female) (2)
Defective engine controller
20-398 HD255-5
(10)
G-30 Error code [C082] [Disconnection in No. 2 fuel injector <E> system]
or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.
Cause Remedy
1
Is resistance between No. 2 Defective No. 2 fuel injector Replace
• Disconnect No. 2
injector <E> connector CN2
injector <E> connector
CN2. (male) (1) and (2) 0.4 – 1.1 z?
YES
2 disconnection in wiring harness
NO between CN6 (female) (4) and Repair or
• Turn starting switch OFF. Is resistance between CN6
No. 2 injector <E> connector CN2 replace
• Disconnect CN6. (female) (4) and (10) 0.4 – 1.1 z?
(female) (1) or between CN6
(female) (10) and No. 2 injector
YES <E> connector CN2 (female) (2)
HD255-5 20-399
(10)
G-31 Error code [C083] [Disconnection in No. 3 fuel injector <C> system]
Cause Remedy
1
injector <C> connector CN3 Defective No. 3 fuel injector Replace
• Disconnect No. 3 injector
<C> connector CN3. (male) (1) and (2) 0.4 – 1.1 z?
YES
disconnection in wiring harness
2
• Turn starting switch OFF. Is resistance between CN6 NO Repair or
No. 3 injector <C> connector CN3
• Disconnect CN6. (female) (3) and (9) 0.4 – 1.1 z? replace
YES <C> connector CN3 (female) (2)
20-400 HD255-5
(10)
G-32 Error code [C084] [Disconnection in No. 4 fuel injector <F> system]
Cause Remedy
1
• Turn starting switch OFF. Is resistance between No. 4
NO
• Disconnect No. 4 injector injector <F> connector CN4 Defective No. 4 fuel injector Replace
<F> connector CN4. (male) (1) and (2) 0.4 – 1.1 z?
YES
• Turn starting switch OFF. Is resistance between CN7 NO Repair or
No4 injector <F> connector CN4
YES <F> connector CN4 (female) (2)
HD255-5 20-400-1
(10)
G-33 Error code [C085] [Disconnection in No. 5 fuel injector system]
Cause Remedy
1
• Disconnect No. 5 injector injector connector CN5 Defective No. 5 fuel injector Replace
 connector CN5. (male) (1) and (2) 0.4 – 1.1 z?
YES
NO between CN7 (female) (1) and
• Turn starting switch OFF. Is resistance between CN7 Repair or
No. 5 injector connector
CN5 (female) (1) or between CN7
YES connector CN5 (female) (2)
20-400-2 HD255-5
(10)
G-34 Error code [C086] [Disconnection in No. 6 fuel injector <D> system]
Cause Remedy
1
• Disconnect No. 6 injector injector <D> connector CN6 Defective No. 6 fuel injector Replace
<D> connector CN6. (male) (1) and (2) 0.4 – 1.1 z?
YES
NO between CN7 (female) (2) and Repair or
• Turn starting switch OFF. Is resistance between CN7
No. 6 injector <D> connector CN6 replace
• Disconnect CN7. (female) (2) and (8) 0.4 – 1.1 z?
YES <D> connector CN6 (female) (2)
HD255-5 20-400-3
(10)
G-35 Error code [C08A] [Short circuit in No. 1 <A>, No. 2 <E>, No. 3 <C> fuel injector system]
a) Determining location of problem
Cause Remedy
1
Is resistance between CN6 Go to trouble-
• Turn starting switch OFF. (female) (7) and (8), between NO Abnormality in No. 1 <A> fuel
shooting
• Disconnect CN6. (7)(8) and ground as shown in injector
procedure b)
Table 1?
YES
2
Is resistance between CN6 Go to trouble-
• Turn starting switch OFF. (female) (4) and (10), between NO Abnormality in No. 2 <E> fuel
shooting
procedure c)
Table 1?
YES
3
Go to trouble-
• Turn starting switch OFF. (female) (3) and (9), between NO Abnormality in No. 3 <C> fuel
shooting
procedure d)
Table 1?
YES
4
• Disconnect CN7.
than 1 z?
and ground
YES
Table 1
CN6 (female) CN6 (female) CN6 (female) Resistance value
Between (7) and (8) Between (4) and (10) Between (3) and (9) 0.4 – 1.1 z
Between (7)(8) and ground Between (4)(10) and ground Between (3)(9) and ground Min. 1 Mz
20-400-4 HD255-5
(10)
b) Troubleshooting No. 1 fuel injector <A> system
Cause Remedy
1
Is resistance between No. 1
• Turn starting switch OFF. injector <A> connector CN1 NO
• Disconnect No. 1 injector Defective No. 1 fuel injector <A> Replace
<A> connector CN1.
(male) (1) and (2), between (1)(2)
and ground as shown in Table 2? Short circuit with chassis ground
YES in wiring harness between CN6
(female) (7) and No. 1 injector Repair or
<A> connector CN1 (female) (1) replace
or between CN6 (female) (8)
and No. 1 injector <A> connector
CN1 (female) (2)
Table 2
No.1 injector <A> connector CN1 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
c) Troubleshooting No. 2 fuel injector <E> system
Cause Remedy
1
injector <E> connector CN2
• Disconnect No. 2 injector Defective No. 2 fuel injector <E> Replace
<E> connector CN2. (male) (1) and (2), between (1)(2)
<E> connector CN2 (female) (1) replace
and No. 2 injector <E> connector
CN2 (female) (2)
Table 3
No.2 injector <E> connector CN2 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
d) Troubleshooting No. 3 fuel injector <C> system
Cause Remedy
1
injector <C> connector CN 3
• Disconnect No. 3 injector Defective No. 3 fuel injector Replace
<C> connector CN3. (male) (1) and (2), between (1)(2)
<C> connector CN3 (female) (1) replace
or between CN6 (female) (9) and
No.3 injector <C> connector CN3
(female) (2)
Table 4
No.3 injector <C> connector CN3 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
HD255-5 20-400-5
(10)
G-35 a), b) Related electrical circuit diagram
G-35 a), c) Related electrical circuit diagram
G-35 a), d) Related electrical circuit diagram
20-400-6 HD255-5
(10)
G-36 Error code [C08b] [Short circuit in No. 4 <F>, No. 5 , No. 6 <D> fuel injector system]
a) Determining location of problem
Cause Remedy
1
NO Go to trouble-
• Turn starting switch OFF. (female) (3) and (9), between Abnormality in No. 4 fuel
shooting
• Disconnect CN7. (3)(9) and ground as shown in injector <F>
procedure b)
Table 1?
YES
2
NO Go to trouble-
• Turn starting switch OFF. (female) (1) and (7), between Abnormality in No. 5 fuel
shooting
• Disconnect CN7. (1)(7) and ground as shown in injector 
procedure c)
Table 1?
YES
3
Go to trouble-
• Turn starting switch OFF. (female) (2) and (8), between NO Abnormality in No. 6 fuel
shooting
• Disconnect CN7. (2)(8) and ground as shown in injector <D>
procedure d)
Table 1?
YES
4
• Disconnect CN7.
than 1 z?
and ground
YES
Table 1
CN7 (female) CN7 (female) CN7 (female) Resistance value
Between (3) and (9) Between (1) and (7) Between (2) and (8) 0.4 – 1.1 z
Between (3)(9) and ground Between (1)(7) and ground Between (2)(8) and ground Min. 1 Mz
HD255-5 20-400-7
(10)
b) Troubleshooting No. 4 fuel injector <F> system
Cause Remedy
1
injector <F> connector CN4
• Disconnect No. 4 injector Defective No. 4 fuel injector <F> Replace
<F> connector CN4. (male) (1) and (2), between (1)(2)
in wiring harness between CN7
YES Repair or
<F> connector CN4 (female) (1) replace
and No. 4 injector <F> connector
CN4 (female) (2)
Table 2
No.4 injector <F> connector CN4 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
c) Troubleshooting No. 5 fuel injector system
Cause Remedy
1
• Turn starting switch OFF. NO Replace
injector connector CN5
• Disconnect No. 5 injector Defective No. 5 fuel injector 
 connector CN5. (male) (1) and (2), between (1)(2)
YES in wiring harness between CN7 Repair or
(female) (1) and No. 5 injector replace
 connector CN5 (female) (1)
and No. 5 injector connector
CN5 (female) (2)
Table 3
No.5 injector connector CN5 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
d) Troubleshooting No. 6 fuel injector <D> system
Cause Remedy
1
injector <D> connector CN6 NO
• Disconnect No. 6 injector Defective No. 6 fuel injector <D> Replace
<D> connector CN6. (male) (1) and (2), between (1)(2)
<D> connector CN6 (female) (1) replace
and No. 6 injector <D> connector
CN6 (female) (2)
Table 4
No.6 injector <D> connector CN6 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 z
20-400-8 HD255-5
(10)
G-36 a), b) Related electrical circuit diagram
G-36 a), c) Related electrical circuit diagram
G-36 a), d) Related electrical circuit diagram
HD255-5 20-400-9
(10)
TROUBLESHOOTING OF ENGINE ELECTRICAL
SYSTEM FOR START/STOP SYSTEM
(ENG MODE)
Serial No.: 1001 – 1599

ENG-1 Engine does not start (Fuel injection pump stop lever stays at STOP position) ........... 20-400-12
ENG-2 Engine does not stop (Fuel injection pump stop lever stays at RUN position) ............. 20-400-19

ENG-1 Engine does not start (Starting motor does not rotate) ................................................... 20-400-24
HD255-5 20-400-11
(10)
TROUBLESHOOTING ENG-1
ENG-1 Engine does not start

(Fuel injection pump stop lever stays at STOP position)
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Check that fuses (9) and (10) are not blown. (If they are blown, check for a short circuit with the ground
in the circuits related to fuses (9) and (10).)
Serial No.: 1001 – 1200
YES
YES
6
Is voltage
YES between ENS (7)
and chassis
normal?
1 • Turn starting
5 switch ON.
Does condition Is resistance
become normal • 20 – 30V
when 121 is YES between ENS NO
(female) (8) and
interchanged with chassis ground
another relay? normal?
• Turn starting 4 • Turn starting
switch to START. Is voltage switch OFF.
YES between ENS (4) • Disconnect ENS.
and chassis • Max. 1 Ω
ground normal?
NO
3 • Turn starting
Is resistance switch ON.
YES between 121 • 20 – 30V
(female) (2) and
chassis ground NO
2 normal?
Is voltage • Turn starting
between 121 (1) switch OFF.
NO and chassis • Disconnect 121. NO
ground normal? • Min. 1 MΩ
• Turn starting
switch ON.
• 20 – 30V
NO
20-400-12 HD255-5
(10)
Cause Remedy
Defective engine stop

Replace
relay
Defective engine stop Replace

motor
disconnection in wiring
8 YES harness between 121 Repair or
(female) (3) and ENS replace
Is voltage
YES between 121 (5) (female) (7)
7 and chassis Defective contact or
normal? disconnection in wiring Repair or
Is voltage harness between 121
between ENS (5) • Turn starting NO replace
(female) (5) and ENS
and chassis switch ON. (female) (5)
normal? • 20 – 30V
• Turn starting Defective engine stop
motor Replace
switch ON. NO
• 20 – 30V
harness between ENS Repair or
(female) (8) and chassis replace
ground
disconnection in wiring Repair or
harness between fuse FB1 replace
(9) and ENS (female) (4)
harness between 121
ground
harness between starting replace
switch terminal ACC1 and
121 (female) (1)
HD255-5 20-400-13
(10)
20-400-14 HD255-5
(10)
Serial No.: 1201 – 1599
YES
YES
6
Is voltage
YES between ENS (7)
and chassis
normal?
1 • Turn starting
5 switch ON.
Does condition Is resistance
become normal • 20 – 30V
when R01 is YES between ENS NO
(female) (8) and
another relay? normal?
• Turn starting 4 • Turn starting
switch to START. Is voltage switch OFF.
YES between ENS (4) • Disconnect ENS.
and chassis • Max. 1 Ω
ground normal?
NO
3 • Turn starting
Is resistance switch ON.
YES between R01 • 20 – 30V
(female) (2) and
chassis ground NO
2 normal?
Is voltage • Turn starting
between R01 (1) switch OFF.
NO and chassis • Disconnect R01. NO
normal? • Min. 1 MΩ
• Turn starting
switch ON.
• 20 – 30V
NO
20-400-16 HD255-5
(10)
Cause Remedy
Defective engine stop

Replace
relay
Defective engine stop Replace

motor
8 YES disconnection in wiring
harness between R01 Repair or
(female) (3) and ENS replace
Is voltage
YES between R01 (5) (female) (7)
7 and chassis Defective contact or
Is voltage
between ENS (5) harness between R01 replace
• Turn starting NO (female) (5) and ENS
and chassis switch ON. (female) (5)
normal? • 20 – 30V
• Turn starting Defective engine stop
Replace
switch ON. NO motor
• 20 – 30V
harness between ENS Repair or
ground
(9) and ENS (female) (4)
harness between R01 replace
(female) (2) and chassis
ground
harness between starting replace
switch terminal ACC1 and
R01 (female) (1)
HD255-5 20-400-17
(10)
20-400-18 HD255-5
(10)
ENG-2 Engine does not stop

(Fuel injection pump stop lever stays at RUN position)
fl Check that fuses (9) and (10) are not blown. (If they are blown, check for a short circuit with the
ground in the circuits related to fuses (9) and (10).)
Serial No.: 1001 – 1200
Cause Remedy
YES Defective engine stop

relay Replace
1
3 YES Defective engine stop
Does condition motor Replace
Is voltage
become normal between ENS
when 121 is YES (female) (8) and Defective contact or
another relay? disconnection in wiring
normal? harness between ENS Repair or
• Turn starting • Turn starting NO (female) (8) and chassis replace
2 switch OFF. ground
switch OFF.
Is voltage be- • Disconnect ENS.
tween ENS (7) • Max. 1 Ω
5 YES disconnection in wiring Repair or
NO and chassis harness between 121 replace
ground normal? Is voltage be- (female) (3) and E05
YES tween 121 (fe- (female) (7)
• Turn starting male) (6) and
switch OFF. chassis normal?
• 20 – 30V Is voltage be- disconnection in wiring Repair or
harness between 121 replace
tween ENS (3) • Turn starting NO (female) (6) and ENS
NO and chassis nor- switch OFF. (female) (3)
mal? • 20 – 30V
• Turn starting Defective engine stop Replace
switch OFF. NO motor
• 20 – 30V
HD255-5 20-400-19
(10)
20-400-20 HD255-5
(10)
Serial No.: 1201 – 1599
Cause Remedy
YES Defective engine stop

relay Replace
1
3 YES Defective engine stop
Does condition motor Replace
Is voltage
become normal between ENS
when R01 is YES (female) (8) and Defective contact or
another relay? disconnection in wiring
normal? harness between ENS Repair or
• Turn starting • Turn starting NO (female) (8) and chassis replace
2 switch OFF. ground
switch OFF.
Is voltage be- • Disconnect ENS.
tween ENS (7) • Max. 1 Ω
NO and chassis harness between R01 replace
ground normal? Is voltage be- (female) (3) and E05
YES tween R01 (fe- (female) (7)
• Turn starting male) (6) and
switch OFF. chassis normal?
• 20 – 30V Is voltage be- disconnection in wiring Repair or
harness between R01 replace
tween ENS (3) • Turn starting NO (female) (6) and ENS
NO and chassis nor- switch OFF. (female) (3)
mal? • 20 – 30V
• Turn starting Defective engine stop Replace
switch OFF. NO motor
• 20 – 30V
HD255-5 20-400-21
(10)
20-400-22 HD255-5
(10)
ENG-1 Engine does not start (Starting motor does not rotate)
fl When carrying out troubleshooting, set the directional lever in the "NEUTRAL" position.
fl Before carrying out troubleshooting, check that fuses FB1 (2), (20), and FB2 (16) are normal. (If any of
them is broken, check its circuit for a grounding fault.)
(1/2)
4 YES
Is voltage between
YES starting motor ter-
minal B and chassis
ground normal?
• 20 – 30 V NO
• Starting switch:
START
6 YES
3 Is voltage
Is voltage YES between SR (2)
YES between starting and chassis
motor terminal C ground normal?
and GND
normal? • Max. 12 V NO
• 20 – 30 V • Starting switch:
• Starting switch: ON
START
YES
5
Is voltage 8
between R13 (3) Is voltage
NO and chassis YES between R14 (6)
ground normal? and chassis
ground normal?
• 20 – 30 V
• Starting switch: • Shift lever at N:
START 20 – 30 V
2
• Shift lever not at
Does battery re- N: Max. 1 V NO
YES 15 • Starting switch:
lay make operat-
ing sound? ON
Is voltage
between R13 (6)
NO and chassis
ON ← → OFF ground normal?
• 20 – 30 V
START
1
13 YES
Are electrolyte Is voltage be-
specific gravity tween starting
and battery switch terminal C
and chassis
voltage normal? ground normal?
• Min. 1.26 NO
• Min. 25 V
NO
NO
20-400-24 HD255-5
(10)
Cause Remedy
Defective starting motor Repair or

replace
Disconnection or defective
between starting motor Repair or
terminal B – battery relay replace
terminal M
contact in wiring harness Repair or
between R13 (female) (3) – replace
SR (female) (1)
Repair or
Defective alternator replace
Defective relay R13 Replace
10 YES
Defective relay R14 Replace
Is voltage
YES between R14 (2)
and chassis
9 ground normal?
To (2/2) A
Is voltage • Shift lever at N: NO
between R14 (1) 20 – 30 V
• Shift lever not at N: Max.1V
and chassis • Starting switch:ON Defective fusible link or dis-
ground normal? connection or defective
12 YES Repair or
• 20 – 30 V between battery relay ter- replace
Is voltage between
• Starting switch: battery relay termi- minal M – R14 (female) (1)
ON
NO nal M and chassis
ground normal?
Defective battery relay Replace
• 20 – 30 V NO (between B and M)
ON
contact in wiring harness Repair or
between starting switch replace
terminal C – R13 (female)
Defective starting switch Replace

(between B and C)
To (2/2) B
Charge or
Lowering battery capacity replace
HD255-5 20-400-25
(10)
(2/2)
Cause Remedy
11 YES
Defective shift lever Replace
Is resistance
(1/2) between R14
A (female) (2) and
SF (female) (4) Disconnection or defec-
normal? tive contact in wiring har- Repair or
NO ness between R14 (fe- replace
• Max. 1 Ω male) (2) – SF (female) (4)
• Disconnect R14 and SF.
• Starting switch: OFF
15 YES
Defective battery relay Replace
Is resistance be-
YES tween battery re-
lay terminal E
and chassis Disconnection or defec-
ground normal? Repair wiring harness. tive contact in wiring har- Repair or
14 ness between battery re-
replace
• Max. 1 Ω NO lay terminal E – chassis
Is voltage • Disconnect terminal E. ground
(1/2) between battery
B relay terminal BR • Starting switch: OFF
Disconnection or defec-
and chassis YES tive contact in wiring har- Repair or
ground normal? 16 ness between starting replace
Is voltage be- switch terminal BR – bat-
• 20 – 30 V tery relay terminal BR
• Starting switch: tween starting
switch terminal
ON NO BR and chassis 17 YES Defective starting switch Replace
ground normal? Is voltage (between B and BR)
• 20 – 30 V between starting
switch terminal B
• Starting switch: NO and chassis
ON ground normal? To C
• 20 – 30 V NO
19 YES contact in wiring harness
between battery relay ter- Repair or
Is voltage be- minal B - FU (1), (2) – start- replace
YES tween FU (2) and ing switch terminal B
18 chassis ground
Is voltage be- normal?
tween battery re- Defective fuse unit Replace
• 20 – 30 V NO
C lay terminal B
and chassis
ground normal?
Disconnection or defec-
• 20 – 30 V tive contact in wiring har- Repair or
NO ness between battery – replace
• Starting switch: battery relay terminal B
ON
20-400-26 HD255-5
(10)
HD255-5 20-400-27
(10)
TROUBLESHOOTING A-1
A-1 Abnormality in power source

a) [Defective controller power source] is displayed (all LEDs OFF)
Serial No.: 1001 –␣ 1599

Cause Remedy
YES
Defective controller Replace
2
Is voltage Defective contact or
YES between CN1 disconnection in wiring
(9),(17) and
3 YES harness between fuse FB2 Repair or
(8),(18) normal? Is voltage between (14),(15) and CN1 (female) replace
1 CN1 (9),(17) and (9),(17)
• Turn starting chassis ground Defective contact or
Is shift indicator switch ON. normal? disconnection in wiring
NO Repair or
display normal? • 20 – 30 V harness between CN1
• Turn starting NO (female) (8),(16) and replace
switch ON. chassis ground
• Turn starting • 20 – 30 V
switch ON. disconnection in wiring Repair or
NO harness between battery replace
relay BRN and fuse
box
Serial No.: 1001 –␣ 1200
20-406 HD255-5
(10)
TROUBLESHOOTING A-1
Serial No.: 1201 – 1599
HD255-5 20-407
(10)
TROUBLESHOOTING A-1
Cause Remedy
YES
2
Is voltage Defective contact or
YES between CN1 disconnection in wiring
(9),(17) and
3 YES harness between fuse FB2 Repair or
(8),(18) normal? Is voltage between (8),(10) and CN1 (female) replace
1 CN1 (9),(17) and (9),(17)
• Turn starting chassis ground Defective contact or
Is shift indicator switch ON. normal? disconnection in wiring
NO Repair or
display normal? • 20 – 30 V harness between CN1
• Turn starting NO (female) (8),(16) and replace
switch ON. chassis ground
• Turn starting • 20 – 30 V
switch ON. disconnection in wiring Repair or
NO harness between battery replace
relay BRN and fuse
box
20-407-1 HD255-5
(10)
TROUBLESHOOTING A-1
b) 0.1 (Drop in voltage of controller) is displayed

Cause Remedy
harness between replace
Is voltage alternator terminal B –
between
alternator battery terminal (+).
terminal B and
chassis normal? Defective generation of
Replace
• 20 – 30 V NO electricity by alternator
• Start engine.
20-408 HD255-5
(10)
TROUBLESHOOTING A-1
c) 0.2 (Drop in voltage of solenoid) is displayed

Serial No.: 1001 –␣ 1200
Cause Remedy
YES
Go to A-4
1
Is failure code
[0.6] displayed at 2 YES Defective transmission cut
same time? When transmis- Replace
relay
sion cut relay is
interchanged
with another Defective contact, or
NO relay, does failure disconnection in wiring
code [0.6] go out? harness between CN2 Repair or
NO (female)(1),(12) and (18) replace
• Turn starting
switch ON. (female) (5)
HD255-5 20-409
(10)
TROUBLESHOOTING A-1

Cause Remedy
YES
Go to A-4
1
Is failure code
[0.6] displayed at 2 YES Defective transmission cut
same time? When transmis- Replace
relay
sion cut relay is
interchanged
with another Defective contact, or
NO relay, does failure disconnection in wiring
code [0.6] go out? harness between CN2 Repair or
NO (female)(1),(12) and R20 replace
• Turn starting
switch ON. (female) (5)
Serial No.: 1201 – 1599
20-410 HD255-5
(10)
TROUBLESHOOTING A-2
A-2 0.3 (Neutral safety) is displayed

fl When the starting switch is turned to ON with the transmission shift lever at a position other than N, or
when the power source is momentarily cut when traveling.
Cause Remedy
Use correct
procedure given
1 YES Mistaken operation in Operation and
Was starting key Maintenance
turned to START Manual when
when lever was starting
at position other
than N? disconnection in wiring
harness between battery Repair or
NO relay BRN and CN1 replace
(female) (9),(17)
Serial No.: 1001 –␣ 1200
HD255-5 20-411
(10)
TROUBLESHOOTING A-2
Serial No.: 1201 – 1599
20-412 HD255-5
(10)
TROUBLESHOOTING A-3
A-3 Controller system

a) . [Only dot lights up] or 0.4 (Data error) is displayed
Cause Remedy
3 YES
Does failure code Go to Item 4
go out when
YES newly installed
wireless or elec- Defective installation of
2 tronic equipment
is removed? wireless or surge generat- Repair or
Has wireless or ed by electronic equip- replace
YES electronic equip- NO ment
ment been newly
installed?
4 YES Surge absorber diode is Repair or
1 defective or has come out replace
Is failure code dis-
Is voltage played only when
between CN1 a certain switch is
(9),(17) and NO operated?
(8),(16) normal? Defective controller Replace
NO
• Turn starting
switch ON.
• 20 – 30V
Go to A-1, a)
NO
b) 0.5 (Double engagement for clutch) is displayed

Cause Remedy
1 YES
Go to A-13, a)
Is [3. ← 1 – 6,8]
displayed at
same time?
NO
HD255-5 20-413
(10)
TROUBLESHOOTING A-4
A-4 0.6 (Disconnection, short circuit, short circuit with ground in

transmission cut relay) is displayed
fl This display is given when there is defective contact, short circuit, short circuit with ground or discon-
nection in the transmission cut relay system.
Serial No.: 1001 –␣ 1200
Cause Remedy
YES Defective transmission cut

Replace
relay
1
Does failure code
go out when 3 YES
transmission cut Defective controller Replace
relay is inter- Is voltage
changed with YES between CN1
another relay? (female) (15) and
2 chassis ground Defective contact or dis-
Is voltage normal? connection in wiring har- Repair or
between 18 (1) NO ness between CN1 (fe- replace
• Disconnect CN1.
male) (15) – 18 (female) (2)
NO and chassis • Turn starting
ground normal? switch ON. Defective contact or
• 20 – 30V disconnection in wiring
• Turn starting Repair or
switch ON. NO (14),(15) and 18 (female)
• 20 – 30V (2)
20-414 HD255-5
(10)
TROUBLESHOOTING A-4
Serial No.: 1201 – 1599
Cause Remedy

Replace
relay
1
Does failure code
go out when 3 YES
relay is interchan- Is voltage
ged with another YES between CN1
relay? (female) (15) and Defective contact or
2 chassis ground disconnection in wiring
Is voltage be- normal? harness between CN1 Repair or
tween R20 (1) and • Disconnect CN1. NO (female) (15) – R20 replace
• Turn starting (female) (2)
NO chassis ground
normal? switch ON.
• 20 – 30V
• Turn starting disconnection in wiring Repair or
switch ON. harness between fuse FB2 replace
NO (14),(15) and R20 (female)
• 20 – 30V
(1),(3)
HD255-5 20-415
(10)
TROUBLESHOOTING A-4
Cause Remedy

Replace
relay
1
Does failure code
go out when 3 YES
relay is interchan- Is voltage
ged with another YES between CN1
relay? (female) (15) and Defective contact or
2 chassis ground disconnection in wiring
Is voltage be- normal? harness between CN1 Repair or
tween R20 (1) and • Disconnect CN1. NO (female) (15) – R20 replace
• Turn starting (female) (2)
NO chassis ground
normal? switch ON.
• 20 – 30V
switch ON. harness between fuse FB2 replace
NO (8),(10) and R20 (female)
• 20 – 30V
(1),(3)
20-415-1 HD255-5
(10)
TROUBLESHOOTING A-5

automatic retarder solenoid) is displayed
Serial No.: 1001 –␣ 1200 Cause Remedy
3 YES
Is voltage
YES between CN1 (4)
and chassis Defective contact or
2 ground normal? disconnection in wiring
harness between CN1 Repair or
Is resistance
• Turn starting NO (female) (4) and fuse FB2 replace
YES between CN1 (fe-
male) (13) and switch ON. (14),(15)
chassis ground • 20 – 30V
normal? Defective contact or
1 • Turn starting harness between CN1 replace
switch OFF. Is resistance (female) (13) and ARS2
Is resistance • Disconnect CN1. between ARS1 (fe-
between ARS1 (female)
• 20 – 60Ω male) and chassis
(male) and ARS2 NO ground normal?
Defective contact or Repair or
(male) normal? disconnection in wiring replace
• Turn starting NO harness between ARS1
• Turn starting switch OFF. (female) and chassis
switch OFF. • Disconnect ARS1. ground
• Disconnect ARS1 • Max. 1Ω
and ARS2. Defective automatic Replace
• 20 – 60Ω NO retarder solenoid
20-416 HD255-5
(10)
TROUBLESHOOTING A-5
Serial No.: 1201 – 1599
Cause Remedy
3 YES
Is voltage
YES between CN1 (4)
Is resistance
YES between CN1
(female) (13) and switch ON. (14),(15)
switch OFF. Is resistance
Is resistance between ARS (female) (13) and ARS
• Disconnect CN1. (female) (1)
between ARS • 20 – 60Ω (female) (2) and
(male) (1) and (2) NO chassis ground
normal? Defective contact or Repair or
normal? disconnection in wiring replace
• Turn starting NO harness between ARS
• Turn starting switch OFF. (female) (2) and chassis
switch OFF. • Disconnect ARS ground
• Disconnect ARS. • Max. 1Ω
• 20 – 60Ω Defective automatic Replace
NO retarder solenoid
HD255-5 20-417
(10)
TROUBLESHOOTING A-5
Cause Remedy
3 YES
Is voltage be-
YES tween CN1 (4)
Is resistance
YES between CN1
(female) (13) and switch ON. (8),(10)
switch OFF. Is resistance
Is resistance be- between ARS (female) (13) and ARS
tween ARS (male) • 20 – 60Ω (female) (2) and
(1) and (2) nor- NO chassis ground
mal? disconnection in wiring replace
• Turn starting NO harness between ARS
switch OFF. • Disconnect ARS ground
• Disconnect ARS. • Max. 1Ω
• 20 – 60Ω Defective automatic Replace
NO retarder solenoid
20-417-1 HD255-5
(10)
TROUBLESHOOTING A-6

exhaust brake solenoid) is displayed
Serial No.: 1001 –␣ 1599

Cause Remedy
3 YES
Is voltage be-
YES tween CN1 (5)
Is resistance replace
YES between CN1 (14) • Turn starting NO (female) (5) and fuse FB2
switch ON. (14),(15)
and chassis • 20 – 30V
switch OFF. Is resistance be-
Is resistance between EXH1 (fe- (female) (14) and EXH1
tween EXH1 • 20 – 60Ω male) (2) and
• Turn starting NO harness between EXH1
switch OFF. • Disconnect EXH1. ground
• Disconnect • Max. 1Ω
EXH1. Defective exhaust brake Replace
• 20 – 60Ω NO solenoid
Serial No.: 1001 –␣ 1200
20-418 HD255-5
(10)
TROUBLESHOOTING A-6
Serial No.: 1201 – 1599
HD255-5 20-419
(10)
TROUBLESHOOTING A-6
Cause Remedy
3 YES
Is voltage be-
YES tween CN1 (5)
Is resistance replace
YES between CN1 (14) • Turn starting NO (female) (5) and fuse FB2
switch ON. (8),(10)
and chassis • 20 – 30V
switch OFF. Is resistance be-
Is resistance between EXH1 (fe- (female) (14) and EXH1
tween EXH1 • 20 – 60Ω male) (2) and
• Turn starting NO harness between EXH1
switch OFF. • Disconnect EXH1. ground
• Disconnect • Max. 1Ω
EXH1. Defective exhaust brake Replace
• 20 – 60Ω NO solenoid
20-419-1 HD255-5
(10)
TROUBLESHOOTING A-7
A-7 Speed sensor system

a) 1.0 (Disconnection in engine speed sensor) or 6.0 (Defective output of engine speed sensor)
Cause Remedy
1 YES Defective controller Replace

Is resistance
between CN31 Defective contact or
(female) (13) and disconnection in wiring
(14), and between 2 harness between CN31
(13) and chassis as YES (female) (13) and E12 Repair or
Is resistance (female) (1) or between replace
shown in Table? between E12 CN31 (female) (14) and
• Turn starting (male) (1) and (2), E12 (female) (2), or short
circuit with ground
switch OFF. NO and between (1)
• Disconnect and chassis ground
as shown in Table? Defective engine speed Replace
CN31.
NO sensor
• Turn starting
switch OFF.
• Disconnect E12.
Table 1
CN31 (female) E12 (male) Resistance value

Between (13) – (14) Between (1) and (2) 500 – 1000 Ω
Between (13) and chassis Between (1) and chassis Min. 1 MΩ
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
20-420 HD255-5
(10)
TROUBLESHOOTING A-7
HD255-5 20-420-1
(10)
TROUBLESHOOTING A-7
b) 1.1 (Disconnection in transmission input shaft speed sensor) or 6.1 (Defective output of trans-
mission input shaft speed sensor)
Cause Remedy

Is resistance
(2) and chassis as Is resistance YES (female) (2) and N1 Repair or
shown in Table? between N1 (female) (1) or between replace
(male) (1) and (2), CN31 (female) (14) and N1
• Turn starting (female) (2), or short
switch OFF. NO and between (1) circuit with ground
• Disconnect and chassis as
CN31. shown in Table? Defective transmission Replace
NO input shaft speed sensor
• Turn starting
switch OFF.
• Disconnect N1.
Table 1
CN31 (female) N1 (male) Resistance value

HD255-5 20-421
(10)
TROUBLESHOOTING A-7
c) 1.2 (Disconnection in transmission intermediate shaft speed sensor) or 6.2 (Defective output of
transmission intermediate shaft speed sensor)
Cause Remedy

Is resistance
shown in Table? (female) (1) or between replace
between N2 CN31 (female) (14) and N2
• Turn starting (male) (1) and (2), (female) (2), or short
NO intermediate shaft speed
• Turn starting sensor
switch OFF.
• Disconnect N2.
Table 1

20-422 HD255-5
(10)
TROUBLESHOOTING A-7
d) 1.3 (Disconnection in transmission output shaft speed sensor) or 6.3 (Defective output of
transmission output shaft speed sensor)
Cause Remedy

Is resistance
shown in Table? (female) (1) or between replace
between N3 CN31 (female) (14) and N3
• Turn starting (male) (1) and (2), (female) (2), or short
NO output shaft speed sensor
• Turn starting
switch OFF.
• Disconnect N3.
Table 1

HD255-5 20-423
(10)
TROUBLESHOOTING A-8
A-8 Slipping clutch or speed sensor system

a) 2.1 [Defective lock-up clutch system] is displayed
Cause Remedy
1 YES
Go to A-7
Is failure code
[6. ← 0 – 3]
displayed at
same time? Go to H Mode (check
clutch oil pressure) Replace
NO
b) 2.2 [Failure in Hi clutch or input shaft speed sensor system] or 2.3 [Failure in Lo clutch or input
shaft speed sensor system] is displayed
Cause Remedy
1 YES
Go to A-7
Is failure code
[6. ← 0 – 3]
displayed at
NO
c) 2.4 [Failure in 1st clutch or output shaft speed sensor system] or 2.5 [Failure in 2nd clutch or
output shaft speed sensor system] or 2.6 [Failure in 3rd clutch or output shaft speed sensor
system] or 2.8 [Failure in R clutch or output shaft speed sensor system] is displayed
Cause Remedy
1 YES
Go to A-7
Is failure code
[6. ← 0 – 3]
displayed at
NO
20-424 HD255-5
4
TROUBLESHOOTING A-9
A-9 A.1 Abnormality in model selection signal is displayed

Cause Remedy
1 YES
Is resistance
between CN52
(30), (31), (32) and Defective contact or
chassis normal? disconnection in wiring Repair or
harness between C52 replace wiring
NO harness
(female) (30), (31), (32)
and chassis ground
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
HD255-5 20-425
(10)
TROUBLESHOOTING A-10
A-10 Abnormality in shift lever system

a) 0.7 [Short circuit with 12 V output circuit] is displayed
Cause Remedy
YES
1
Is resistance
between CN2
2
(female) (14) and YES Defective shift lever
When SF is dis- Replace
chassis normal? connected, does assembly
• Turn starting resistance value
between CN2 (fe-
switch OFF. Defective contact or
• Disconnect
NO male) (14) and disconnection in wiring
chassis ground Repair or
CN2 become normal? harness between CN2
NO replace
• Min. 1MΩ • Turn starting (female) (14) and SF
switch OFF. (female) (1)
• Disconnect CN2 and SF
• Min. 1MΩ
20-426 HD255-5
(10)
b) 1.5 [Short circuit, short circuit with ground in lever signal system] is displayed
Cause Remedy
YES
Defective shift lever as- Replace
sembly
1
When SF is
disconnected, YES
does [1.5] display Defective transmission
neutral relay Replace
go out and [1.6] 2
display appear?
Does failure code
• Turn starting [1.5] go out when
switch ON and transmission YES Defective backup alarm
disconnect SF. NO neutral relay is Replace
3 relay
disconnected? Does failure code
switch ON. backup alarm 3 YES Defective shift indicator
NO relay is Replace
disconnected? Does failure code controller assembly
switch ON. C2 is disconnec-
NO Wiring harness between
ted? controller – shift lever – Repair or
• Turn starting NO relay short circuiting with replace
switch ON. chassis ground (See Note)
Note: Turn the starting switch ON, move the gearshift lever one stage at a time from the D position to the
R position, and check the position where the failure code [1.5] display goes out.
If the signal for the circuit which is short circuiting with the ground matches the signal for the
gearshift lever, the input signal becomes one, so the failure code goes out. In other words, the
wiring harness of the signal system where the failure code goes out is short circuiting with the
ground.
HD255-5 20-427
(10)
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
20-428 HD255-5
(10)
HD255-5 20-428-1
(10)
20-430 HD255-5
(10)
A-11 A.1 [Disconnection in accelerator signal, defective adjustment,

disconnected link] is displayed
Serial No.: 1001 –␣ 1599

Cause Remedy
4 YES
Is voltage be-
YES tween CN32 (31)
and CN31 (16)
3 Defective contact or dis-
normal? connection in wiring har- Repair or
Is voltage be-
YES tween SR1 (male) • Turn starting NO ness between CN32 (fe-
male) (31) and SR1 (fe-
replace
(1) and (3) nor- switch ON. male) (2)

mal? • 0.6 – 4.75 V
5 YES
2 • Turn starting Defective controller Replace
Is resistance
Is voltage between switch ON. between CN31 Wiring harness between
YES SR1 (male) (2) and • 4.6 – 5.4 V (female) (16) and CN32 (female) (6) – SR1
(3) as shown in NO (6), (6) and chassis
drawing below (female) (1), CN31
when accelerator normal? (female) (16) – SR1 Repair or
1 pedal is operated? • Turn starting NO (female) (3) short
circuiting with chassis replace
Is resistence • Turn starting switch OFF. ground, contact with other
between SR1 • Disconnect CN31 wiring harness
switch OFF.
(male) (1) and (3)
• Disconnect SR1. Defective accelerator Repair or
normal? sensor linkage or
NO replace
accelerator sensor
• 4.6 – 5.4 kΩ
• Turn starting
switch OFF.
• Disconnect SR1. NO Defective accelerator Replace
sensor
Table
CN31 (female) Resistance value

Between (16) – (6) 4.6 – 5.4 KΩ
Between (6) and chassis Min. 1 MΩ
HD255-5 20-431
(10)
20-431-1 HD255-5
(10)
Cause Remedy
4 YES
Is voltage be-
YES tween CN32 (31)
and CN31 (16)
normal? connection in wiring har- Repair or
Is voltage be-
YES tween WAS2 • Turn starting NO ness between CN32 (fe-
male) (31) and WAS2 (fe-
replace
(male) (1) and (3) switch ON. male) (2)

normal? • 0.6 – 4.75 V
5 YES
2 • Turn starting Defective controller Replace
Is resistance
Is voltage between switch ON. between CN31 Wiring harness between
YES WAS2 (male) (2) • 4.6 – 5.4 V (female) (16) and CN32 (female) (6) – WAS2
and (3) as shown NO (6), (6) and chassis
in drawing below (female) (1), CN31
when accelerator normal? (female) (16) – WAS2 Repair or
1 pedal is operated? • Turn starting NO (female) (3) short
circuiting with chassis replace
Is resistence • Turn starting switch OFF. ground, contact with other
between WAS2 • Disconnect CN31 wiring harness
switch OFF.
(male) (1) and (3)
• Disconnect WAS2. Defective accelerator Repair or
normal? sensor linkage or
NO replace
• 4.6 – 5.4 kΩ accelerator sensor
• Turn starting
switch OFF.
• Disconnect WAS2. Defective accelerator Replace
NO sensor
Table
CN31 (female) Resistance value

Between (16) – (6) 4.6 – 5.4 KΩ
Between (6) and chassis Min. 1 MΩ
HD255-5 20-431-2
(10)
20-432 HD255-5
(10)
A-12 1.9 [Short circuit with ground in transmission valve oil

temperature sensor] is displayed
Cause Remedy
YES
2
Defective contact or discon-
Is resistance nection in wiring harness
YES between CN31 between CN31 (female) (16)
(female) (16) and 3 YES Repair or
and C/V.T (female) (2) or
CN32 (female) Is resistance between CN32 (female) (29) replace
1 (29) normal? and C/V.T (female) (1), or
between C/V.T
• Turn starting (male) (1) and (2) short circuit with ground
Is torque conver- NO
ter oil tempera- switch OFF. normal?
• 1 – 500 kΩ Defective transmission oil
ture gauge in temperature sensor Replace
green range? • Disconnect CN31 • Turn starting NO
and CN32. switch OFF.
• Turn starting • Disconnect C/V.T.
switch ON. • 1 – 500 Ω
See H-8
NO
HD255-5 20-433
(10)
A-13 Pressure control valve system

a) 3.1 [Defective lock-up clutch pressure control valve system I] or 3.2 [Defective Hi clutch pres-
sure control valve system I]
3.3 [Defective Lo clutch pressure control valve system I] or 3.4 [Defective 1st clutch pressure
control valve system I]
3.5 [Defective 2nd clutch pressure control valve system I] or 3.6 [Defective 3rd clutch pressure
control valve system I]
3.8 [Defective R clutch pressure control valve system I] is displayed
fl Always connect any disconnected connectors before going on to
the next step. Cause Remedy
YES
1 Go to H-6
Is resistance
between
applicable pin of Wiring harness between
CN51 (female) 2 YES controller – shift indicator
and chassis Is resistance – fill switch short Replace
ground normal? between fill switch circuiting with ground
• Turn starting connector (male)
switch OFF. NO (1) and chassis
• Disconnect ground normal? Repair or
Defective fill switch
CN51. • Turn starting NO replace
• Min. 1 MΩ switch OFF.
• Disconnect applicable
connector.
• Min. 1 MΩ
20-434 HD255-5
(10)
b) 4.1 [Defective lock-up clutch pressure control valve system II] or 4.2 [Defective Hi clutch pres-
sure control valve system II]
4.3 [Defective Lo clutch pressure control valve system II] or 4.4 [Defective 1st clutch pressure
control valve system II]
4.5 [Defective 2nd clutch pressure control valve system II] or 4.6 [Defective 3rd clutch pressure
control valve system II]
4.8 [Defective R clutch pressure control valve system II] is displayed
b1) Checking fill signal system Cause Remedy
YES
1 Go to H-6
Is resistance
between
applicable pin of Defective contact or
CN51 (female) 2 YES disconnection in wiring
and chassis Is resistance be- harness between Replace
ground normal? tween fill switch controller and fill switch
• Start engine. connector (male)
• Disconnect NO (1) and chassis
CN51. ground normal? Repair or
Defective fill switch
• Max. 1 Ω • Disconnect NO replace
applicable
connector.
• Start engine.
• Max. 1M Ω
HD255-5 20-435
(10)
b2) Checking when 4.2 or 4.3 is displayed
Cause Remedy
Go to A-8 b)
b3) Checking when 4.4 or 4.6 or 4.8 is displayed
Cause Remedy
Go to A-8 c)
20-436 HD255-5
4
HD255-5 20-439
(10)
b) 9.1 [Short circuit in lock-up clutch pressure control solenoid system] or 9.2 [Short circuit in Hi
clutch pressure control solenoid system]
9.3 [Short circuit in Lo clutch pressure control solenoid system] or 9.4 [Short circuit in 1st
9.5 [Short circuit in 2nd clutch pressure control solenoid system] or 9.6 [Short circuit in 3rd
9.8 [Short circuit in R clutch pressure control solenoid system] is displayed
Cause Remedy
YES
1
Is resistance
between pins of Defective contact or
CN2 (female) and 2
Is resistance YES disconnection in wiring Repair or
chassis ground as
shown in Table 1? between solenoid harness between replace
connector (male) controller and solenoid
• Turn starting (1) and (2), and
switch OFF. NO between (1)(2) and
• Disconnect CN2. chassis ground as
shown in Table 2? NO Defective solenoid Replace
• Turn starting switch
OFF.
• Disconnect
applicable connector.
Table 1
Failure code Measurement position Resistance value Measurement position Resistance value
9.1 Between CN2 (female) (10) – (20) Between CN2 (female) (10)(20) – chassis
9.4 Between CN2 (female) (2) – (13) 5 – 25 Ω Between CN2 (female) (2)(13) – chassis Min. 1 MΩ
Table 2
Failure code Measurement position Resistance value Measurement position Resistance value
9.1 Between L/C.PS (male) (1) - (2) Between L/C.PS (female) (1)(2) - chassis
9.2 Between H.PS (female) (1) - (2) Between H.PS (female) (1)(2) - chassis
9.3 Between L.PS (female) (1) - (2) Between L.PS (female) (1)(2) - chassis
9.4 Between 1.PS (female) (1) - (2) 5 – 25 Ω Between 1.PS (female) (1)(2) - chassis Min. 1 MΩ
9.5 Between 2.PS (female) (1) - (2) Between 2.PS (female) (1)(2) - chassis
9.6 Between 3.PS (female) (1) - (2) Between 3.PS (female) (1)(2) - chassis
9.8 Between R.PS (female) (1) - (2) Between R.PS (female) (1)(2) - chassis
20-440 HD255-5
4
HD255-5 20-441
(10)
A-16 Pressure sensor system

a) 8.1 [Defective output of torque converter inlet pressure sensor] or 8.3 [Defective output of
torque converter inlet pressure sensor] is displayed
Cause Remedy
2 YES Defective torque converter Replace

Is voltage inlet oil pressure sensor
YES between T/C IN
1 (1) and (3) Defective contact or
Is voltage • Turn starting harness between CN31 replace
between T/C IN NO
switch ON. (female) (7) and T/C IN
(1) and (2) • 0.5 – 4.5 V (female) (3)
normal?
• Turn starting Defective contact or
switch ON. disconnection in wiring
NO Repair or
• 20 – 30 V harness between CN1
replace
(female) (3) and T/C IN
(female) (2), short circuit
with ground
20-442 HD255-5
(10)
b) 8.2 [Defective output of torque converter outlet pressure sensor] or 8.4 [Defective output of
torque converter outlet pressure sensor] is displayed
Cause Remedy

Is voltage outlet oil pressure sensor
YES between T/C OUT
(1) and (3) Defective contact or
1 disconnection in wiring
normal? Repair or
Is voltage harness or contact with replace
• Turn starting NO ground between CN31
between T/C OUT switch ON.
(1) and (2) (female) (8) and T/C OUT
• 0.5 – 4.5 V
normal? (female) (3)
• Turn starting Defective contact or
switch ON. NO disconnection in wiring
• 20 – 30 V harness between CN1 Repair or
(female) (3) and T/C OUT replace
(female) (2), short circuit
with ground
HD255-5 20-443
(10)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR A MODE SYSTEM

Serial No.: 1001 –␣ 1200
20-444 HD255-5
4
Serial No.: 1201 – 1599
20-448 HD255-5
(10)
HD255-5 20-451
4
20-452 HD255-5
(10)
HD255-5 20-453
(10)
20-454 HD255-5
(10)
HD255-5 20-455
(10)
TROUBLESHOOTING FOR METER PANEL
SYSTEM
(E MODE)
E-1 Water temperature gauge gives no display or gives abnormal display ................................... 20-472
a) Gives no display ..................................................................................................................... 20-472
b) Gives abnormal display ......................................................................................................... 20-472
E-2 Torque converter oil temperature gauge gives no display or gives abnormal display ........... 20-474
E-3 Retarder oil temperature gauge gives no display or gives abnormal display ......................... 20-476
E-4 Fuel gauge gives no display or gives abnormal display ............................................................ 20-478
E-5 Service meter does not move (Serai No.: 1001 – 1599) ............................................................. 20-480
E-6 Service meter and tachometor does not move (Serai No.: 1601 and up) ................................ 20-481
HD255-5 20-471
(10)
TROUBLESHOOTING E-1
E-1 Water temperature gauge gives no display or gives abnormal

display
fl Check that fuse (7) is not blown. (If it is blown, check for a short circuit with the ground in the circuit
related to fuse (7).)
a) Gives no display
Cause Remedy
3 YES Defective engine water Replace

Is voltage temperature gauge
YES between EW1
2 and chassis
Defective contactor or
ground normal? disconnection in wiring
Is resistance Repair or
YES between EW2 (wir- • Turn starting NO harness between FB1 (7) – replace
ing harness end) switch ON. EW1
1 and chassis ground • 20 – 30 V
Is resistance as shown in Table? Defective contactor or
between EWTS • Turn starting disconnection in wiring Repair or
(male) and chas- switch OFF. NO harness between EW2 replace
sis ground as • Disconnect EW2. (terminal) – EWTS
shown in Table?
• Turn starting
Defective water Replace
switch OFF.
temperature sensor
• Disconnect EWTS. NO
Table 1
Temperature (˚C) Resistance value (Ω)

50 153.4 ± 12
67 79.4 ± 5.4
80 50.1 ± 2.9
102 25.5 ± 1.1
b) Gives abnormal display
Cause Remedy
1 YES Defective engine water

Is resistance temperature gauge Replace
between EWTS
(male) and chas-
sis ground as
shown in Table? Defective water
Replace
• Turn starting NO temperature sensor
switch OFF.
• Disconnect
EWTS.
20-472 HD255-5
4
TROUBLESHOOTING E-1
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
HD255-5 20-473
(10)
TROUBLESHOOTING E-2
E-2 Torque converter oil temperature gauge gives no display or gives

abnormal display
fl Check that fuse (6) (Serial No.: 1001 – 1200) or (7) (Serial No.: 1201 and up) is not blown. (If it is blown,
check for a short circuit with the ground in the circuit related to the fuse.)
a) Gives no display
Cause Remedy

Is voltage oil temperature gauge
YES between TC1 and
2 chassis ground
Is resistance normal? disconnection in wiring Repair or
between TC2 (wir- harness between FB1 (6) replace wiring
YES • Turn starting NO harness
ing harness end) or (7) and TC1
and chassis ground switch ON.
1
as shown in Table? • 20 – 30 V
Is resistance Defective contact or
Repair or
between TC.SE • Turn starting disconnection in wiring
replace wiring
(male) and chassis switch OFF. NO harness between TC2 and
harness
ground as shown . Disconnect TC2. TC.SE
in Table?
• Turn starting
switch OFF. Defective torque converter Replace
• Disconnect TC.SE. NO oil temperature sensor
Table 1

50 153.4 ± 12
67 79.4 ± 5.4
80 50.1 ± 2.9
102 25.5 ± 1.1
Cause Remedy
1 YES Defective torque converter

Is resistance oil temperature gauge Replace
between TC.SE
(male) and
chassis ground as
shown in Table?
Defective sensor Replace
• Turn starting NO
switch OFF.
• Disconnect
TC.SE.
20-474 HD255-5
4
TROUBLESHOOTING E-2
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
HD255-5 20-475
(10)
TROUBLESHOOTING E-3
E-3 Retarder oil temperature gauge gives no display or gives abnormal

display
a) Gives no display
Cause Remedy
3 YES Defective retarder oil Replace

Is voltage temperature gauge
YES between RH1 and
2 chassis ground
Is resistance normal? disconnection in wiring Repair or
YES between RH2 (wir- • Turn starting NO harness between FB1 (7) – replace wiring
ing harness end) RH1 harness
and chassis ground switch ON.
1 • 20 – 30 V
as shown in Table? Defective contact or
Is resistance Repair or
between ROTS • Turn starting disconnection in wiring replace wiring
(male) and chas- switch OFF. NO harness between RH2 – harness
sis ground as • Disconnect RH2. ROTS
shown in Table?
• Turn starting
switch OFF. Defective retarder oil
Replace
temperature sensor
• Disconnect ROTS. NO
Table 1

50 80 ± 10
60 56.9 ± 5
80 29.5 ± 2.5
100 16.5 ± 0.9
Cause Remedy
1 YES Defective retarder oil

Is resistance temperature gauge Replace
between ROTS
(male) and chas-
sis ground as
shown in Table? Defective retarder oil
Replace
switch OFF.
• Disconnect
ROTS.
20-476 HD255-5
4
TROUBLESHOOTING E-3
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
HD255-5 20-477
(10)
TROUBLESHOOTING E-4
E-4 Fuel gauge gives no display or gives abnormal display

a) Gives no display
Cause Remedy
4 YES
Defective fuel gauge Replace
Is voltage be-
YES tween FG1 termi-
3 nal and chassis Defective contact or
Is resistance ground normal? disconnection in wiring Repair or
between FG2 harness between fuse FB1 replace wiring
YES terminal (wiring • Turn starting NO (7) and FG1 terminal harness
2 harness end) and switch ON.
chassis ground as • 20 – 30 V Defective contact or
Is resistance shown in Table? Repair or
between FG2 replace wiring
YES connector (male) • Turn starting harness between FG2
NO terminal and FG1 harness
1 and chassis switch OFF.
• Disconnect FG2 connector (female)
ground normal?
Is resistance be- terminal.
tween FG1 con- • Turn starting Defective contact or Repair or
nector (male) and switch OFF. disconnection in wiring replace wiring
FG2 connector • Disconnect FG2
NO harness between FG2 harness
(male) as shown connector (male) and
in Table? connector.
• Max. 1Ω chassis ground
• Turn starting
switch OFF. Defective fuel sensor Replace
NO
• Disconnect FG1
and FG2.
Table 1
Float position Resistance value (Ω)
FULL Max. 10
+10
EMPTY 85 0
Cause Remedy
1 YES Defective retarder oil

Replace
Is resistance be- temperature gauge
tween FG1 con-
nector (male) and
FG2 connector as
shown in Table? Defective retarder oil
Replace
switch OFF.
• Disconnect FG1
and FG2.
20-478 HD255-5
(10)
TROUBLESHOOTING E-4
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
HD255-5 20-479
(10)
TROUBLESHOOTING E-5
E-5 Service meter does not move

Serial No.: 1001 – 1599

Cause Remedy
2 YES Defective service meter Replace

Is voltage be-
YES tween SMR (fe-
1 male) and chassis Defective contact or
ground normal? disconnection in wiring Repair or
Is voltage harness between SMR replace
between AR3 and • Turn starting NO (female) and AR3
chassis ground switch ON.
normal? • 20 – 30 V
• Turn starting Defective alternator Replace

switch ON. NO
• 20 – 30 V
Serial No.: 1001 –␣ 1200
Serial No.: 1201 – 1599
20-480 HD255-5
(10)
TROUBLESHOOTING E-6
E-6 Service meter and tachometor does not move

fl Before carrying out troubleshooting, check that travel is controlled normally.
fl Check that fuse FB1-(10) is normal.

Cause Remedy
3 YES Defective service meter or Replace

Is resistance be- tachometer
YES tween RM1 (fe-
male) (2) and
chassis ground Disconnection or defec-
2 tive contact in wiring har-
normal? Repair or
Is signal between ness between RM1 (fe-
• Disconnect RM1. NO male) (2) – RJ11 – G1 replace
YES RM1 (3) and chas-
• Turn starting (chassis ground)
sis ground nor- switch OFF.
1 mal? • Max. 1 Ω Disconnection or defec-
Is voltage be- tive contact in wiring har- Repair or
• Start engine.
tween RM1 (1) ness between CN31 (fe- replace
• 5 – 175 Hz
and chassis (At 750 rpm: NO male) (5) – TMB – 108 –
ground normal? 35 – 40 Hz) RM1 (female) (3)
• Turn starting Disconnection or defec- Repair or

switch ON. tive contact in wiring har- replace
• 20 – 30 V NO ness between fuse FB1-
(10) – RM1 (female) (1)
HD255-5 20-481
(10)
TROUBLESHOOTING FOR PILOT LAMP SYSTEM
(F MODE)
F-1 Abnormality in lighting up of retarder pilot lamp ...................................................................... 20-502

F-2 Abnormality in lighting up of parking brake pilot lamp ............................................................. 20-506
F-3 Abnormality in lighting up of front brake oil level pilot lamp ................................................... 20-510
F-4 Abnormality in lighting up of rear brake caution lamp .............................................................. 20-514
F-5 Abnormality in lighting up of engine oil pressure caution lamp .............................................. 20-518
F-6 Abnormality in lighting up of battery charge caution lamp ...................................................... 20-520
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM .................................................................... 20-526
HD255-5 20-501
(10)
TROUBLESHOOTING F-1
F-1 Abnormality in lighting up of retarder pilot lamp

Serial No.: 1001 –␣ 1200

a) Retarder is not being operated, but pilot lamp lights up.
Cause Remedy
YES Defective rear brake pilot

2 Replace
relay
Does condition
YES become normal
when relay 15 is Short circuit with power
interchanged with 3 YES source in wiring harness Repair or
another relay? Is resistance between 15 (female) (4) replace
1 between 15
• Turn starting and CN1 (female) (7)
Is resistance switch ON. (female) (6) and
between RLS • Turn retarder NO chassis ground Wiring harness between 15
normal? (female) (6) and RLS Repair or
(male) (1) and (2) OFF.
normal? • Turn starting NO (female) (2) short circuiting replace
switch OFF. with ground
• Turn starting • Disconnect 15.
switch OFF. • Turn retarder OFF.
• Disconnect RLS. • Min. 1 MΩ Defective retarder lamp Replace
• Turn retarder OFF. NO switch
• Min. 1 MΩ
b) Pilot lamp does not light up even when retarder is operated
Cause Remedy
YES Defective rear brake pilot Replace

relay

connection in wiring har-
Does condition 4 YES ness between 15 (female) Repair or
YES become normal Is voltage (4) and CN1 (female) (7) or replace
when relay 15 is YES between 15 between CN1 (female) (4)
interchanged with (female) (3) and and chassis ground
another relay? chassis ground
3 normal? Defective contact or dis-
• Turn starting
switch ON.
Is resistance • Turn starting NO connection in wiring har- Repair or
1 between 15 switch ON. ness between fuse FB2
• Turn retarder ON. (19) and 15 (female) (3) replace
Is resistance (female) (6) and • 20 – 30 V
between RLS NO chassis ground
(male) (1) and (2) normal?
Defective contact or dis-
normal? • Turn starting connection in wiring har-
switch OFF. ness between 15 (female) Repair or
• Turn starting • Disconnect 15. (6) and RLS (female) (2) or replace
switch OFF. • Turn retarder ON.
NO between RLS (female) (1)
• Disconnect RLS. • Max. 1 Ω and chassis ground
• Turn retarder ON.
• Max. 1 Ω Replace
Defective retarder lamp
NO switch
20-502 HD255-5
(10)
TROUBLESHOOTING F-1
HD255-5 20-503
(10)
TROUBLESHOOTING F-1
Serial No.: 1201 – 1599

Cause Remedy

2 Replace
relay
Does condition
become normal
YES when relay R17 is
Short circuit with power
interchanged with 3 YES Repair or
another relay? source in wiring harness
Is resistance between R17 (female) (4) replace
1 • Turn starting between R17 and 114 (female) (7)
between RLS • Turn retarder NO chassis ground Wiring harness between
(male) (1) and (2) OFF. normal? R17 (female) (6) and RLS Repair or
• Turn starting • Disconnect R17.
• Disconnect RLS. • Min. 1 MΩ Defective retarder lamp
• Turn retarder OFF. NO Replace
switch
• Min. 1 MΩ
Cause Remedy

relay

Does condition 4 YES ness between R17 (female) Repair or
YES become normal (4) and 114 (female) (7) or replace
when relay R17 is Is voltage between between 114 (female) (4)
interchanged with YES R17 (female) (3) and chassis ground
another relay? and chassis
3 ground normal? Defective contact or dis-
• Turn starting connection in wiring har- Repair or
switch ON. Is resistance • Turn starting NO ness between fuse FB2
1 between R17 (fe- switch ON.
replace
• Turn retarder ON. (19) and R17 (female) (3)
Is resistance male) (6) and • 20 – 30 V
between RLS NO chassis ground
(male) (1) and (2) normal? disconnection in wiring
normal? • Turn starting harness between R17
• Turn starting switch OFF. (female) (6) and RLS Repair or
switch OFF. • Disconnect R17. NO (female) (2) or between replace
• Disconnect RLS. • Turn retarder ON. RLS (female) (1) and
• Turn retarder ON. • Max. 1Ω chassis ground
• Max. 1Ω
Defective retarder lamp Replace
NO switch
20-504 HD255-5
(10)
TROUBLESHOOTING F-1
HD255-5 20-505
(10)
TROUBLESHOOTING F-1

Cause Remedy

2 Replace
relay
Does condition
become normal
YES when relay R17 is
Short circuit with power
interchanged with 3 YES Repair or
another relay? source in wiring harness
Is resistance between R17 (female) (4) replace
1 • Turn starting between R17 and 114 (female) (7)
between RLS • Turn retarder NO chassis ground Wiring harness between
(male) (1) and (2) OFF. normal? R17 (female) (6) and RLS Repair or
• Disconnect RLS. • Min. 1 MΩ Defective retarder lamp
• Turn retarder OFF. NO Replace
switch
• Min. 1 MΩ
Cause Remedy

relay

Does condition 4 YES ness between R17 (female) Repair or
YES become normal (4) and 114 (female) (7) or replace
when relay R17 is Is voltage between between 114 (female) (4)
interchanged with YES R17 (female) (3) and chassis ground
3 ground normal? Defective contact or dis-
• Turn starting connection in wiring har- Repair or
switch ON. Is resistance be- • Turn starting NO ness between fuse FB2
1 tween R17 (fe- switch ON.
replace
• Turn retarder ON. (18) and R17 (female) (3)
Is resistance be- male) (6) and • 20 – 30 V
tween RLS (male) NO chassis ground
(1) and (2) nor- normal? disconnection in wiring
mal? • Turn starting harness between R17
• Turn starting switch OFF. (female) (6) and RLS Repair or
switch OFF. • Disconnect R17. NO (female) (2) or between replace
• Disconnect RLS. • Turn retarder ON. RLS (female) (1) and
• Turn retarder ON. • Max. 1Ω chassis ground
• Max. 1Ω
Defective retarder lamp Replace
NO switch
20-505-1 HD255-5
(10)
TROUBLESHOOTING F-1
HD255-5 20-505-2
(10)
TROUBLESHOOTING F-2
HD255-5 20-507
(10)
TROUBLESHOOTING F-2
Serial No.: 1201 – 1599

a) Parking brake is at TRAVEL position, but pilot lamp lights up
Cause Remedy
YES Defective parking brake Replace

2 relay
Does condition
YES become normal Wiring harness between Repair or
when relay R16 is R16 (female) (3) and 114 replace wiring
interchanged with 3 YES (female) (6) short circuiting
Is voltage harness
1 another relay? with ground
between R16
Is resistance • Turn starting (female) (1) and Defective contact or
between PBS switch ON. NO chassis ground disconnection in wiring Repair or
(male) (1) and (2) • Set parking brake normal? harness between fuse FB1
lever to TRAVEL. replace wiring
normal? • Disconnect R16. NO (1) and PBS (female) (1) or harness
• Turn starting switch ON. between PBS (female) (2)
• Turn starting • Set parking brake lever to
switch OFF. and R16 (female) (1)
TRAVEL.
• Disconnect PBS. • 20 – 30 V
• Set parking brake Defective parking brake Replace
lever to TRAVEL. NO switch
• Max. 1Ω
b) Pilot lamp does not light up even when parking brake lever is set to PARKING position
Cause Remedy

relay
2
Does condition Repair or
YES become normal 4 YES disconnection in wiring replace wiring
harness between R16
when relay R16 is Is voltage between harness
(female) (2), (6) and
interchanged with YES R16 (female) (3) chassis ground
• Turn starting 3 ground normal? Defective contact or dis- Repair or
switch ON. connection in wiring har-
1 Is voltage between • Disconnect R16. NO ness between fuse FB2 replace wiring
R16 (female) (1) • Turn starting (19) and 114 (female) (10) harness
Is resistance
between PBS and chassis switch ON. or between 114 (female)
NO ground normal? • 20 – 30 V
(male) (1) and (2) (6) and R16 (female) (3)
normal? • Disconnect R16.
• Turn starting Short circuit with power
• Turn starting source in wiring harness Repair or
switch OFF. switch ON. replace wiring
• Set parking brake NO between R16 (female) (1)
• Disconnect PBS. and PBS (female) (2) harness
• Set parking brake lever to PARKING.
lever to • Max. 1 V
PARKING. Defective parking brake Replace
• Min. 1 MΩ NO switch
20-508 HD255-5
(10)
TROUBLESHOOTING F-2
HD255-5 20-509
(10)
TROUBLESHOOTING F-2

a) Parking brake is at TRAVEL position, but pilot lamp lights up
Cause Remedy

2 relay
Does condition
YES become normal Wiring harness between Repair or
when relay R16 is R16 (female) (3) and 114 replace wiring
interchanged with 3 YES (female) (6) short circuiting
Is voltage harness
1 another relay? with ground
between R16
Is resistance • Turn starting (female) (1) and Defective contact or
between PBS switch ON. NO chassis ground disconnection in wiring Repair or
(male) (1) and (2) • Set parking brake normal? harness between fuse FB1
lever to TRAVEL. replace wiring
normal? • Disconnect R16. NO (2) and PBS (female) (1) or harness
• Turn starting switch ON. between PBS (female) (2)
• Turn starting • Set parking brake lever to
switch OFF. and R16 (female) (1)
TRAVEL.
• Disconnect PBS. • 20 – 30 V
• Set parking brake Defective parking brake Replace
lever to TRAVEL. NO switch
• Max. 1Ω
b) Pilot lamp does not light up even when parking brake lever is set to PARKING position
Cause Remedy

relay
2
YES become normal 4 YES disconnection in wiring replace wiring
harness between R16
when relay R16 is Is voltage between harness
(female) (2), (6) and
interchanged with YES R16 (female) (3) chassis ground
• Turn starting 3 ground normal? Defective contact or dis- Repair or
switch ON. connection in wiring har-
1 Is voltage between • Disconnect R16. NO ness between fuse FB2 replace wiring
R16 (female) (1) • Turn starting (18) and 114 (female) (10) harness
Is resistance be-
tween PBS (male) and chassis switch ON. or between 114 (female)
NO ground normal? • 20 – 30 V
(1) and (2) nor- (6) and R16 (female) (3)
mal? • Disconnect R16.
• Turn starting Short circuit with power
• Turn starting source in wiring harness Repair or
switch OFF. switch ON. replace wiring
• Set parking brake NO between R16 (female) (1)
• Disconnect PBS. and PBS (female) (2) harness
• Set parking brake lever to PARKING.
lever to • Max. 1 V
PARKING. Defective parking brake Replace
• Min. 1 MΩ NO switch
20-509-1 HD255-5
(10)
TROUBLESHOOTING F-2
HD255-5 20-509-2
(10)
TROUBLESHOOTING F-3
HD255-5 20-511
(10)
TROUBLESHOOTING F-3
Serial No.: 1201 – 1599

a) Front brake oil level is normal, but pilot lamp lights up
Cause Remedy
YES Defective brake oil level Replace

relay
2
Wiring harness between Repair or
Does condition 4 YES R22 (female) (3) and 114 replace
YES become normal (female) (3) short
when relay R22 is YES Is voltage between circuiting with ground
interchanged with R22 (female) (1)
another relay? 3 and chassis Defective contact or
Is resistance ground normal? disconnection in wiring Repair or
1 • Turn starting harness between fuse FB2 replace
between R22 (fe- • Turn starting NO (19) and R22 (female) (1)
Is resistance switch ON. male) (2) and
between FBT NO chassis ground switch ON.
normal? • Disconnect R22. Defective contact or
(male) (1) and (2) disconnection in wiring
• 20 – 30 V Repair or
normal? • Turn starting harness between R22 replace
• Turn starting switch OFF. NO (female) (2) and FBT
• Disconnect R22. (female) (1) or between
switch OFF. FBT (female) (2) and
• Disconnect FBT. • Max. 1Ω
chassis ground
• Max. 1Ω
Defective brake oil level Replace
NO relay
b) There is abnormality in front brake oil level, but pilot lamp does not light up
Cause Remedy

relay
YES become normal 4 YES harness between R22 replace
when relay R22 is Is voltage between ground
interchanged with YES R22 (female) (3)
1 • Turn starting Is resistance harness between fuse FB1 Repair or
switch ON. between R22 (fe- • Turn starting NO (7) and 114 (female) (1) or replace
Is resistance male) (2) and
between FBT switch ON. between 114 (female) (3)
NO chassis ground • Disconnect R22. and R22 (female) (3)
(male) (1) and (2) normal?
normal? • Turn starting • 20 – 30 V
Wiring harness between
switch OFF. NO R22 (female) (2) and FBT Repair or
switch OFF. (female) (1) short replace
• Min. 1 MΩ circuiting with ground
• Disconnect FBT.
• Min. 1 MΩ
NO relay
20-512 HD255-5
(10)
TROUBLESHOOTING F-3
HD255-5 20-513
(10)
TROUBLESHOOTING F-3

a) Front brake oil level is normal, but pilot lamp lights up
Cause Remedy

relay
2
Wiring harness between Repair or
Does condition 4 YES R22 (female) (3) and 114 replace
YES become normal (female) (3) short
when relay R22 is YES Is voltage between circuiting with ground
interchanged with R22 (female) (1)
Is resistance be- ground normal? disconnection in wiring Repair or
1 • Turn starting harness between fuse FB2 replace
tween R22 (fe- • Turn starting NO (18) and R22 (female) (1)
Is resistance be- switch ON. male) (2) and
tween FBT (male) NO chassis ground switch ON.
normal? • Disconnect R22. Defective contact or
(1) and (2) nor- disconnection in wiring
• 20 – 30 V Repair or
mal? • Turn starting harness between R22 replace
• Turn starting switch OFF. NO (female) (2) and FBT
• Disconnect R22. (female) (1) or between
switch OFF. FBT (female) (2) and
• Disconnect FBT. • Max. 1Ω
chassis ground
• Max. 1Ω
NO relay
b) There is abnormality in front brake oil level, but pilot lamp does not light up
Cause Remedy

relay
4 YES harness between R22 replace
YES become normal (female) (6) and chassis
when relay R22 is Is voltage between ground
interchanged with YES R22 (female) (3)
1 • Turn starting Is resistance be- harness between fuse FB1 Repair or
switch ON. tween R22 (fe- • Turn starting NO (16) and 114 (female) (1) replace
Is resistance be- male) (2) and
tween FBT (male) switch ON. or between 114 (female)
NO chassis ground • Disconnect R22. (3) and R22 (female) (3)
(1) and (2) nor- normal?
mal? • Turn starting • 20 – 30 V
switch OFF. NO R22 (female) (2) and FBT Repair or
switch OFF. (female) (1) short replace
• Min. 1 MΩ circuiting with ground
• Disconnect FBT.
• Min. 1 MΩ
NO relay
20-513-1 HD255-5
(10)
TROUBLESHOOTING F-3
HD255-5 20-513-2
(10)
TROUBLESHOOTING F-4
HD255-5 20-515
(10)
TROUBLESHOOTING F-4
Serial No.: 1201 – 1599

a) Rear brake oil pressure is normal, but caution lamp lights up
Cause Remedy
YES Defective rear brake Replace

chamber stroke relay
2 Wiring harness between
Does condition R21 (female) (3) and 114 Repair or
YES become normal 4 YES (female) (9) short circuit- replace
ing with ground
when relay R21 is YES Is voltage
interchanged with between R21
(female) (1) and Defective contact or dis-
another relay? 3 connection in wiring har-
chassis ground
Is resistance normal? ness between fuse FB2 Repair or
1 • Turn starting (16) and R21 (female) (1)
switch ON. between R21 • Turn starting NO replace
Is resistance (female) (2) and
NO chassis ground switch ON. Defective contact or dis-
between BCS1, connection in wiring har-
BCS2 (male) (1) • 20 – 30 V ness between R21 (female) Repair or
and (2) normal? • Turn starting (2) and BCS1 (female) (1), replace
switch OFF. NO between BCS1 (female) (2)
• Turn starting and BCS2 (female) (1), or
switch OFF. • Disconnect R21.
• Max. 1Ω between BCS2 (female) (2)
BCS1 and BCS2.
• Max. 1Ω Replace
Defective rear brake
NO chamber stroke relay
b) There is abnormality in rear brake, but caution lamp does not light up
Cause Remedy

Does condition disconnection in wiring Repair or
when relay R21 is Is voltage ground
interchanged with YES between R21
another relay? (female) (3) and Defective contact or
3 chassis ground
1 Is resistance normal? harness between fuse FB1
switch ON. between R21 replace
Is resistance
(female) (2) and • Turn starting NO (4) and 114 (female) (8) or
between BCS1, switch ON. between 114 (female) (9)
BCS2 (male) (1) NO chassis ground • Disconnect R21. and R21 (female) (3)
normal?
and (2) normal? • 20 – 30 V
• Turn starting Wiring harness between
• Turn starting switch OFF. NO R21 (female) (2) and BCS1 Repair or
• Disconnect R21. (female) (1) short replace
switch OFF. circuiting with ground
• Disconnect BCS1 • Min. 1 MΩ
and BCS2. Defective rear brake
• Min. 1 MΩ Replace
NO
20-516 HD255-5
(10)
TROUBLESHOOTING F-4
HD255-5 20-517
(10)
TROUBLESHOOTING F-4

a) Rear brake oil pressure is normal, but caution lamp lights up
Cause Remedy

2 Wiring harness between
Does condition R21 (female) (3) and 114 Repair or
YES become normal 4 YES (female) (9) short circuit- replace
ing with ground
when relay R21 is YES Is voltage
interchanged with between R21
(female) (1) and Defective contact or dis-
another relay? 3 connection in wiring har-
chassis ground
Is resistance normal? ness between fuse FB2 Repair or
1 • Turn starting (12) and R21 (female) (1)
switch ON. between R21 • Turn starting NO replace
Is resistance be- (female) (2) and
NO chassis ground switch ON. Defective contact or dis-
tween BCS1, connection in wiring har-
BCS2 (male) (1) • 20 – 30 V ness between R21 (female) Repair or
and (2) normal? • Turn starting (2) and BCS1 (female) (1), replace
switch OFF. NO between BCS1 (female) (2)
• Turn starting and BCS2 (female) (1), or
switch OFF. • Disconnect R21.
• Max. 1Ω between BCS2 (female) (2)
BCS1 and BCS2.
• Max. 1Ω Replace
Defective rear brake
NO chamber stroke relay
b) There is abnormality in rear brake, but caution lamp does not light up
Cause Remedy

Does condition disconnection in wiring Repair or
when relay R21 is Is voltage ground
interchanged with YES between R21
another relay? (female) (3) and Defective contact or
3 chassis ground
1 Is resistance normal? harness between fuse FB1
switch ON. between R21 replace
Is resistance be- • Turn starting NO (8) and 114 (female) (8) or
(female) (2) and between 114 (female) (9)
tween BCS1, switch ON.
BCS2 (male) (1) NO chassis ground • Disconnect R21. and R21 (female) (3)
normal?
and (2) normal? • 20 – 30 V
• Turn starting Wiring harness between
• Turn starting switch OFF. NO R21 (female) (2) and BCS1 Repair or
• Disconnect R21. (female) (1) short replace
switch OFF. circuiting with ground
• Disconnect BCS1 • Min. 1 MΩ
and BCS2. Defective rear brake
• Min. 1 MΩ Replace
NO
20-517-1 HD255-5
(10)
TROUBLESHOOTING F-4
HD255-5 20-517-2
(10)
TROUBLESHOOTING F-5
F-5 Abnormality in lighting up of engine oil pressure pilot lamp

Serial No.: 1001 –␣ 1200

a) Pilot lamp lights up when engine is running (engine oil pressure is normal)
Cause Remedy

1 YES CN1 (female) (2) and EOP
Is resistance short circuiting with chassis Repair or replace
between EOP ground
(switch end) and
chassis ground
normal? Defective engine oil Replace
• Remove EOP. NO pressure switch
• Start engine.
Serial No.: 1001 –␣ 1200

b) Pilot lamp does not light up when starting switch is at ON (engine stopped)
Cause Remedy
1 YES Defective engine oil

Is resistance pressure switch Replace
between EOP
(switch end) and
chassis ground Wiring harness between
normal? CN1 (female) (2) and EOP Replace
• Remove EOP. NO short circuiting with chassis
• Start engine. ground
20-518 HD255-5
(10)
TROUBLESHOOTING F-5
Serial No.: 1201 – 1599

Cause Remedy

1 YES 114 (female) (2) and EOP
between EOP ground
(switch end) and
chassis ground
• Remove EOP. NO pressure switch
• Start engine.
Serial No.: 1201 – 1599

Cause Remedy

between EOP
(switch end) and
chassis ground Wiring harness between 114
normal? (female) (2) and EOP short Replace
• Remove EOP. NO circuiting with chassis
HD255-5 20-519
(10)
TROUBLESHOOTING F-5

Cause Remedy

1 YES 114 (female) (2) and PSL
between PSL ground
(switch end) and
chassis ground
• Remove PSL. NO pressure switch
• Start engine.

Cause Remedy

between PSL
(switch end) and
chassis ground Wiring harness between 114
normal? (female) (2) and PSL short Replace
• Remove PSL. NO circuiting with chassis
20-519-1 HD255-5
(10)
TROUBLESHOOTING F-6
F-6 Abnormality in lighting up of battery charge caution lamp

Serial No.: 1001 –␣ 1200

a) Caution lamp lights up when engine is running
Cause Remedy
YES
2 Defective battery charge Replace
Does condition relay
become normal
YES when relay CN3 Defective contact or
is interchanged 3 YES disconnection in wiring Repair or
with another harness between CN3
1 Is voltage (female) (2) and chassis replace
relay? between CN3
Is voltage • Start engine. ground
(female) (1) and
between AR3 NO chassis ground
(alternator end) normal? Defective contact or
and chassis Repair or
ground normal? • Disconnect CN3. NO harness between CN3 replace
• Disconnect AR3. • Start engine. (female) (1) and AR3
• Start engine. • 20 – 30 V
• 20 – 30 V
Defective alternator Replace
NO
Cause Remedy
YES Defective battery charge Replace

relay
Does condition
YES become normal 4 YES harness between CN3 Repair or
(female) (6) and CN1 replace
when relay CN3 is Is voltage (female) (5), or between
interchanged with YES between CN3 CN1 (female) (4) and
another relay? (female) (3) and chassis ground
3 chassis ground
1 • Turn starting Is voltage normal? Defective contact or dis- Repair or
Is voltage switch ON. between CN3 • Disconnect CN3. NO connection in wiring har- replace
between AR3 (female) (1) and • Turn starting ness between fuse FB1 (6)
(alternator end) NO chassis ground switch ON. and CN3 (female) (3)
and chassis normal?
• 20 – 30 V Defective contact or dis- Repair or
ground normal? • Disconnect CN3.
connection in wiring har- replace
• Disconnect AR3. • Turn starting NO ness between CN3 (fe-
• Turn starting switch ON. male) (1) and AR3
switch ON. • Max. 1 V
• 20 – 30 V Replace
Defective alternator
NO
20-520 HD255-5
4
TROUBLESHOOTING F-6
HD255-5 20-521
(10)
TROUBLESHOOTING F-6
Serial No.: 1201 – 1599

Cause Remedy
YES
Defective battery charge Replace
2
relay
Does condition
YES become normal
when relay R05 is
interchanged with 3 YES disconnection in wiring Repair or
another relay? harness between R05
• Start engine. between R05 ground
Is voltage (female) (1) and
between AR3
(alternator end) NO chassis ground Defective contact or
normal? Repair or
and chassis disconnection in wiring
ground normal? • Disconnect R05. NO harness between R05 replace
• 20 – 30 V
NO
Cause Remedy

relay
Does condition
YES become normal 4 YES harness between R05 Repair or
(female) (6) and 114 replace
when relay R05 is Is voltage (female) (5), or between
interchanged with YES between R05 114 (female) (4) and
3 chassis ground
• Turn starting normal?
1 Is voltage Defective contact or Repair or
switch ON. between R05
Is voltage • Disconnect R05. NO disconnection in wiring replace
between AR3 (female) (1) and • Turn starting harness between fuse FB1
(alternator end) NO chassis ground (6) and R05 (female) (3)
normal? switch ON.
and chassis • 20 – 30 V
ground normal? • Disconnect R05. Defective contact or Repair or
• Turn starting disconnection in wiring replace
• Disconnect AR3. NO harness between R05
• Turn starting switch ON. (female) (1) and AR3
NO
20-522 HD255-5
(10)
TROUBLESHOOTING F-6
HD255-5 20-523
(10)
TROUBLESHOOTING F-6

Cause Remedy
YES
Defective battery charge Replace
2
relay
Does condition
YES become normal
when relay R05 is
interchanged with 3 YES disconnection in wiring Repair or
another relay? harness between R05
• Start engine. between R05 ground
Is voltage (female) (1) and
between AR3
(alternator end) NO chassis ground Defective contact or
normal? Repair or
and chassis disconnection in wiring
ground normal? • Disconnect R05. NO harness between R05 replace
• 20 – 30 V
NO
Cause Remedy

relay
Does condition
YES become normal 4 YES harness between R05 Repair or
(female) (6) and 114 replace
when relay R05 is Is voltage (female) (5), or between
interchanged with YES between R05 114 (female) (4) and
3 chassis ground
• Turn starting normal?
1 Is voltage Defective contact or Repair or
switch ON. between R05
Is voltage • Disconnect R05. NO disconnection in wiring replace
between AR3 (female) (1) and • Turn starting harness between fuse FB1
(alternator end) NO chassis ground (12) and R05 (female) (3)
normal? switch ON.
and chassis • 20 – 30 V
ground normal? • Disconnect R05. Defective contact or Repair or
• Turn starting disconnection in wiring replace
• Disconnect AR3. NO harness between R05
• Turn starting switch ON. (female) (1) and AR3
NO
20-524 HD255-5
(10)
TROUBLESHOOTING F-6
HD255-5 20-525
(10)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM

Serial No.: 1001 –␣ 1200
20-526 HD255-5
(10)
Serial No.: 1201 – 1599
HD255-5 20-527
(10)
20-528 HD255-5
(10)
TROUBLESHOOTING OF ARSC [AUTOMATIC
RETARDER SPEED CONTROLLER] SYSTEM
(R MODE)
Outline ..................................................................................................................................................... 20-702
Electrical circuit diagram for ARSC
[Automatic Retarder Speed Controller] system ................................................................................... 20-706
R- 1 0.1 (Abnormality in power source voltage) is displayed ....................................................... 20-708
R- 2 1.0 (Disconnection in engine speed sensor system) is displayed ......................................... 20-709
R- 3 1.3 (Disconnection in transmission output shaft speed sensor system) is displayed ......... 20-710
R- 4 1.5 (Failure in retarder oil temperature sensor system) is displayed ................................... 20-711
R- 5 1.7 (Failure in accelerator signal system) is displayed ........................................................... 20-712
R- 6 1.8 (Failure in suspension pressure sensor “left” system) is displayed ............................... 20-713
R- 7 1.9 (Failure in suspension pressure sensor “right” system) is displayed ............................ 20-714
R- 8 4.2 (Disconnection in exhaust brake selector signal system) is displayed ........................... 20-715
R- 9 4.3 (Disconnection in ARSC caution lamp system) is displayed ........................................... 20-716
R-10 4.4 (Disconnection in READY lamp system) is displayed ...................................................... 20-717
R-11 4.5 (Disconnection in panel caution and buzzer system) is displayed .................................. 20-718
R-12 5.2 (Short circuit with ground in exhaust brake selector signal output system)
is displayed ........................................................................................................................ 20-719
R-13 5.3 (Short circuit with ground in ARSC caution lamp system) is displayed ......................... 20-720
R-14 5.4 (Short circuit with ground in READY output circuit system) is displayed ...................... 20-721
R-15 5.5 (Short circuit with ground in panel caution lamp and buzzer output system)
is displayed ........................................................................................................................ 20-722
R-16 6.0 (Failure in engine speed system) is displayed .................................................................. 20-723
R-17 7.0 (Disconnection in travel speed display UP output system) is displayed ........................ 20-724
R-18 7.1 (Disconnection in travel speed display DOWN output system) is displayed ................. 20-725
R-19 7.2 (Disconnection in travel speed display CLEAR output system) is displayed ................. 20-726
R-20 7.3 (Short circuit with ground in travel speed display UP output system) is displayed ..... 20-727
R-21 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed ... 20-728
R-22 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed ... 20-729
R-23 8.1 (Short circuit with ground in pressure control valve system) is displayed .................... 20-730
R-24 8.3 (Disconnection in pressure control valve system) is displayed ...................................... 20-731
R-25 8.5 (Failure in pressure control valve (pressure control valve remains open) is displayed .... 20-732
R-26 8.7 (Failure in pressure control valve (pressure control valve does not open) is displayed ... 20-733
R-27 8.9 (Short circuit with ground in pressure switch valve system) is displayed ..................... 20-734
R-28 9.0 (Disconnection in pressure switch valve system) is displayed ....................................... 20-735
R-29 9.1 (Failure in pressure switch valve system (remains open)) is displayed ......................... 20-736
R-30 9.2 (Failure in pressure switch valve system (does not open)) is displayed ........................ 20-737
R-31 9.3 (Disconnection in system switch system) is displayed .................................................... 20-738
R-32 9.4 (Short circuit with ground in system switch system) is displayed ................................. 20-739
R-33 9.5 (Disconnection, short circuit with ground in travel speed setting switch system)
is displayed ........................................................................................................................ 20-740
R-101 Set speed cannot be set ............................................................................................................ 20-741
R-102 Failure code is always cleared (controller display window always shows “– –”)
or failure code cannot be cleared ..................................................................................... 20-744
R-103 Effect of retarder is too strong when machine is empty, or too weak when
machine is loaded (does not judge loaded/unloaded condition properly) ................... 20-745
R-104 Abnormality appears in other controller ................................................................................. 20-745
R-105 When traveling downhill, even when set speed is exceeded, no control is carried out ..... 20-746
R-106 Monitor lamp (buzzer) stays ON (or OFF) ............................................................................... 20-747
R-107 READY lamp does not light UP (or stays lighted up) ............................................................. 20-748
R-108 Exhaust brake does not work properly .................................................................................... 20-750
[Exhaust brake is actuated when exhaust brake switch is OFF; or exhaust brake
is not actuated when exhaust brake switch is ON] ......................................................... 20-750
R-109 Retarder lamp does not light up, or stays lighted up ............................................................. 20-752
R-110 Travel speed display always gives display (or does not give any display) .......................... 20-753
HD255-5 20-701
(10)
TROUBLESHOOTING OUTLINE
OUTLINE
1. OUTLINE 1) Remedy pattern 1
This explains the procedure for inspection and If the central warning lamp and the ARSC
repair if any problem or failure occurs in the caution lamp flash and the buzzer sounds
ARSC. This means that a serious problem has oc-
The ARSC is equipped with a self-diagnostic curred in the ARSC system.
function, so for failures which the controller Operation of the ARSC system is stopped
can recognize, the central warning lamp, alarm and the retarder is released. Operate the
buzzer, and ARSC caution lamp inform the brake pedal or retarder lever as necessary
operator when a failure occurs. It also displays to ensure safety.
an error code on the controller display to When the system switch is turned OFF, the
inform the operator of the nature of the fail- central warning lamp and ARSC caution
ure. lamp go out and the buzzer stops.
The following explains the troubleshooting flIf the service code is “9.3” or “9.4”, it
and inspection method for the location of the shows that there is a failure in the sys-
failure if an error code is displayed. tem switch, so even if the system switch
is turned OFF, the central warning lamp
2. PRECAUTIONS WHEN CARRYING and ARSC caution lamp will flash and the
OUT TROUBLESHOOTING buzzer will sound.
1) Before carrying out troubleshooting, always 2) Remedy pattern 2
carry out a re-enaction test. When only the ARSC caution lamp flashes
2) With failures in the electrical system, there The ARSC system continues to be actuated,
are cases where failures occur because of but an abnormality has occurred in the sys-
vibration of the machine (for example, when tem.
the engine is running at high speed or the Turn the system switch OFF to stop use of
truck is traveling at high speed on rough the ARSC.
road surfaces), particularly at the initial When the system switch is turned OFF, the
stage of the occurrence of the failure. ARSC caution lamp will go out.
Therefore, it is necessary to investigate the flIn the case of patterns 1 and 2 above, turn
conditions under which the failure occurred. the system switch OFF quickly, stop use
(In particular, in cases where the problem of the ARSC.
cannot be re-enacted or the abnormality
cannot be found.) Note 1: The set travel speed display is also
3) If there is a failure in the electrical system, equipped with a self-diagnostic func-
check carefully that there is no improper tion, and a failure code is displayed on
connection of the connectors. the set travel speed display.
4) Always check that there is no effect from
any radio or other electrical equipment that Failure
No. code Details Method of resetting
was installed later. (Remove the equipment
and carry out a re-enaction test.)
1 E1 Abnormality Turn the machine starting
If there is any effect from electrical equip- in CPU switch ON again or turn the
system switch ON again.
ment, modify the method and location for
installing that equipment. Abnormality Turn the machine starting
5) Read the precautions for troubleshooting in 2 E2 switch ON again or turn the
in memory
system switch ON again.
the shop manual carefully before starting
troubleshooting. Note 2: If the engine is started while the air pres-
sure in the air tank is low, error code
3. METHOD FOR PROCEEDING WITH "9.2" may be displayed. In this case,
TROUBLESHOOTING increase the air pressure to the normal
If a failure occurs in the ARSC, distinguish the level, and then start the engine again.
service codes for each failure based on the
table on the next page. Then carry out the
inspection for the respective service code to
locate the location of the failure, and carry out
repairs or replacement.
20-702 HD255-5
(10)
4. WHEN SYSTEM IS NORMAL 6. METHOD OF CLEARING SERVICE

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

TIRE LARGE DIAMETER/SMALL
DIAMETER, REFERENCE FOR FAIL-
URE CODE
When the machine starting switch is turned
ON, the codes below are automatically dis-
played in the following order ((1) – (6)) on the
controller LED.
1) LEDs all light up.
2) Model
Code Model name
25 HD255-5
3) Tire diameter
Code Tire diameter
B.– Large diameter
S.– Small diameter
For the HD255-5, “– –” is displayed.

4) Initial service code
5) Service code that occurred immediately be-
fore the service code in 4)
6) Service code that occurred immediately be-
fore the service code in 5)
HD255-5 20-703
(10)
7. SERVICE CODE JUDGMENT TABLE

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

4 Abnormality appears in other controller R-104
5 When traveling downhill, even when set speed is exceeded, no control is carried out R-105
6 Monitor lamp (buzzer) stays on (or off) R-106
7 READY lamp does not light up (or stays lighted up) R-107
8 Exhaust brake does not work properly R-108
Exhaust brake is actuated when exhaust brake switch is OFF; or
Exhaust brake is not actuated when exhaust brake switch is ON
9 There is difference between travel speed rod value and actual machine value R-109
10 Retarder lamp does not light up, or stays lighted up R-110
11 Travel speed display always gives display (or does not give any display) R-111
20-704 HD255-5
(10)
Failure codes related to ARSC

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

ing code
1 1.8 (Failure in suspension pressure sensor “left” system) is displayed R-6
2 1.9 (Failure in suspension pressure sensor “right” system) is displayed R-7
3 4.2 (Disconnection in exhaust brake selector signal system) is displayed R-8
4 4.4 (Disconnection in READY lamp system) is displayed R-10
Error display is given
5 5.2 (Short circuit with ground in exhaust brake selector signal output system) is displayed R-12
6 5.4 (Short circuit with ground in READY output circuit system) is displayed R-14
7 7.0 (Disconnection in travel speed display UP output system) is displayed R-17
8 7.1 (Disconnection in travel speed display DOWN output system) is displayed R-18
9 7.2 (Disconnection in travel speed display CLEAR output system) is displayed R-19
10 7.3 (Short circuit with ground in travel speed display UP output system) is displayed R-20
11 7.4 (Short circuit with ground in travel speed display DOWN output system) is displayed R-21
12 7.5 (Short circuit with ground in travel speed display CLEAR output system) is displayed R-22
13 9.3 (Disconnection in system switch) is displayed R-31
14 9.4 (Short circuit with ground in system switch) is displayed R-32
15 9.5 (Disconnection, short circuit with ground in travel speed setting switch R-33
1 Set speed cannot be set R-101
No error display is given
2 Retarder does not work when machine is empty, or effect of retarder is poor R-103
when machine is loaded (does not judge loaded/unloaded condition properly)
3 When traveling downhill, even when set speed is exceeded, no control is carried out R-105
4 READY lamp does not light up (or stays lighted up) R-107
5 Exhaust brake does not work properly R-108
Exhaust brake is actuated when exhaust brake switch is OFF; or
Exhaust brake is not actuated when exhaust brake switch is ON
6 There is difference between travel speed rod value and actual machine value R-109
7 Retarder lamp does not light up, or stays lighted up R-110
8 Travel speed display always gives display (or does not give any display) R-111
HD255-5 20-705
(10)
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC
TROUBLESHOOTING (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC (AUTOMATIC RE-

TARDER SPEED CONTROLLER) SYSTEM
20-706 HD255-5
(10)
ELECTRICAL CIRCUIT DIAGRAM FOR ARSC
TROUBLESHOOTING (AUTOMATIC RETARDER SPEED CONTROLLER) SYSTEM
HD255-5 20-707
(10)
TROUBLESHOOTING R-1
R-1 0.1 (Abnormality in power source voltage) is displayed

fl Troubleshooting is carried out while the abnormality is being generated, so when the connector is
disconnected and the T-adapter is inserted, or when the T-adapter is removed and the connector is
connected again to its original position, if the error code is not displayed on the monitor, the system
has been reset.
fl The ARSC controller is used to observe the power source voltage. If the power source voltage is less
than 19V and the engine speed is more than 500 rpm continuously for 0.2 seconds, the error is
detected.
fl Divide into battery - fuse and fuse - controller when checking. If the voltage at the inlet port of the
controller is normal, judge that the controller is defective.
Cause Remedy
3 YES
YES Is voltage between
ARC1 (8), (18) –
2 (9), (19) normal? Defective contact or After inspec-
disconnection in wiring tion, repair or
YES Is fuse III-(26) • 20 – 30 V harness between fuse III- replace wiring
normal (not NO
1 • Turn starting (26) and controller harness
blown)? switch ON. Short circuit with chassis After inspec-
Are other control-
ground in wiring harness tion, repair or
lers (electronic between fuse III-(26) -
display panel, NO replace, replace
controller ARC1 (female) fuse
transmission con- (8), (18)
troller) normal? After carrying out
troubleshooting,
Disconnection in wiring
repair or replace
harness between battery (for other con-
NO and fuse, defective trollers, see
battery Troubleshooting
A-1, etc.)
R-1 Related electrical circuit diagram
20-708 HD255-5
(10)
TROUBLESHOOTING R-2
R-2 1.0 (Disconnection in engine speed sensor system) is displayed

has been reset.
fl The controller observes if there is any disconnection or other problem in the engine speed sensor.
fl The engine speed sensor is shared by the transmission controller and electronic display panel. On
the electronic governor specification machine, it is also shared by the engine controller.
fl Divide into sensor - junction E12 and CN31 - ARC3 (5), (12) when checking. If there is no abnormality,
judge that the controller is defective.
Cause Remedy
3 YES
When connector is
YES connected again,
2 does problem ap-
pear again? Mating of ARC3 contactor
Is resistance be- is defective (reset to Repair or replace
YES
1 tween ARC3 (fe- NO normal)
male) (5) and
(12) normal? Defective contact or
Are other control- disconnection in wiring Repair or
lers (transmis- • 500 – 1000 Ω harness between ARC3 replace wiring
sion controller) • Turn starting NO (female) (5), (12) - CN31 harness
normal? switch OFF. (female) (13), (14)
• Disconnect See A-7 in
connector. Troubleshoot-
— ing of transmis-
NO sion controller
system
HD255-5 20-709
(10)
TROUBLESHOOTING R-3
R-3 1.3 (Disconnection in transmission output shaft speed sensor system)

is displayed
has been reset.
fl The controller observes if there is any disconnection or other problem in the transmission output
shaft speed sensor.
fl The transmission output shaft speed sensor is shared by the transmission controller and electronic
display panel.
fl Divide into sensor - junction N3 and CN31 - ARC3 (4), (12) when checking. If there is no abnormality,
judge that the controller is defective.
Cause Remedy
3 YES
When connector is
YES connected again,
2 does problem ap-
pear again? Mating of ARC3 contactor
Is resistance is defective (reset to Repair or replace
YES between ARC3 NO normal)
1 (female) (4) and
Are other control- disconnection in wiring
lers (transmission • 500 – 1000 Ω Repair or
harness between ARC3
controller) nor- • Turn starting NO replace wiring
(female) (4), (12) - CN31
mal? switch OFF. (female) (13), (14)
• Disconnect See A-7 in
connector. Troubleshooting
— of transmission
NO controller
system (A Mode)
20-710 HD255-5
(10)
TROUBLESHOOTING R-4
R-4 1.5 (Failure in retarder oil temperature sensor system) is displayed

has been reset.
fl The controller observes if there is any disconnection or short circuit with the ground in the retarder
oil temperature sensor.
Cause Remedy
2 YES
Is voltage be-
YES tween ARC2 (9)
Disconnection, short cir-
1 and ARC3 (10) cuit with ground in wiring
Are other con- normal? harness between ARC3
Repair or replace
trollers (trans- •1–5V NO (female) (10) – RTO (fe-
mission con- • Turn starting male) (1), ARC2 (female)
troller) normal? switch ON. (9) – RTO (female) (2) See A-20 in
Troubleshooting
— of transmission
NO controller
system (A Mode)
HD255-5 20-711
(10)
TROUBLESHOOTING R-5
R-5 1.7 (Failure in accelerator signal system) is displayed

has been reset.
fl The controller observes if there is any disconnection or short circuit with the ground in the accelera-
tion sensor signal sensor.
Cause Remedy
2 YES
Is voltage be-
YES Disconnection, short cir-
tween ARC2 (9)
1 cuit with ground in wiring
and (19) normal?
Are other con- harness between ARC2
(female) (19) – CN32 (fe- Repair or replace
trollers (trans- • 0.6 – 4.75 V NO
mission con- male) (13), ARC2 (female)
• Turn starting (9) – CN31 (female) (16)
troller) normal? switch ON. See A-11 in
Troubleshooting
— of transmission
NO controller
system (A Mode)
20-712 HD255-5
(10)
TROUBLESHOOTING R-6
R-6 1.8 (Failure in suspension pressure sensor “left” system) is displayed

has been reset.
fl The controller observes if there is any disconnection or short circuit with the ground in the suspen-
sion pressure sensor (left).
Cause Remedy
YES
2
Is voltage be-
YES tween ARC3 (9) Disconnection or short cir-
and chassis 3 YES cuit with chassis ground
ground normal? in wiring harness between Repair or replace
Is voltage be- ARC3 (female) (9) – SUSL
•1–5V tween SUSL (3) (female) (2)
• Turn starting NO and chassis
1 switch ON. ground normal? Defective suspension
Replace
Is voltage be- •1–5V NO pressure sensor
tween SUSL (2) • Turn starting
and chassis switch ON.
ground normal? 5 YES
• 20 – 30 V Is resistance be-
• Turn starting YES tween ARC2 (fe-
switch ON. 4 male) (9) and SUSL
(female) (1) normal? Disconnection or defective
Is voltage be- contact in wiring harness
Repair or replace
tween ARC1 (13) • Max. 1 Ω NO between ARC2 (female) (9)
– SUSL (female) (1)
NO and chassis • Disconnect ARC2 and SUSL.
ground normal? • Turn starting switch OFF. Disconnection or defective
• 20 – 30 V contact in wiring harness
Repair or replace
• Turn starting NO between ARC1 (female)
switch ON. (13) – SUSL (female) (2)
HD255-5 20-713
(10)
TROUBLESHOOTING R-7
R-7 1.9 (Failure in suspension pressure sensor “right” system) is displayed

has been reset.
fl Selection connector: HD325, connect connectors SPR and SP2.
Cause Remedy
YES
2
Is voltage be-
YES tween ARC3 (1) Disconnection or short cir-
and chassis 3 YES cuit with chassis ground
ground normal? in wiring harness between Repair or replace
Is voltage be- ARC3 (female) (1) – SUSR
•1–5V tween SUSR (3) (female) (2)
• Turn starting NO and chassis
1 switch ON. ground normal? Defective suspension
Replace
Is voltage be- •1–5V NO pressure sensor
tween SUSR (2) • Turn starting
and chassis switch ON.
ground normal? 5 YES
• 20 – 30 V Is resistance be-
• Turn starting YES tween ARC2 (fe-
switch ON. 4 male) (9) and SUSR
(female) (1) normal? contact in wiring harness
Is voltage be- Repair or replace
tween ARC1 (13) • Max. 1 Ω NO between ARC2 (female) (9)
– SUSR (female) (1)
NO and chassis • Disconnect ARC2 and SUSR.
ground normal? • Turn starting switch OFF. Disconnection or defective
Repair or replace
NO between ARC1 (female)
(13) – SUSL (female) (2)
20-714 HD255-5
(10)
TROUBLESHOOTING R-8
R-8 4.2 (Disconnection in exhaust brake selector signal system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the exhaust brake selector signal system.
Cause Remedy
YES
Defective RB relay Replace
1
Does condition
become normal 3 YES
when RB relay is Is resistance be-
replaced? YES tween ARC3 (female)
2 (16) and chassis Defective contact or dis-
Is resistance be- ground (ER) normal? connection in wiring harness
between RB (female) (2) and
Repair or replace
tween ARC3
• Max. 350 Ω NO chassis ground (ER)
NO (female) (16) and RB • Turn starting switch OFF.
(female) (1) normal?
• Disconnect connector. Defective contact or
• Max. 350 Ω disconnection in wiring
harness between ARC3 Repair or replace
• Turn starting NO
switch OFF. (female) (16) and RB (1)
• Disconnect
connector.
HD255-5 20-715
(10)
TROUBLESHOOTING R-9
R-9 4.3 (Disconnection in ARSC caution lamp system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the output circuit of ARSC caution lamp.
fl Check for defective contact or disconnection in wiring harness between the controller and lamp, in
the lamp itself, and lamp - cab ground.
fl (When the starting switch is turned ON, the ARSC caution lamp lights up for 3 seconds.)
Cause Remedy
YES
1 Defective lamp Replace
Is there any abnormal-
ity, such as a blown
ARSC caution lamp 2
bulb? (Does condition YES harness between ARC1
Is there defective con- Repair or replace
become normal when (female) (10) and RED,
tact or disconnection
lamp is replaced?) and between RED and
in wiring harness be-
tween ARC1 (female) chassis ground (ER)
NO
(10) and chassis
ground (ER)? Defective controller Replace
NO
20-716 HD255-5
(10)
TROUBLESHOOTING R-10
R-10 4.4 (Disconnection in READY lamp system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the READY lamp output circuit system.
Cause Remedy
YES
Defective RZ relay Replace
1
Does condition
become normal 3 YES
when RZ relay is Is resistance be-
replaced? YES tween ARC3 (female)
between RZ (female) (2) and
Repair or replace
tween ARC3
• Max. 400 Ω NO chassis ground
NO (female) (7) and RZ • Turn starting switch OFF.
(female) (1) normal? Defective contact or
• Disconnect connector.
• Max. 400 Ω harness between ARC3 Repair or replace
• Turn starting NO (female) (7) and RZ
• Disconnect
connector.
HD255-5 20-717
(10)
R-11 4.5 (Disconnection in panel caution and buzzer system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the panel caution and buzzer output circuit
system.
Cause Remedy
YES
Defective RW relay Replace
1
Does condition
become normal 3 YES
when RW relay is
YES Is resistance be-
replaced? tween ARC3 (female)
tween ARC3 between RW (female) (6) and Repair or replace
• Max. 400 Ω NO chassis ground (ER)
NO (female) (8) and RW • Turn starting switch OFF.
(female) (5) normal? Defective contact or
• Disconnect connector.
• Max. 400 Ω harness between ARC3 Repair or replace
• Turn starting NO (female) (8) and RW
• Disconnect
connector.
20-718 HD255-5
(10)
R-12 5.2 (Short circuit with ground in exhaust brake selector signal out-
put system) is displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the RB relay output.
Cause Remedy
YES
Defective RB relay Replace
1
Does condition
become normal
when RB relay is 2 YES
replaced? Is resistance be-
tween ARC3
NO (female) (16) and RB Short circuit with chassis
(female) (2) normal?
Repair or replace
• 200 – 400 Ω NO between ARC3 (female)
• Turn starting (16) and RB (female) (1)
switch OFF.
• Disconnect
connector.
HD255-5 20-719
(10)
R-13 5.3 (Short circuit with ground in ARSC caution lamp system) is dis-
played
has been reset.
fl The controller observes if there is any short circuit with the ground in the ARSC caution lamp system
output circuit.
Cause Remedy
YES
1 Defective lamp Replace
Is there any abnormal-
ity, such as a blown Defective contact, short
ARSC caution lamp circuit with ground in
bulb? (Does condition 2 YES
become normal when Is there defective con- wiring harness between Repair or replace
lamp is replaced?) tact or short circuit ARC1 (female) (10) and
with ground in wiring RED
NO harness between
ARC1 (female) (10)
and RED (female)? Defective controller Replace
NO
20-720 HD255-5
(10)
R-14 5.4 (Short circuit with ground in READY output circuit system) is
displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the READY lamp output circuit
system.
Cause Remedy
YES
1 Defective RZ relay Replace
Does condition
become normal
when RZ relay is 2 YES
replaced? Is resistance
between ARC3 (7)
NO and RZ (2) Short circuit with chassis
normal? ground in wiring harness
between ARC3 (female) Repair or replace
• 200 – 400 Ω NO
• Turn starting (7) and RZ (female) (1)
switch OFF.
• Disconnect
connector.
HD255-5 20-721
(10)
R-15 5.5 (Short circuit with ground in panel caution lamp and buzzer out-
put system) is displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the panel caution lamp and
buzzer system.
Cause Remedy
YES
1 Defective RW relay Replace
Does condition
become normal
when RW relay is 2 YES
replaced? Is resistance
between ARC3
NO (female) (8) and RW Short circuit with chassis
(female) (5) normal? ground in wiring harness
• 200 – 400 Ω NO
• Turn starting (8) and RW (female) (5)
switch OFF.
• Disconnect
connector.
20-722 HD255-5
(10)
R-16 6.0 (Failure in engine speed system) is displayed

has been reset.
fl Always connect any disconnected connectors before going on
to the next step. Cause Remedy
fl The mutual relationship between the engine speed sensor and
the transmission output shaft speed sensor is observed by the
controller. 3 YES Replace
fl Judge from the condition of the machine Defective controller controller
Is condition between
when the abnormality occurred to locate YES ARC3 (female) (5) and
TMD1 (female) (13)
the failed sensor or wiring 2 and between ARC3 (fe-
harness. male) (12) and TMD1
Is monitor panel (female) (14) normal? Abnormality in wiring
When engine is Repair or replace
display normal? • Is there any effect NO harness
running
from radio waves (remove
any electric equipment that
was installed after the
machine was delivered and
carry out re-enactment test) Defective engine speed
1 sensor Replace
NO
Does problem occur
when engine is
5 YES
running or when
machine is traveling Replace
(machine is moving)?
Defective controller
Is condition between controller
YES ARC3 (female) (4) and
TMA1 (female) (1) and
between ARC3 (fe-
4 male) (12) and TMA1
(female) (2) normal? Abnormality in wiring
• Is there any effect NO harness Repair or replace
When machine Is monitor panel
from radio waves (remove
is traveling display normal? any electric equipment that
was installed after the
machine was delivered and
carry out re-enactment test) Defective transmission
Replace
NO output shaft speed sensor
HD255-5 20-723
(10)
R-17 7.0 (Disconnection in travel speed display UP output system) is dis-

played
has been reset.
fl The controller observes if there is any disconnection in the UP output to the travel speed display.
Cause Remedy

When travel speed
YES display is replaced,
1 does problem
appear again?
Is there continuity Defective travel speed
between ARC1 Replace
NO display
(female) (21) and
SPDIS- R3? Defective contact or
• Turn starting Repair or replace
switch OFF. NO (female) (21) and SPDIS-
• Disconnect
R3
connector.
20-724 HD255-5
(10)
R-18 7.1 (Disconnection in travel speed display DOWN output system) is

displayed
has been reset.
fl The controller observes if there is any disconnection in the DOWN output to the travel speed display.
Cause Remedy
2 YES
When travel speed
1 does problem
appear again? Defective travel speed
Is there continuity
display Replace
between ARC1 NO
(female) (20) and
• Turn starting harness between ARC1 Repair or replace
• Disconnect R4
connector.
HD255-5 20-725
(10)
R-19 7.2 (Disconnection in travel speed display CLEAR output system) is

displayed
has been reset.
fl The controller observes if there is any disconnection in the CLEAR output to the travel speed display.
Cause Remedy
2 YES
When travel speed
1 does problem
appear again?
Is there continuity Defective travel speed
Replace
between ARC1 NO display
(female) (11) and
• Turn starting
• Disconnect
R2
connector.
20-726 HD255-5
(10)
R-20 7.3 (Short circuit with ground in travel speed display UP output sys-
tem) is displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the UP output to the travel
speed display.
Cause Remedy
Short circuit with chassis

YES ground in wiring harness
Repair or replace
1 between ARC1 (female)
(21) and SPDIS-R3
Is there continuity
between ARC1
(female) (21) and 2 YES
chassis ground (ER)? Defective controller Replace
When travel speed
• Turn starting display is replaced,
switch OFF. NO does problem
• Disconnect appear again?
Defective travel speed
connector. Replace
NO display
HD255-5 20-727
(10)
R-21 7.4 (Short circuit with ground in travel speed display DOWN output
has been reset.
fl The controller observes if there is any short circuit with the ground in the DOWN output to the travel
speed display.
Cause Remedy

1
(20) and SPDIS-R4
Is there continuity
between ARC1
When travel speed
appear again?
• Disconnect Defective travel speed Replace
connector. NO display
20-728 HD255-5
(10)
R-22 7.5 (Short circuit with ground in travel speed display CLEAR output
has been reset.
fl The controller observes if there is any short circuit with the ground in the CLEAR output to the travel
speed display.
Cause Remedy

1
(11) and SPDIS-R2
Is there continuity
between ARC1
When travel speed
appear again?
• Disconnect Defective travel speed
display Replace
connector. NO
HD255-5 20-729
(10)
R-23 8.1 (Short circuit with ground in pressure control valve system) is
displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the command system circuit to
the pressure control valve.
fl Divide into controller - relay connector, relay connector - valve, and pressure control valve proper
when checking.
Cause Remedy

2 YES ground in wiring harness
Is there continuity
Repair or replace
between BRJ (male) (7),
YES between ARC1 (female) (8) - BSOR (female) (1), (2)
(7) and ARC1 (female)
(16) when ARC1 and Short circuit with chassis
BRJ are disconnected? ground in wiring harness
Repair or replace
NO between ARC1 (female) (7),
1 • Turn starting
(16) - BRJ (female) (7), (8)
switch OFF.
Is there continuity
• Disconnect Short circuit with chassis
between ARC1 (fe- 4 YES
male) (7) and ARC1 connector. ground in wiring harness
(female) (16) when Is there continuity be- between ARC1 (female) (7), Repair or replace
ARC1 and BSOR are YES tween ARC1 (female) (16) - BRJ (female) (7), (8)
disconnected? (7) and chassis ground
3 (ER) when ARC1 and Short circuit with chassis
• Turn starting BRJ are disconnected? ground in wiring harness
Is there continuity Repair or replace
switch OFF. between BRJ (male) (7), (8)
between ARC1 (fe- • Turn starting NO
• Disconnect male) (7) and chassis - BSOR (female) (1), (2)
switch OFF.
connector.
NO ground (ER) when • Disconnect connector.
ARC1 and BSOR are
disconnected?
5 YES
• Turn starting Is resistance of pres-
sure control valve
switch OFF.
• Disconnect NO normal when check-
ed as individual part? Defective pressure control
connector. Replace
• Approx. 20 Ω NO valve
• Turn starting
switch OFF.
• Disconnect
connector.
20-730 HD255-5
(10)
R-24 8.3 (Disconnection in pressure control valve system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the pressure control valve.
fl Divide into ARC1 - relay connector: BRJ, relay connector: BRJ - BSOR, and pressure control valve
proper when checking.
Cause Remedy
2 YES
Is resistance of pres-
YES sure control valve
normal when check-
1 ed as individual part? Defective pressure control
Is there continuity be- Replace
• Approx. 20 Ω NO valve
tween ARC1 (female)
(7), (16) - BSOR (fe- • Turn starting switch OFF.
male) (1), (2) when • Disconnect connector. Defective contact or dis-
ARC1 and BSOR are connection in wiring
disconnected? 3 YES
harness between BRJ Repair or replace
Is there continuity
• Turn starting between ARC1 (fe-
(male) (7), (8) - BSOR
switch OFF. male) (7), (8) - BRJ (female) (1), (2)
• Disconnect NO (female) (7), (8) when Defective contact or dis-
connector. ARC1 and BRJ are
disconnected? connection in wiring
• Turn starting NO (female) (7), (16) - BRJ
switch OFF.
(female) (7), (8)
• Disconnect
connector.
HD255-5 20-731
(10)
R-25 8.5 (Failure in pressure control valve (pressure control valve remains
open) is displayed
has been reset.
fl The controller observes failures in the pressure control valve from the mutual relationship between
the pressure switch and the command value to the pressure control valve.
fl “Pressure control valve remains open” means that the solenoid is energized and the pressure con-
trol valve is open (supplying air).
Cause Remedy
YES
Defective pressure switch Replace
2
When pressure 4 YES
YES switch is replaced, Defective controller Replace
YES When pressure
does problem ap-
pear again? 3 control valve is re-
Is air flowing in placed, does prob-
1 lem appear again?
opposite direction Defective pressure control
Is there continuity Replace
from double check NO valve
between BRR (fe-
male) (1) and chas- NO valve of auto
retarder air system
sis ground (ER)
circuit?
when connector BRR Defective double check
is disconnected?
Replace
• When manual NO valve
• Turn starting retarder or service brake
switch OFF. are operated.
• Disconnect Defective wiring harness
connector. Replace
NO (short circuit with ground)
20-732 HD255-5
(10)
R-26 8.7 (Failure in pressure control valve (pressure control valve does
not open) is displayed
has been reset.
fl The controller observes if there is any failure in the pressure control valve from the mutual relation-
ship between the pressure switch and the command value to the pressure control valve.
Cause Remedy
YES Defective pressure switch

2 Replace
When pressure
YES switch is re-
placed, does 3 YES
1 problem appear Defective controller Replace
again? When pressure
Is there continuity control valve is
between BRR replaced, does
(male) (1) and NO problem appear
ARC2 (female) (5) again? Defective pressure
when connector Replace
NO control valve
BRR is disconnec-
ted?
• Turn starting Defective contact or Repair or
switch OFF. disconnection in wiring replace wiring
• Disconnect NO harness harness
connector.
HD255-5 20-733
(10)
R-27 8.9 (Short circuit with ground in pressure switch valve system) is
displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the pressure switch valve
output circuit.
fl Divide into ARC3 - relay connector BRJ, relay connector BRJ - SHUT, and pressure switch valve
Cause Remedy
2 Short circuit with chassis

YES ground in wiring harness Repair or
Is there continuity
between ARC3 between ARC3 (female) replace
YES (female) (15) and (15) and BRJ (female) (5)
1 chassis ground
(ER) when BRJ is Short circuit with chassis
Is there continuity removed? ground in wiring harness Repair or
between ARC3 NO between BRJ (male) (5)
(female) (15) and •Turn starting replace
switch OFF. and SHUT (female) (1)
chassis ground
•Disconnect
(ER) when ARC3 connector.
and SHUT are dis- 3 YES
connected? Is resistance of Defective controller Replace
pressure switch
• Turn starting
valve normal
switch OFF.
when checked as
• Disconnect NO individual part?
connector. Defective pressure switch
Replace
•Approx. 35Ω NO valve
20-734 HD255-5
(10)
R-28 9.0 (Disconnection in pressure switch valve system) is displayed

has been reset.
fl The controller observes if there is any short circuit with the ground in the pressure switch valve
output circuit.
fl Divide into ARC3 - relay connector BRJ, relay connector BRJ - SHUT, and pressure switch valve
Cause Remedy
2 YES
Is resistance of Defective controller Replace
YES pressure switch
valve normal
when checked as
1 individual part? Defective pressure switch
Replace
Is there continu- • Approx. 35Ω NO valve
ity between • Turn starting
ARC3 (female) switch OFF. Defective contact or
(15) and SHUT • Disconnect 4 YES disconnection in wiring
(female) (1) connector.
when ARC3 and Is there continu- harness between BRJ (male) Repair or
SHUT are dis- 3 YES ity between BRJ (5), (2) - SHUT (female) (1), (2) replace
connected? Is there continu- (female) (2) and
ity between chassis ground? Defective contact or
• Turn starting Repair or
ARC3 (female) disconnection in wiring
switch OFF. • Turn starting replace
(15) and BRJ (fe- NO harness between BRJ
• Disconnect switch OFF.
NO male) (5) when (female) (2) and chassis
connector. • Disconnect
BRJ is discon- connector. ground
nected? Defective contact or Repair or
• Turn starting NO disconnection in wiring replace
switch OFF. harness between ARC3
• Disconnect (female) (15) and BRJ
connector. (female) (5)
HD255-5 20-735
(10)
R-29 9.1 (Failure in pressure switch valve system (remains open)) is dis-
played
has been reset.
fl The controller observes if there is any failure in the pressure switch valve from the mutual relation-
ship between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES disconnection in wiring Repair or
harness between ARC2 replace
1
(female) (2) and SOSW
Is there continu- (female) (1)
ity between
SOSW (1) and YES
chassis ground 2 Defective pressure switch Replace
(ER) when SOSW
is disconnected? When pressure
switch is re-
• Turn starting placed, does YES Defective pressure
switch OFF. NO problem appear 3 Replace
control valve
• Disconnect again?
connector. Does air flow in
opposite direc-
tion from pres- 4 YES
NO sure control Defective controller
When pressure Replace
valve?
switch valve is
replaced, does
NO problem appear
again? Defective pressure switch Replace
NO valve
20-736 HD255-5
(10)
R-30 9.2 (Failure in pressure switch valve system (does not open)) is dis-
played
has been reset.
fl The controller observes if there is any failure in the pressure switch valve from the mutual relation-
ship between the pressure switch and the command value to the pressure switch valve.
Cause Remedy
YES
3 Defective pressure switch Replace
When pressure
YES switch is re-
placed, does
problem appear
4 YES
When pressure Defective controller Replace
2 again?
switch valve is
Is there replaced, does
YES continuity NO problem appear
between SOSW again?
1 (female) (2) and Defective pressure switch Replace
chassis ground? NO valve
Is there continuity
between SOSW • Turn starting Defective contact or
(female) (1) and switch OFF. disconnection in wiring
ARC2 (female) (2) • Disconnect Repair or
when SOSW and connector. harness between SOSW
NO replace
ARC2 are discon- (female) (2) and chassis
nected? ground (ER)
• Turn starting
Defective contact or Repair or
switch OFF.
• Disconnect NO disconnection in wiring replace
connector. harness between ARC2
(female) (2) and SOSW
(female) (1)
HD255-5 20-737
(10)
R-31 9.3 (Disconnection in system switch system) is displayed

has been reset.
fl The controller observes if there is any disconnection in the system switch from the mutual relation-
ship between the system ON input and the system OFF input.
Cause Remedy
4
YES
When system Defective controller Replace
YES switch is re-
placed, does
3 problem appear
again?
Is there continu- Defective system switch Replace
YES ity between SW NO
2 (female) (4) and
TMC1 (1)?
Is there continu- Defective contact or
• Turn starting
YES ity between switch OFF. disconnection in wiring
Repair or
ARC2 (female) NO harness between SW
1 (17) and SW (fe- • Disconnect replace
connector. (female) (4) and TMC1 (1)
Is there continu- male) (2)?
ity between • Turn starting Defective contact or
ARC2 (female) switch OFF. disconnection in wiring
(1) and SW (fe- • Disconnect NO Repair or
male) (1)? connector. replace
(17) and SW (female) (2)
• Turn starting
switch OFF. Defective contact or
• Disconnect NO
harness between ARC2 replace
connector.
(1) and SW (female) (1)
20-738 HD255-5
(10)
R-32 9.4 (Short circuit with ground in system switch system) is displayed
has been reset.
fl The controller observes if there is any short circuit with the ground in the system switch from the
mutual relationship between the system ON input and the system OFF input.
Cause Remedy
YES disconnection in wiring Repair or
1 harness between SW replace
(female) (2) and TMC1 (1)
Is there continu-
ity between SW
(female) (2) and Defective contact or
2 YES disconnection in wiring
TMC1 (1) when Repair or
SW is discon- Is there continu- harness between SW replace
nected? ity between SW (female) (1) and TMC1 (1)
(female) (1) and
• Turn starting 3
switch OFF. NO TMC1 (1) when YES
SW is discon- When system Defective controller Replace
• Disconnect nected? switch is re-
connector.
• Turn starting placed, does
switch OFF. NO problem appear
• Disconnect again?
Defective system switch Replace
connector. NO
HD255-5 20-739
(10)
R-33 9.5 (Disconnection, short circuit with ground in travel speed setting
switch system) is displayed
has been reset.
fl Always connect any disconnected connectors before going on
to the next step. Cause Remedy
fl The controller observes if there is any disconnection or short
circuit with the ground from the travel speed set switch input.
YES ground in wiring harness Repair or
between SPSW - ARC3 (2) - replace
resistor CN-250 (250Ω) (2)
1 4 YES
Is there continui- Go to A
ty between Is resistance be-
SPSW (female) tween SPSW (fe-
(1) and chassis 3 YES male) (1) and Defective contact or
ground (ER) ARC2 (female)
when SPSW is disconnection in wiring
Is voltage be- (10) normal? Repair or
disconnected? harness between SPSW
YES tween ARC2 • 250 ± 25Ω NO (female) (1) and ARC2 replace resistor
(male) (10) and
• Turn starting • Turn starting switch (female) (10), or defective
2 chassis ground
switch OFF. OFF.
normal? resistor (250 Ω)
• Disconnect Is there continui- • Disconnect connector.
connector. • Approx. 5 V Replace
ty between ARC3 Defective controller
(female) (2) and • Turn starting NO controller
SPSW (female) switch ON.
NO • Disconnect Defective contact or
(1)?
connector. disconnection in wiring Repair or
• Turn starting harness between ARC3
switch OFF. NO replace
(female) (2) and SPSW
• Disconnect
(female) (1)
connector.
7
YES
When travel Defective controller Replace
speed setting
YES switch is re-
6
placed, does
Is resistance be- problem appear
tween SPSW (fe- Defective travel speed
YES male) (2) and again? Replace
NO setting switch
5 SPSW (female)
Is resistance be-
tween resistor • 1020 ± 102 Ω disconnection in wiring Repair or
From A CN-1020 (female) • Turn starting harness between SPSW
switch OFF.
NO replace
(1) and (2) nor- (female) (2), (3) - CN-1020
mal? • Disconnect (male) (2), (1)
connector.
• 1020 ± 102 Ω
• Turn starting Defective resistor (1020 Ω) Replace
switch OFF. NO
• Disconnect
connector.
20-740 HD255-5
(10)
R-101 Set speed cannot be set

a) Nothing is displayed in controller display window
fl If nothing is displayed in the ARSC controller display window when the starting switch is ON, check
the controller power source voltage.
1) Check according to R-1 0.1 (Abnormality in power source voltage) is displayed.
2) Check for continuity between ARC1 (9), (19) - TMC1 (1). (If there is no continuity, there is defective
contact or a disconnection in the wiring harness.)
b) There is no response. “8.8” is displayed on the controller.
fl Check according to R-1 0.1 (Abnormality in power source voltage) is displayed.
HD255-5 20-741
(10)
c) Tap up/down, cancel cannot be operated
fl This is a failure in setting switch system circuit or a failure in shift lever system circuit.
Cause Remedy
YES
See Item [9.5] —
4 YES
Go to A
1 YES Is resistance
between ARC3
(2) and ARC2 (9)
Is error code normal? Defect inside ARSC set
Replace
[9.5] displayed? 3 • Setting switch ON: NO switch
Is there continui- 1020 ± 102 Ω
ty between • At tap up: 68 ± 6.8 Ω
YES SPSW (female) • At tap down:
(3) and ARC2 (fe- 198 ± 19.8 Ω
2 male) (9)? • At cancel: 418 ± 41.8
Ω
Is resistance of • Turn starting • Turn starting switch
CN-250 (male) and switch OFF. OFF.
1020 (male) • Disconnect • Disconnect connector. Defective contact or
normal when connector.
NO resistor connected disconnection in wiring Repair or
harness between SPSW replace
to CN-250 and NO
1020 is removed? (female) (3) and ARC2 (9)
• CN-250: 250 ± 25 Ω
• CN-1020: Defective resistor Connect
1020 ± 102 Ω NO connection resistor again
• Turn starting switch
OFF.
• Disconnect 7 YES
connector. Defective controller Replace
YES Is there continuity
6
between CN52F (4)
Is there continui- and ARC2 (8), be-
ty between tween CN52F (5) and
CN52F (4) and ARC2 (7), between
CN52M (4), be- CN52F (6) - ARC2 (6),
tween CN52F (5) between CN52F (7)
and CN52M (5), and ARC2 (5), and
YES between CN52F
between CN52F (8)
(6) - CN52M (6), and ARC2 (18)? Defective wiring harness Repair or
5 between CN52F NO replace
(7) and CN52M • Turn starting
When CN52F and switch OFF.
CN52M are re- (7), and between
CN52F (8) and • Disconnect
moved, and CN52 connector.
connected, are CN52M (8)?
From A monitor panel Defective wiring harness Repair or
• Turn starting
and transmission switch OFF. NO replace
controller actu- • Disconnect
ated according to connector. See A-10 in
shift lever?
Troubleshooting of trans-
—
NO mission controller system
(A Mode)
20-742 HD255-5
(10)
HD255-5 20-743
(10)
R-102 Failure code is always cleared (controller display window always

shows “– –”) or failure code cannot be cleared
fl Disconnect connectors CR1 and CR2, and after approx. 3 seconds, the operation to clear the failure
code is completed.
a) When failure code cannot be cleared
Cause Remedy

1 YES ground in wiring harness Repair or
Is there continui- between ARC2 (14) and replace
ty between CR1 CR1 (1)
(2) and chassis
ground (ER)?
• Turn starting Defective controller Replace
NO
switch OFF.
• Disconnect
connector.
b) When failure code is continuously cleared

Cause Remedy
2 YES
Defective connector Repair or
Is there defective replace
YES contact of con-
1 nectors CR1 and
CR2?
Is there continuity
between ARC2 Defective connector Replace
(14) and CR1 (1)
NO
or between CR2 Defective contact or
(1) and ER (GND)? disconnection in wiring Repair or
• Turn starting harness between ARC2
switch OFF. NO replace
(14) - CR1 (1) or between
• Disconnect CR2 (1) - ER (GND)
connector.
20-744 HD255-5
(10)
TROUBLESHOOTING R-103, R104
R-103 Effect of retarder is too strong when machine is empty, or too weak
when machine is loaded (does not judge loaded/unloaded condi-
tion properly)
fl Check the suspension pressure sensor systems (left and right) according to error codes 1.8 and 1.9.
Check also that there is no abnormality in the suspension itself or in the installation of the pressure
sensors.
fl Check that the connections of connectors SPF, SPR, and SP2 are correctly matched for each model.
HD325, HD405: SPR and SP2 are connected
HD465, HD605: SPF and SP2 are connected
HD785, HD985: SPF and SP2 are connected
R-104 Abnormality appears in other controller

fl The existing connector is joined by the ARSC in a T- adapter condition through a connector, so check
the effect.
a) Transmission controller system

a-1) Accelerator abnormal: see Troubleshooting A-11 for transmission controller system
Check wiring harness between TMA1 (13) and TMA2 (13)
Check wiring harness between TMB1 (9) and TMB2 (9)
a-2) Abnormality in transmission output shaft speed sensor
Check wiring harness between TMA1 (1),(2) and TMA2 (1),(2)
a-3) Abnormality in engine speed sensor
Check wiring harness between TMD1 (13),(14) and TMD2 (13),(14)
a-4) Other abnormality
Check wiring harness between TMA1 and TMA2, TMB1 and TMB2, TMC1 and TMC2
a-5) Travel speed display is strange
Check wiring harness between TMA1 (1),(2) and TMA2 (1),(2)
a-6) Engine speed is strange
Check wiring harness between TMD1 (13),(14) and TMD2 (13),(14)
a-7) Shift lever position is strange
Check wiring harness between TMB1 (4),(5),(6),(7),(8) and TMB2 (4),(5),(6),(7),(8)
b) Suspension controller system

b-1) Abnormality displayed on suspension controller
Check wiring harness between J04-EL (1),(2),(3),(4),(5) and 1J04-EL2 (1),(2),(3),(4),(5)
c) Payload meter system

c-1) Abnormality displayed in payload meter (PLM)
Check wiring harness between ARC3 (6) and PM4-1 (5)
HD255-5 20-745
(10)
R-105 When traveling downhill, even when set speed is exceeded, no con-
trol is carried out
fl If no control is carried out when the accelerator pedal is not being depressed, it means that the
voltage input to the accelerator sensor is not normal.
fl The ARSC controller LED display is “0.0” when the accelerator pedal is being depressed, and “0.0”
when the accelerator pedal is not being depressed.
Cause Remedy
1 YES
Is LED display on
ARSC controller
normal?
Defective accelerator Replace
sensor, or defective accelerator
• When accelerator NO adjustment of accelerator sensor, or
is OFF, display is link adjust
"0.0"
• When accelerator accelerator link
is ON, display is
"0.0"
20-746 HD255-5
(10)
R-106 Monitor lamp (buzzer) stays on (or off)

Cause Remedy
YES Repair or
Defective wiring harness
2 replace
Is there discon-
YES nection in wiring 3 YES
harness between Repair or
RW (2), (4) and Is there short cir- Defective wiring harness replace
chassis ground cuit with ground
(ER)? or disconnection
1 in wiring harness 4 YES Defective between lamp Repair or
NO between RW (3) - When 112F (113F) (buzzer) and monitor replace
When RW relay 113F (2) (or be- and 112M (113M) panel
is replaced, does tween RW (1) -
problem appear are removed and
112F (2)? 112 (113) is con-
again?
nected, does Defective wiring harness
NO problem appear between 112F (113F) and Repair or
again? NO 112M (113M) replace
Defective relay Replace

NO
HD255-5 20-747
(10)
R-107 READY lamp does not light up (or stays lighted up)
YES
YES
3
1
Is there short cir-
cuit with ground
Is READY lamp YES or disconnection
bulb blown? in wiring harness 4 YES
between RZ (fe- Is there short cir-
male) (3) - ARC1 cuit with ground
(female) (8),(18)? or disconnection
in wiring harness 5 YES
2 NO between RZ (fe-
Is there discon-
When RZ relay is male) (5) and
nection in wiring
replaced, does GREEN?
harness between
problem appear GREEN and
NO again? • GREEN:
ARSC standby NO chassis ground
lamp (green) (ER)?
NO
NO
20-748 HD255-5
(10)
Cause Remedy
Defective lamp Replace
Disconnection, defective
Replace
contact, short circuit with
Replace
contact, short circuit with
Replace
Defective RZ relay Replace
HD255-5 20-749
(10)
R-108 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 

YES
2
When CN1F,
CN1M are re-
YES moved and CN1
is connected, YES
does problem ap- 3
pear again? Is there short cir-
cuit with ground
or disconnection
NO in wiring harness 4 YES
between RB (3) Is there short
1 and CN1F (5)? circuit with 5
ground or
When RB relay is disconnection in Is there short
replaced, does circuit with ground YES
NO wiring harness
problem appear between RB (6) or disconnection
again? and CN1M (5)? in wiring harness
between ARC2
(16) and CN31M
NO (4), or between
CN31M (11) and NO
EXH (2)?
NO
20-750 HD255-5
(10)
Cause Remedy
See A-6 and A-

12 in Troublesho
oting of
— transmission
controller
system(A Mode)
Defective wiring harness Repair or

replace

replace

replace
Defective relay Replace
HD255-5 20-751
(10)
R-109 Retarder lamp does not light up, or stays lighted up

Cause Remedy
Check
YES according to
— error code
1 [8.7(8.5)]
See P-1 in
Is error code [8.7
(8.5)] displayed? 2 YES — Troubleshootin
g of monitor
Is there continui- panel system (P
ty between D02
Mode)
(female) (2) and
chassis ground 3 YES Defective wiring harness Repair or
NO when D02 and Is there continuity
104F, M are dis- replace
between 104F (11)
connected? and D02 (female)
(2) and is there con-
tinuity between
NO D02 (female) (2)
and chassis ground 4 YES
when 104F, M and Is there continuity
D02 are disconnec- between 104M
ted? (male) (11) and
• Turn starting D04 (female) (1)
switch OFF. NO and between D04
• Disconnect (female) (2) and
connector. D02 (female) (2)? Repair or
NO replace
20-752 HD255-5
(10)
R-110 Travel speed display always gives display (or does not give any dis-
play)
Cause Remedy
1 YES Repair or
replace
1. Is there con-
tinuity between 4
SPDIS-R5 and YES
SW (female) (2) When system Defective system switch Replace
and is there con- YES switch is re-
tinuity between placed, does
SPDIS-R5 and 3 problem appear
chassis when Is there continuity again?
SPDIS and SW YES between CN1F Defective set travel speed
are disconnec- NO display Replace
(16) and CN1M
ted? (16)?
2
• Turn starting Is there continui- • Turn starting Defective wiring harness
switch OFF. ty between SW switch OFF. Repair or
NO (defective contact or
• Disconnect NO (female) (4) and • Disconnect replace
connector. connector. disconnection)
CN1F (16)?
• Turn starting
switch OFF. Defective wiring harness
Repair or
• Disconnect NO (defective contact or
replace
connector. disconnection)
HD255-5 20-753
(10)
30 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST....................................... 30- 4 ENGINE

SKETCHES OF SPECIAL TOOLS .................. 30- 8 Removal ................................................... 30-36-20
STARTING MOTOR Installation ................................................ 30-36-23
Removal and Installation ............................... 30-10 RADIATOR
ALTERNATOR Removal ................................................... 30-36-28
Removal and Installation ............................... 30-11 Installation ................................................ 30-36-30
ENGINE OIL COOLER OIL COOLER
Removal and Installation ............................... 30-12 Removal and Installation............................... 30-37
FUEL INJECTION PUMP OUTPUT SHAFT
FUEL SUPPLY PUMP Disassembly.................................................. 30-39
Removal ........................................................ 30-14 Assembly ...................................................... 30-41
Installation ..................................................... 30-16 TORQUE CONVERTER, TRANSMISSION
AIR COMPRESSOR Removal ........................................................ 30-45
Removal and Installation ............................... 30-18 Installation ..................................................... 30-47
AIR CONDITIONER COMPRESSOR Disconnection ............................................ 30-48-1
Removal and Installation ............................... 30-20 Connection ................................................. 30-48-2
AIR CONDITIONER CONDENSER TORQUE CONVERTER
Removal and Installation ............................... 30-22 Disassembly............................................... 30-48-3
WATER PUMP Assembly ................................................... 30-48-9
Removal and Installation ............................... 30-23 PTO
AFTERCOOLER CORE Disassembly............................................. 30-48-15
Removal and Installation ............................... 30-24 Assembly ................................................. 30-48-16
EXHAUST BRAKE CYLINDER TRANSMISSION
Removal and Installation ............................... 30-25 Disassembly............................................. 30-48-18
TURBOCHARGER Assembly ................................................. 30-48-36
Removal and Installation ............................... 30-26 TRANSMISSION CONTROL VALVE
NOZZLE HOLDER (ECMV)
FUEL INJECTOR TRANSMISSION, MAIN RELIEF VALVE
Removal ........................................................ 30-28 Removal and Installation............................... 30-50
Installation ..................................................... 30-30 DIFFERENTIAL
NOZZLE TIP Removal ........................................................ 30-51
Removal ........................................................ 30-32 Installation ..................................................... 30-52
Installation ..................................................... 30-34 Disassembly.................................................. 30-53
CYLINDER HEAD Assembly ...................................................... 30-56
Removal ........................................................ 30-36 FRONT WHEEL
Installation ..................................................30-36-2 Removal and Installation............................... 30-64
ENGINE FRONT SEAL REAR WHEEL
Removal ...................................................30-36-13 Removal and Installation............................... 30-65
Installation ................................................30-36-14 FRONT BRAKE CALIPER PAD
ENGINE REAR SEAL Removal and Installation............................... 30-66
Removal ...................................................30-36-16
Installation ................................................30-36-17
HD255-5 30-1
(11)
FRONT BRAKE CALIPER STEERING VALVE
Removal and Installation ...............................30-67 Removal and Installation ............................. 30-118
Disassembly ..................................................30-68 Disassembly................................................ 30-119
Assembly ....................................................30-68-1 Assembly..................................................... 30-124
FRONT WHEEL HUB DEMAND VALVE
Disassembly ..................................................30-69 Removal and Installation ............................. 30-132
Assembly .......................................................30-70 Disassembly and Assembly ........................ 30-133
FINAL DRIVE CARRIER RELIEF VALVE
Removal and Installation ...............................30-73 Disassembly and Assembly ........................ 30-134
Disassembly and Assembly...........................30-74 HOIST VALVE
REAR WHEEL BRAKE Removal and Installation ............................. 30-135
Removal ........................................................30-75 Disassembly................................................ 30-136
Installation .....................................................30-77 Assembly..................................................... 30-137
REAR BRAKE STEERING CYLINDER
Assembly .......................................................30-81 Disassembly................................................ 30-139
FRONT SUSPENSION CYLINDER Assembly..................................................... 30-141
Removal ........................................................30-84 HOIST CYLINDER
Installation .....................................................30-85 Removal and Installation ............................. 30-143
Disassembly ..................................................30-86 Disassembly................................................ 30-144
Assembly .......................................................30-87 Assembly..................................................... 30-147
REAR SUSPENSION CYLINDER DUMP BODY
Removal and Installation ...............................30-88 Removal and Installation ............................. 30-150
Disassembly ..................................................30-89 SHIM OF DUMP BODY
Assembly .......................................................30-90 Procedure for adjusting ............................... 30-151
AIR GOVERNOR TRANSMISSION CONTROLLER
Removal and Installation ...............................30-91 Removal and Installation .......................... 30-151-1
Disassembly and Assembly...........................30-92 ENGINE CONTROLLER
BRAKE VALVE Removal and Installation .......................... 30-151-2
Removal and Installation ...............................30-93 SHIFT INDICATOR CONTROLLER
Assembly .......................................................30-96 PARKING BRAKE SHOE
PARKING BRAKE SPRING CYLINDER Removal ...................................................... 30-153
Removal and Installation ...............................30-98 Installation ................................................... 30-154
PARKING BRAKE CHAMBER
Disassembly ..................................................30-99
Assembly .....................................................30-100
FRONT BRAKE CHAMBER
Removal and Installation .............................30-101
Disassembly ................................................30-102
Assembly .....................................................30-104
REAR BRAKE CHAMBER
Removal and Installation .............................30-106
Disassembly ................................................30-107
Assembly ..................................................... 30-111
SLACK ADJUSTER
Removal and Installation ............................. 30-114
Disassembly and Assembly......................... 30-115
AIR DRIER (DESICCANT TYPE)
Removal and Installation ..........................30-115-1
Disassembly and Assembly......................30-115-2
TRANSMISSION CONTROL, RETARDER BRAKE
COOLING PUMP AND HOIST, STEERING PUMP
EMERGENCY STEERING MOTOR PUMP
30-2 HD255-5
(13)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Sketch
Q’ty
Nature of work Symbol Part No. Part Name Remarks
1 796-514-2110 Hammer 1
Removal of injection nozzle
Removal and installa- Serial No.: 1001 – 1600
tion of nozzle holder 1 2 01011-51090 Bolt 1
assembly
795-799-1170 Puller 1 Serial No.: 1601 and up
Removal and installa-

tion of cylinder head 2 790-331-1110 Wrench 1 Tightening of head assembly
assembly
1 790-101-5401 Push tool KIT 1
2 • 790-101-5421 Grip 1
Installation of front seal
Serial No.: 1001 – 1600
3 • 790-101-5431 Plate 1
4 • 01010-51240 Bolt 1
3
5 795T-521-1140 Push tool 1 Q
6 • 790-101-5221 • Grip 1
Press fitting of engine front seal
7 • 01010-81225 • Bolt 1
tion of front and rear oil 8 • 01050-31640 • Bolt 3
seals
4 795-931-1100 Puller 1 Removal of rear seal
A
1 795-931-1210 Sleeve 1
2 01050-31645 Bolt 3
3 01050-31625 Bolt 3
5 Installation of rear seal
4 795-931-1220 Sleeve 1
5 01050-31625 Bolt 3
6 01050-31645 Bolt 3
Installation of engine
assembly and torque 6 792-220-1110 Centering tool 1 Centering of engine and torque
converter and transmis- converter
sion assembly
795-471-1900 Remover 1
• 795-471-1910 • Bracket 1
Removal of fuel supply 7 • 795-471-1920 • Bolt 1 Removal of fuel supply pump
pump
• 01435-01055 • Bolt 4
• 01435-01080 • Bolt 2

tion of nozzle tip
8 • 795T-471-1550 • Wrench 1 Q Removal and installation of noz-
zle tip
30-4 HD255-5
(11)
Sketch
Q’ty
Unit repair stand 1

790-501-5000 (For 100 V)
1 or Unit repair stand
790-501-5200 (For 110 – 120 V or 220 1
1 – 240 V)
Disassembly and
assembly of torque B 2 790-901-2110 Bracket 1
converter and P.T.O.
assembly
3 790-901-2130 Plate 1
2 790-102-1871 Nut wrench 1

Removal and installation of
P.T.O. gear bearing round nut
3 792-213-1110 Wrench 1
Disassembly and
assembly of transmis- C 1 799-301-1600 Oil leak tester (KIT A) 1 Check of operation of clutch and
sion assembly piston
Unit repair stand

(For 100 V) 1
790-501-5000
1 or Unit repair stand
790-501-5200 (For 110 – 120 V or 220 1
1 – 240 V)
Disassembly and 2 790-901-2110 Bracket 1

assembly of differential D
assembly 3 790-901-2130 Plate 1
1 792-525-1230 Adapter 1
2 2 792-525-1000 Differential micrometer 1 Pre-load on bearing
3 792-510-1400 Wrench 1
1 92T-233-1110 Fixture 3 Q
1 792-520-2121 Installer 1
When floating seal (small) is
Disassembly and used
2 791-580-1600 Push tool 1
assembly of final drive
and rear wheel brake E 2
3 792-520-2110 Installer 1
assembly When floating seal (large) is
used
4 791-580-1600 Push tool 1
3 Commercially Depth gauge 1

available
1 792-240-1150 Holder 1
2 792-240-1160 • Plate 1
1 Disassembly steering unit
3 04020-00514 • Pin 1
4 04020-00820 • Pin 1
Disassembly and 2 792-240-1140 Seal installer 1 Installation of dust seal

assembly of steering F
valve assembly 1 792-240-1100 Seal installer 1
2 792-240-1110 • Body 1
3 3 792-240-1120 • Guide 1 Installation of lip seal
4 792-240-1130 • Spring 1
5 01252-30870 • Bolt 1
HD255-5 30-5
(11)
Sketch
Q’ty
1 790-201-1881 Push tool 1
1 2 792-101-5021 Grip 1 Press fitting of suspension cylin-

der roll bushing
Disassembly and 3 01010-50816 Bolt 1
assembly of front and G
rear suspension cylin-
der assemblies 1 792-610-1000 Suspension tool 1
2 2 792-610-1100 Pump joint 1 Charging suspension cylinder

with oil and gas
3 792-610-1200 Charging tool 1
1 790-502-1003 Cylinder repair stand 1
1 790-101-1102 Pump 1
2 Removal and installation of cyl-
inder round head
2 790-102-2302 Wrench assembly 1
Removal and installation of
3 790-302-1480 Socket 1 nylon nut
1 792-715-1800 Push tool 1
Press fitting of No. 1 roll bushing
4 2 790-101-5421 Grip 1 (Hoist cylinder)
3 01010-51240 Bolt 1
1 792-715-1900 Push tool 1

3 01010-51240 Bolt 1
1 790-201-1861 Push tool 1

3 01010-51240 Bolt 1
Disassembly and
assembly of hoist cylin- 1 792-715-1300 Push tool 1
der and steering cylin- H Press fitting of No. 1 dust seal
der assemblies 7 2 790-101-5421 Grip 1 (Hoist cylinder)
3 01010-51240 Bolt 1
1 792-715-1400 Push tool
8 2 790-101-5421 Grip 1 Press fitting of No. 2 dust seal

(Hoist cylinder)
3 01010-51240 Bolt 1
1 790-201-1670 Plate 1
9 2 790-101-5201 Grip 1 Press fitting of No. 3 dust seal

(Hoist cylinder)
3 01010-50816 Bolt 1
1 790-201-1560 Plate 1
10 2 790-101-5021 Grip 1 Press fitting of dust seal

(Steering cylinder)
3 01010-50816 Bolt 1
11 790-720-1000 Expander 1
1 796-720-1680 Ring 1 Installation of piston (No. 3 hoist

cylinder)
12
2 07281-01589 Clamp 1
30-6 HD255-5
(11)
Sketch
Q’ty
Removal of body I 1 792T-283-1110 Hook 4 Q

799-703-1200 Service tool KIT 1
Removal and installa- 799-703-1100 Vacuum pump (100 V) 1

tion of air conditioner Collection of and charging with
compressor assembly, X 1 799-703-1100 Vacuum pump (220 V) 1 air conditioner refrigerant
radiator assembly, and
engine assembly 799-703-1120 Vacuum pump (240 V) 1
799-703-1400 Gas leak tester 1
HD255-5 30-7
(11)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note: Komatsu cannot accept any responsi-

bility for special tools manufactured
A3 Push tool according to these sketches.
A8 Wrench
30-8 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
E1 Fixture
I1 Hook
HD255-5 30-9
(11)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Disconnect wiring connector (1), and remove

wiring (2) of engine water temperature sensor.
2. Disconnect wiring (3).
3. Remove mounting bolt (4), then remove starting

motor assembly (5).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to
removal.
30-10 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
1. Disconnect 2 wires (1).
2. Loosen nuts (2), remove bolt (3), and let adjust-

ment bolt (4) place upward.
3. oosen mount bolt and nut (5), and remove fan

belt (6) from pulley.
4. Pull out mount bolt and remove alternator

assembly (7). [*1]
INSTALLATION OF
ALTERNATOR ASSEMBLY
removal.
[*1]
a Adjust the fan belt tension. For details, see
STANDARD VALUE TABLE FOR ENGINE.
HD255-5 30-11
(11)
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Open engine hood.
2. Open valve (1) and drain coolant.

6 Coolant: Approx. 45 l
3. Remove turbocharger lubrication return tube (2).
4. Pull out connector (3) from holder.
5. Loosen sleeve nut (5) and remove engine oil dip-

stick (4).
6. Remove cooler mounting bolts (6), then remove

cooler assembly (7).
7. Remove nuts (8), then remove core (10) from

cover (9). [*1]
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
removal.
3 Core mounting nut:

[*1]
43.12 ± 25.08 Nm {4.4 ± 1.6 kgm}
• Refilling with water

a Refill with water to the specified level, and
run the engine to circulate the water through
the system. Then check the water level in
the sub tank again.
30-12 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY
Serial No.: 1001 – 1599
2. Remove coupling cover (1) of fuel injection pump.
3. Disconnect fuel hoses (2), (3), (4), and (5).
4. Remove accelerator rod (6) and engine stop

motor cable (7) together with bracket (8).
5. Disconnect injection pump lubrication pipes (9)

and (10).
6. Disconnect boost compensator tube (11).
7. Remove fuel injection pipe holder brackets (12),

then remove injection pipes (13) and (14). [*1]
8. Align injection timing marks a and b.
9. Remove 2 lock bolts (15) of cross coupling and

laminated coupling. [*2]
10. Remove 4 injection pump lock bolts (16), then lift

off injection pump assembly (17). [*3]
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Serial No.: 1001 – 1599
removal.
3 Injection tube sleeve nut :

[*1]
23.52 ± 0.98 Nm {2.4 ± 0.1 kgm}
3 Laminated coupling mounting bolt :

[*2]
61.74 ± 2.94 Nm {6.3 ± 0.3 kgm}
[*3]
a Install the injection pump. For details, see
TESTING AND ADJUSTING, Testing and
3 Injection pump mounting bolt :

adjusting fuel injection timing.
29.4 ± 4.90 Nm {3.0 ± 0.5 kgm}
HD255-5 30-13
(11)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL OF FUEL SUPPLY

PUMP ASSEMBLY

1. Release the residual pressure in the fuel system.

For details, see TESTING AND ADJUSTING,
Releasing residual pressure in fuel system.
2. Close the fuel stop valve of the fuel tank
3. Remove air conditioner compressor assembly

(1). For details, see REMOVAL OF AIR CONDI-
TIONER COMPRESSOR ASSEMBLY.
4. Remove air compressor assembly (2). For

details, see REMOVAL OF AIR COMPRESSOR
ASSEMBLY.
5. Setting the tool to remove the drive gear of fuel

supply pump (24)
1) Remove mounting nut (4) and washer of fuel
supply pump drive gear (3). [*1]
2) Rotate the crankshaft so that key way A of
the shaft will be in the 12 o'clock direction.
a Be sure to rotate the crankshaft with the
larger mounting bolt of the crank pulley
(Width across flats: 24 mm) only in the for-
ward direction (to prevent the bolt from loos-
ening).
3) Install bracket (6) of tool A7 to mounting hole
C.
4) Fix drive gear (3) to the bracket of tool A7
with mounting hole B.
30-14 HD255-5
(11)
5) Set bolt (7) of tool A7.

a Tighten bolt (7) of tool A7 in step 16.
a Keep tool A7 installed until the pump is
installed so that the meshing point of the fuel
supply pump drive gear and camshaft will not
change.
6. Disconnect fuel supply pump wiring connectors

PCV1 (8), PCV2 (9), and G (10).
7. Remove fuel hose (11) and fuel tube (12). [*2]
8. Remove cover (13). [*3]
9. Remove high-pressure pipe clamps (14), (15),

and another one. [*4]
10. Remove clamp (16) (on the previous page) and

fuel tubes (17) and (18). [*5]
11. Remove 2 covers (19). [*3]
12. Remove 2 high-pressure pipes (20). [*6]
13. Remove clamp (21) and lubrication tube (22).

[*7]
14. Remove bracket (23) and mounting bolts (25) of

fuel supply pump assembly (24) and install the
guide bolt. [*8]
15. Remove the remaining 3 mounting bolts.
16. Tighten bolt (7) of tool A7 to remove fuel supply

pump assembly (24).
HD255-5 30-15
(11)
SUPPLY PUMP ASSEMBLY
removal.
3 Fuel supply pump drive gear mounting nut:

[*1]
127 – 147 {13 – 15 kgm}
[*2]
Fuel hoses (11) and (12):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*3]
a Install cover (13) with the slit on the cylinder
block side and install cover (19) with the slit
directed down.
[*4] [*6] [*8]

k Do not reuse the high-pressure pipe by bending
it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified
torque.
k Install the wiring harnesses at least 10 mm
apart from the high-pressure pipe.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part a: Part of 2 mm
from the end) for visible lengthwise slit b and
spot c and check part d (End of taper seal: Part
at 2 mm from the end) for stepped-type wear
caused by fatigue which your nail can feel. If
there is any of those defects, it can cause fuel
leakage. In this case, replace the high-pressure
pipe.
30-16 HD255-5
(11)
1) Tighten fuel supply pump (24), bracket (23),

and 2 high-pressure pipes (20) temporarily
2 Fuel supply pump mounting bolt:

with your fingers.
LOCTITE (LT-7)
2) Tighten 2 high-pressure pipes (20) to the fol-
3 Common rail-side sleeve nut:

lowing torque.
39.2 – 58.8 Nm {4.0 – 6.0 kgm}

Fuel supply pump-side sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
3) Tighten fuel supply pump mounting bolts
(25).
4) Tighten the mounting bolts of bracket (23).
5) Tighten 3 high-pressure pipe clamps (14),
(15), and (26) temporarily with your fingers.
6) Tighten 3 high-pressure pipe clamps (14),
3 High-pressure pipe clamp:

(15), and (26) to the following torque.
8.82 – 14.7 Nm {0.9 – 1.5 kgm}
3 Fuel tubes (17) and (18):

[*5]
24.5 – 34.3 {2.5 – 3.5 kgm}
3 Lubrication tube (22)

[*7]
Fuel supply pump side:

7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Cylinder block side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
• Checking for fuel leakage

a Check the fuel system for leakage. For
details, see TESTING AND ADJUSTING,
Checking fuel system for leakage.
• Bleeding air
a Bleed air from the fuel circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from fuel circuit.
HD255-5 30-17
(11)
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
REMOVAL OF AIR
COMPRESSOR ASSEMBLY
Serial No.: 1001 – 1599
1. Remove air conditioner compressor assembly.
For details, see REMOVAL OF AIR CONDI-
2. Remove fuel injection pump assembly. For
details, see FUEL INJECTION PUMP ASSEM-
BLY.
3. Loosen drain valve (1) and drain coolant. [*1]
4. Disconnect air outlet tube (2).
5. Disconnect unload tube (3).
6. Disconnect air inlet hose (4). [*2]
7. Disconnect water tubes (5) and (6). [*3]
8. Remove lubrication tube (7). [*4]
9. Remove cover (8).
10. Remove nut (9), using puller, remove drive gear
(10). [*5]
a Remove the drive gear after aligning the counter
marks.
11. Remove compressor mounting bolt (11), then
remove compressor assembly (12).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
Serial No.: 1001 – 1599
removal.
3 Drain valve:
[*1]
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
3 Eyebolt:
[*2]
56.35 ± 7.35 Nm {5.75 ± 0.75 kgm}
3 Eyebolt: 29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}

[*3]
3 Lubrication tube:
[*4]
11.25 ± 1.45 Nm {1.14 ± 0.14 kgm}
3 Nut: 240.0 ± 14.7 Nm {24.5 ± 1.5 kgm}

[*5]
30-18 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
REMOVAL OF AIR
COMPRESSOR ASSEMBLY
1. Remove air conditioner compressor assembly.
For details, see REMOVAL OF AIR CONDI-
2. Remove bracket (1).
3. Loosen drain valve (2) and drain coolant.
4. Disconnect air outlet tube (3).
5. Disconnect unload tube (4).
6. Disconnect air inlet tube (5). [*1]
7. Disconnect water tubes (6) and (7). [*2]
8. Remove lubrication tube (8). [*3]
9. Remove compressor assembly (9).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
removal.
3 Eyebolt:
[*1] [*2]
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Lubrication tube eye bolt:

[*3]
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Nut A: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

Reference
HD255-5 30-19
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 1001 – 1599
k Using air conditioner refrigerant collecting tool

X1, collect air conditioner refrigerant (HFC134a).
1. Remove hose holder bolt (1), then remove hoses

(2) and (3). [*1]
2. Disconnect wiring (4).
3. Remove adjustment bolt (5), then move com-

pressor towards engine and remove belt (6). [*2]
4. Remove nut (7), pull out mount bolt (8), then

remove compressor assembly (9) together with
bracket.
INSTALLATION OF AIR
ASSEMBLY
Serial No.: 1001 – 1599
removal.
[*1]
a Check the O-ring of the hose mouthpiece.
3 Hose holder bolt:
30.5 ± 4.5 Nm {3.11 ± 0.45 kgm}
[*2]
• Adjustment of tension of air conditioner com-
pressor belt
1) The belt should deflect approx. 10 mm when
pushed with a finger pressure of approx.
58.8N {6 kg} at a point midway between the
air conditioner compressor pulley and the
drive pulley.
2) When adjustment is completed, tighten bolt
(5) and mount bolt nut (7).
• Using tool X1, charge the air conditioner with
air conditioner refrigerant (HFC134a).
30-20 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY

1. Remove hose holder bolt (1), then remove hoses

(2) and (3). [*1]
2. Disconnect wiring connector COMP (4) and clip

(5).
3. Loosen adjustment bolts (6) and (7) and nut (8).

Lean the compressor toward the engine and
remove the air conditioner compressor belt. [*2]
4. Remove bolt (7) and mounting bolt (9), and then

remove compressor assembly (10) and bracket
together.
INSTALLATION OF AIR
ASSEMBLY
removal.
[*1]
a Check the O-ring of the hose mouthpiece.
3 Hose holder bolt (M8):
20 – 25 Nm {2 – 2.5 kgm}
[*2]
• Adjustment of tension of air conditioner com-
pressor belt
1) The belt should deflect approx. 10 mm when
pushed with a finger pressure of approx.
58.8N {6 kg} at a point midway between the
air conditioner compressor pulley and the
drive pulley.
2) When adjustment is completed, tighten bolt
(6), (7) and mount bolt nut (9).
air conditioner refrigerant (HFC134a). (1 kg
± 50 g)
HD255-5 30-21
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER a Serial No.: 1001 – 1599
ASSEMBLY
1. Remove radiator grille.
2. Disconnect hoses (1) and (2). [*1]

a Loosen the sleeve nuts slightly and release
the refrigerant (R134a) completely before
disconnecting the hoses.
a Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.
3. Remove mounting bolts (3), then remove con- a Serial No.: 1601 and up
denser assembly (4).
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
[*1]
a Check that the O-ring is not damaged or
deteriorated, then connect the hoses.

air conditioner refrigerant.
30-22 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
2. Remove water pipe (1).
3. Remove hose clamp (2).
4. Remove hose flange mounting bolt (3) connect-

ing thermostat housing and radiator upper tank.
5. Remove wiring clamp (4) and move upward.
6. Remove water pipe (5) and move to chassis end.
7. Remove thermostat housing (6) and move

towards rear of engine.
8. Remove bolt (7), then remove water pump

assembly (8).
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.

a Refill with water to the specified level, and
run the engine to circulate the water through
the system. Then check the water level in
the sub tank again.
HD255-5 30-23
(11)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
REMOVAL OF AFTERCOOLER
CORE ASSEMBLY
Serial No.: 1001 – 1599
k Raise the dump body and lock with the safety

pin.
1. Drain coolant.

3. Disconnect exhaust brake hose (1).
4. Disconnect wiring (2) and (3) from switch.
5. Remove wiring clamp (4) and move towards
chassis end.
6. Remove coolant inlet tube (6).
7. Remove hose clamps (7) and (8).
8. Remove corrosion resistor mounting bracket (9).
9. Remove coolant outlet tube (10).
10. Disconnect joint hose (11).
11. Remove turbocharger lubrication tube clamp
(12).
12. Remove intake connector (13).
13. Remove mounting bolts (15) of cover (14).
a The compressor air take-off hose is at the
bottom of the cover, so loosen the band at
the cover end.
14. Lift off cover (14) and remove core (17).
INSTALLATION OF
AFTERCOOLER CORE
ASSEMBLY
Serial No.: 1001 – 1599
removal.

a Refill with water to the specified level, and run
the engine to circulate the water through the
system. Then check the water level in the
sub tank again.
30-24 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE CYLINDER
REMOVAL OF EXHAUST
BRAKE CYLINDER
ASSEMBLY
Serial No.: 1001 – 1599
1. Disconnect air hose (1).
2. Remove bolt (2), then remove exhaust brake cyl-

inder assembly (3).
INSTALLATION OF EXHAUST
BRAKE CYLINDER
ASSEMBLY
Serial No.: 1001 – 1599
removal.
HD255-5 30-25
(11)
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
Serial No.: 1001 – 1599
2. Loosen bands (1) of hose connecting intake con-

nector and turbocharger, and move hose
towards turbocharger end.
3. Remove hose (2) at turbocharger end.
4. Remove clamp (3).
5. Remove bolts (4), then remove turbocharger

lubrication inlet tube (5). [*1]
a Remove the eyebolts at the main gallery end of
the tube.
6. Remove mounting bolt (6) of exhaust pipe.
7. Remove mounting bolts (7) at exhaust brake

end.
a There is an exhaust pipe vibration stopper band
on the inside of the fender, so remove it.
8. Remove bolts (8), and disconnect exhaust brake

assembly (9).
9. Disconnect turbocharger lubrication return tube

(10). [*2]
10. Remove turbocharger mounting bolts (11), then

remove turbocharger assembly (12). [*3]
INSTALLATION OF
TURBOCHARGER ASSEMBLY
Serial No.: 1001 – 1599
removal.
3 Mounting bolt :
[*1]
66.35 ± 7.15 Nm {6.77 ± 0.7 kgm}
3 Mounting bolt :
[*2]
66.35 ± 7.15 Nm {6.75 ± 0.7 kgm}
3 Mounting bolt :
[*3]
49.0 ± 4.90 Nm {5.0 ± 0.5 kgm}
30-26 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 1001 – 1599
2. Remove rubber cover, then remove sleeve nut

(1). [*1]
3. Remove spill tube (2). [*2]
4. Remove clamps (3).
5. Move injection tube (4) towards outside.
6. Remove intake connector (5). (No. 3 only)
7. Remove nozzle holder mounting bolts (6). [*3]
8. Using sliding hammer A1, remove nozzle holder

assembly (7).
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 1001 – 1599
removal.
3 Sleeve nut :
[*1]
23.5 ± 0.98 Nm {2.39 ± 0.10 kgm}
3 Spill tube :
[*2]
11.25 ± 1.45 Nm {1.14 ± 0.14 kgm}
3 Mounting bolt :
[*3]
21.55 ± 2.95 Nm {2.19 ± 0.30 kgm}
HD255-5 30-27
(11)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
REMOVAL OF FUEL
INJECTOR ASSEMBLY
1. Open the engine hood.
2. Disconnect air hose (1) and remove air tube (2)

together with the bracket.
3. Remove 2 tubes (3) and remove oil filter (4)

together with the bracket. [*1]
4. Remove common rail cover (5). [*2]
5. Remove high-pressure pipe clamps (6) accord-

ing to the fuel injectors to be removed and
installed. [*3]
6. Remove gate-type bracket (7). [*4]
7. Remove injector-side covers (9) and common

rail-side covers (8) from the high-pressure pipe
joints according to the fuel injectors to be
removed and installed. [*5]
8. Remove high-pressure pipe clamp cover (10)

and its clamp according to the fuel injectors to be
removed and installed. [*6]
a Do not remove bracket X. If it is removed,
tighten it permanently after tightening the
high-pressure pipe and all the high-pressure
pipe clamps in the assembly procedure.
9. Loosen common rail-side sleeve nuts (11) and

fuel injector-side sleeve nut (13) and remove
high-pressure pipe (12). [*7]
10. Remove head cover (14). [*8]
30-28 HD255-5
(11)
11. Remove capture nuts (15) and disconnect wiring

harness (16) from the fuel injector. [*9]
12. Remove holder mounting bolt (17), and then

remove the holder and fuel injector assembly
(18) together. [*10]
a Do not grip the solenoid valve at the top of
the injector with pliers, etc.
a If the fuel injector is not removed easily, use
tool A1.
HD255-5 30-29
(11)
INJECTOR ASSEMBLY
removal.
[*1]
3 Air cleaner tube band:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2] [*3] [*4] [*6] [*7]

k Do not reuse the high-pressure pipe by bending
it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified
torque.
k Install the wiring harnesses at least 10 mm
apart from the high-pressure pipe.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part a: Part of 2 mm
from the end) for visible lengthwise slit b and
spot c and check part d (End of taper seal: Part
at 2 mm from the end) for stepped-type wear
caused by fatigue which your nail can feel. If
there is any of those defects, it can cause fuel
leakage. In this case, replace the high-pressure
pipe.
a Install high-pressure pipe (12) between the com-

mon rail and fuel injector according to the follow-
ing procedure.
1) Tighten sleeve nuts (11) and (13) of high-
3 High-pressure pipe sleeve nut:

pressure pipe (12).
39.2 – 49.0 Nm {4.0 – 5.0 kgm}

2) Tighten high-pressure pipe clamps (6) and
(20) temporarily with your fingers, and then
tighten them permanently.
3) Install common rail cover (5) and gate-type
bracket (7) temporarily.
4) Tighten common rail cover (5) (which is also
used as a high-pressure pipe clamp) perma-
nently first, then tighten gate-type bracket (7)
3 Common rail cover:

permanently.
8.82 – 14.7 Nm {0.9 – 1.5 kgm}
30-30 HD255-5
(11)
[*5]
a Install common rail-side cover (8) with the slit
on the cylinder block side.
a Set the slit on fuel injector-side cover (9) at
position a in the figure and match it to the
center of the clip.

[*8]
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Wiring harness mounting nut:

[*9]
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
[*10]
a Install fuel injector assembly (18) according to
the following procedure.
1) Insert gasket b and O-ring c in fuel injector a.
2) Put holder d in injector a and install them to
the rocker housing temporarily.
a Matching key g of the injector to key way
h of the rocker housing, insert the holder
securely until the sealing surface of the
injector touches the sealing surface on
the cylinder head side.
3) Apply engine oil to the spherical part of
spherical washer e.
3 Holder mounting bolt:

4) Tighten holder mounting bolt f.
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
• Checking for fuel leakage

Check the fuel system for leakage. For details,
see TESTING AND ADJUSTING, Checking fuel
system for leakage.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
HD255-5 30-31
(11)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
REMOVAL OF NOZZLE TIP

1. Grip tool A8 with vise [1].
a Do not grip the injector directly with the vise.
2. Set injector assembly (3) to tool A8.
3. Using 19 mm deep socket [3], loosen retaining

nut (4).
30-32 HD255-5
(11)
4. Remove retaining nut (4) from injector assembly

(3).
5. Lift up and remove nozzle assembly (5) verti-

cally.
a Do not remove tip guide (6). (The tip guide
cannot be disassembled.)
a Take care that dirt will not stick to the parts.
HD255-5 30-33
(11)
INSTALLATION OF NOZZLE
TIP
1. Grip tool A8 with vise [1].
a Do not hold the injector directly with the vise.
2. Set injector assembly (3) to tool A8.
3. Clean the lower body and the threads of retain-

ing nut (2) thoroughly with parts cleaner and
blow air against them.
4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).
a Take care not to drop the tip.
30-34 HD255-5
(11)
5. Install the nozzle assembly and tighten retaining

nut (2) with your fingers.
6. Set 19 mm deep socket [2] to a torque wrench

and tighten the retaining nut according to the fol-
lowing procedure.
a Apply rust-preventive oil to the nozzle body.
1) Tighten the retaining nut to 88.3 Nm {9.0
kgm}.
2) Make match marks (6) on retaining nut (2)
and lower body (5).
3) Tighten the retaining nut by 45° (Angle tight-
ening).
HD255-5 30-35
(11)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER
HEAD ASSEMBLY
Serial No.: 1001 – 1599
k Raise the dump body and lock it with the safety
k Disconnect the cable from the negative (E ter-

pin.
1. Drain coolant.
2. Open engine hoods (1) and (2).
3. Remove wiring and piping. For details, see

REMOVAL OF AFTERCOOLER CORE ASSEM-
BLY.
4. Remove exhaust pipe and turbocharger lubrica-

tion tube. For details, see REMOVAL OF TUR-
BOCHARGER ASSEMBLY.
5. Remove fuel tubes and spill tubes. For details,

see REMOVAL OF NOZZLE HOLDER ASSEM-
BLY.
6. Loosen band of hose (3) and move towards tur-

bocharger end.
9. Loosen top band of compressor suction hose (6).
10. Disconnect boost compensator tube (7).
11. Sling inlet manifold (8) with wire and lever block,
remove bolt (9), then lift off manifold assembly
(10). [*1]
a The damper end will interfere with the frame,
so adjust the assembly with the lever block
when lifting off.
30-36 HD255-5
(11)
12. Sling exhaust manifold assembly (11), and

remove mounting bolts (12). [*2]
13. Raise exhaust manifold assembly (13) and

remove.
15. Remove bolts (15), then remove nozzle assem-

bly (16).
16. Remove eyebolt (17), then remove tube (18).
17. Remove bolt (19), then remove cover (20). [*3]
18. Loosen locknuts (21), and pull out 2 push rods

(22). [*4]
19. Remove bolt (23), then push rocker arm assem-

bly (24) to inside and remove. [*5]
20. Remove crosshead (25). [*6]
21. Remove bolt (26), then remove housing (27).

[*7]
22. Remove bolt (28), then remove head (29). [*8]
HD255-5 30-36-1
(11)
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Serial No.: 1001 – 1599
removal.
[*1]
a Screw in the intake manifold mounting bolts
2 – 3 turns by hand, tighten mounting bolts
[1] – [3], then tighten the remaining mounting
3 Intake manifold mounting bolt :

bolts.
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
[*2]
a Screw in the exhaust manifold mounting
bolts 2 – 3 turns by hand, tighten mounting
bolts [1] – [3], then tighten the remaining
3 Exhaust manifold mounting bolt :

mounting bolts.
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
3 Head cover mounting bolt :

[*3]
9.80 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*4]
a Adjust the valve clearance. For details, see
3 Locknut :
Adjusting valve clearance.
66.15 ± 7.35 Nm {6.75 ± 0.8 kgm}
3 Mounting bolt :
[*5]
66.2 ± 7.4 Nm {6.75 ± 0.8 kgm}
[*6]
a Adjust the crosshead as follows.
1) Loosen the locknut, and turn back the adjust-
ment screw.
2) Hold down the top surface of the crosshead
lightly, and screw in the adjustment screw.
3) After the adjustment screw contacts the
valve stem, screw it in a further 20°.
4) Tighten the locknut to hold the adjustment
3 Locknut :
screw in position.
66.15 ± 7.35 Nm {6.75 ± 0.8 kgm}
3 Mounting bolt :
[*7]
66.2 ± 7.4 Nm {6.75 ± 0.8 kgm}
30-36-2 HD255-5
(11)
[*8]
a If any rust of more than 5 mm square is
found on the shaft or thread of any head bolt,
replace the head bolt with a new bolt.
a Check that there is no dirt or dust on the cyl-
inder head mounting surface or inside the
cylinder.
a Check that the grommet does not come out
when installing the gasket.
a Coat the bolt thread, seat surface, and cylin-
der head hole seat surface completely with
molybdenum disulphide (LM-P).
a Screw in the cylinder head mounting bolts 2
– 3 turns by hand, then tighten in the order
shown in the diagram.
3 Mounting bolt :
3 Cylinder head mounting bolt

Anti-friction compound (LM-P)
1st step : Tighten to

68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
2nd step: Tighten to
107.8 ± 4.9 Nm {11.0 ± 0.5 kgm}
3rd step : 1. When using tool A2.
• Using an angle tightening wrench,
tighten the bolt.
2. When not using tool A2.
1) Using the angle of the bolt head
as the base, make start marks
on the cylinder head and socket.
2) Make an end mark at a point 90°
from the start mark.
3) Tighten so that the start mark on
the socket is aligned with the
end mark on the cylinder head at
the 90° position.
a After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightened.
• If any bolt already has five punch marks, do

not reuse it. Replace it with a new bolt.

Add water to the specified level, and run the
engine to circulate the water through the system.
Then check the water level in the sub tank again.
HD255-5 30-36-3
(11)
REMOVAL OF CYLINDER
HEAD ASSEMBLY

pin.
1. Drain the coolant.

2. Open engine hoods (1) and (2).
3. Disconnect fuel supply pump wiring connectors

PCV1 (3), PCV2 (4), and G (5).
4. Remove tie wrap (6) and clip.
5. Disconnect hose (7).
6. Remove tube (8).

a Remove this tube together with the bracket.
7. Remove the clamp and 2 tubes (9), and then

remove oil filter (10).
8. Remove clamp (11) and 2 fuel tubes (12). [*1]
9. Remove fuel filter (13).
10. Remove corrosion resistor (14).
11. Remove common rail cover (15). [*2]
12. Remove connector PIM (16).
13. Remove clip (17).

a A spacer is installed.
14. Disconnect connectors ER2 (18) and ER3 (19)

and remove bracket (20) and spacer (21).
30-36-4 HD255-5
(11)
16. Remove air intake hose (24) and tube (23). [*3]
17. Remove 3 high-pressure pipe clamps (25) and 3

brackets (26). [*4]
18. Remove lubrication tube clamp (27) and lubrica-

tion tube (28). [*5]
19. Disconnect heater switch (29) from the clamp.
20. Disconnect the wiring between heater switch

(29) and electrical intake air heater.
21. Disconnect connector DIODE (30).
22. Disconnect clip (31) and bracket (32), and then

disconnect 6 fuel injector connectors (33).
a Arrange disconnected wiring harness assem-
bly (34) so that it will not be an obstacle. [*6]
a To disconnect fuel injector connector c, insert
flat-head screwdriver [1] in stepped part a
and move it in direction X, pressing stopper
b.
23. Sling air intake manifold assembly (35) tempo-

rarily and remove the air intake manifold mount-
ing bolts. [*7]
a Do not remove XX.
24. Lift off air intake manifold assembly (35).

4 Air intake manifold assembly: 45 kg
25. Remove heat insulation covers (36) and (37).
26. Disconnect lower lubrication tube (38).
HD255-5 30-36-5
(11)
27. Remove hose (39). [*8]
28. Remove hose (40). [*9]
29. Remove exhaust brake assembly (41). [*10]
30. Sling turbocharger assembly (42) temporarily.
31. Remove the mounting bolts of exhaust manifold

(43). [*11]
32. Lift off turbocharger and exhaust manifold

assembly (44).
4 Turbocharger and exhaust manifold assem-
bly: 70 kg
33. Remove common rail-side high-pressure pipe

clamp (45) and gate-type bracket (46). [*12]
34. Remove high-pressure pipe covers (47) and (48)

from the 6 places respectively. [*13]
35. Remove 6 high-pressure pipe sleeve nuts (49)

on the common rail side. [*14]
36. Loosen 6 high-pressure pipe sleeve nuts (50) on

the head side and remove 6 high-pressure pipes
(51). [*15]
37. Remove spill tube (52). [*16]
38. Remove return tube (53). [*17]
39. Remove coolant tube (54). [*18]
40. Remove 6 head covers (55). [*19]
30-36-6 HD255-5
(11)
41. Remove capture nut (56) and disconnect the wir-

ing harness from the injector. [*20]
42. Remove rocker shaft mounting bolts (57), and

then remove rocker arm and rocker shaft assem-
bly (58). [*21]
43. Remove injector mounting bolts (59) and injector

assembly (60). [*22]
a If the injector assembly is not removed eas-
ily, use tool A1.
a Do not hold the solenoid valve on the top of
the injector with pliers, etc.
44. Remove cross head (61). [*23]
45. Remove 2 push rods (62).
46. Remove 6 mounting bolts (63) and rocker hous-

ing (64). [*24]
47. Remove 7 cylinder head mounting bolts (65) and

cylinder head assembly (66). [*25]
HD255-5 30-36-7
(11)
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
• Carry out installation of all the parts, except the
high-pressure pipe, in the reverse order to
removal.
3 Fuel tube (12):

[*1]
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Hose clamp:
[*3]
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
3 Joint bolt on engine block side of lubrica-

[*5]
tion tube: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
Install wiring harness assembly (26) and other
wiring harnesses at least 10 mm apart from the
high-pressure pipe.
[*7]
The tightening torque and tightening order of the
air intake manifold assembly mounting bolts are
not specified.
3 Clamp of hose (39):

[*8]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Clamp of hose (40):

[*9]
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*10]
Before tightening the exhaust manifold, fix
exhaust brake assembly (41) temporarily.
[*11]
Tighten the exhaust manifold assembly mount-
ing bolts shown at right first in the given order,
3 Exhaust manifold assembly mounting bolt:

and then tighten the other bolts.
58.8 – 73.5 Nm {6 – 7.5 kgm}
30-36-8 HD255-5
(11)
[*13]
a For the installation procedure for high-pres-
sure pipe covers (47) and (48), see
REMOVAL AND INSTALLATION OF FUEL
INJECTOR ASSEMBLY.
[*2] [*4] [*12] [*14] [*15]

Installation procedure for high-pressure pipe
a Do not reuse the high-pressure pipe by bending
it.
3 Sleeve nuts (50) and (49):

1) Tighten high-pressure pipe (51) permanently.
39.2 – 49.0 Nm {4.0 – 5.0 kgm}

(25) and bracket (26) with your fingers.
3 Clamp bolt:
(25) permanently.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Tighten bracket (26) permanently.
5) Install cover (48).

a Set the slit on the cylinder head side.
6) Install gate-type bracket (46) and cover

(which is used as the clamp, too) (15) tempo-
rarily.
3 Common rail cover mounting bolt:

7) Tighten common rail cover (15) permanently.
11.8 – 14.7 kgm {1.2 – 1.5 kgm}
8) Tighten gate-type bracket (46) permanently.
HD255-5 30-36-9
(11)
[*16]
3 Spill tube (52):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*17]
3 Return tube (53):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*18]
3 Coolant tube (54):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*19]
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*20]
3 Capture nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
[*21]
1) Loosen the locknut and install the rocker arm
3 Rocker shaft mounting bolt:

and rocker shaft assembly.
58.8 – 73.5 Nm {6 – 7.5 kgm}

2) Adjust the valve clearance. Pointer: P
• Valve clearance
Intake: 0.33 mm
Exhaust: 0.71 mm
a For the adjustment procedure for the valve
clearance, see TESTING AND ADJUSTING,
3 Rocker arm locknut:

Adjusting valve clearance.
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
[*22]
a For the installation procedure for the injector
and holder, see REMOVAL AND INSTALLA-
TION OF FUEL INJECTOR ASSEMBLY.
30-36-10 HD255-5
(11)
[*23]
a Apply engine oil (EO30-CD) to the cross
head guide and cross head top sufficiently.
a Adjust the cross head according to the fol-
lowing procedure.
1) Loosen locknut (73) and return the
adjustment screw.
2) Press the cross head top lightly to put it
to valve stem (74) and tighten the adjust-
ment screw.
3) After the adjustment screw touches the
valve stem, tighten it further by 20°.
3 Locknut:
4) Tighten the locknut at this position.
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*24]
3 Rocker housing mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*25]
a Clean the underside of the head, top of the
block, and liner with dry cloths or cloths
soaked with solvent.
a If a bolt has 5 punch marks on its head,

replace it.
a Tighten the bolts with your fingers into the
2 Bolt threads and underside of bolt

block at least 2 turns.
head: LM-P or engine oil (EO30-CD)
HD255-5 30-36-11
(11)
a Tighten the cylinder head mounting bolts in
3 Cylinder head mounting bolts 1 – 6:

the order shown at right.
1st time : 88.3 – 108 Nm {9 – 11 kgm}

2nd time: 157 – 167 Nm {16 – 17 kgm}
3rd time:
1) When using tool A2
Using tool A2, retighten the bolts in the
order of 1 – 6 by 90° +30°
0 .
2) When not using tool A2

Make marks on the bolt heads with a
marker pen and retighten the bolts in the
order of 1 – 6 by 90° +30°
0 .
a After tightening bolts 1 – 6, tighten
3 Cylinder head auxiliary mounting

auxiliary bolt 7.
bolt 7:
66.2 ± 7.4 Nm {6.8 ± 0.8 kgm}
a After tightening the bolts, make a
punch mark on each bolt head to
show the number of tightening time.
• Refilling with coolant

Add coolant through the coolant filler of the radi-
ator to the specified level. Run the engine to cir-
culate the coolant through the piping. Then,
check the coolant level again.
30-36-12 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
k Stop the machine on level ground, and put
blocks under the wheels.
pin.
1. Remove radiator assembly. For details, see

REMOVAL OF RADIATOR ASSEMBLY.
2. Remove fan (1).
3. Loosen alternator mounting bolts and air com-

pressor mounting bolts, and remove fan belt (2).
[*1]
4. Remove bolts (3), then remove vibration damper

and pulley assembly (4). [*2]
a The crankshaft pulley mounting bolt (immedi-
ately below the dowel pin) is different from
the other 5 mounting bolts, so be careful to
use the correct tightening torque.
5. Using tool A4 (Tip: Drill), take out engine front

seal (5). [*3]
a Be extremely careful not to damage the
crankshaft when removing.
a If tool A4 was used, remove all the chips.
HD255-5 30-36-13
(11)
INSTALLATION OF ENGINE
FRONT SEAL
removal.
[*1]
a Adjust the belt tension. For details, see
TESTING AND ADJUSTING, Testing and
adjusting tension of fan belt.
3 Crankshaft pulley mounting bolt (3) :

[*2]
3 Crankshaft pulley mounting bolt (*) :

276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
176.4 ± 19.6 Nm {18 ± 2.0 kgm}
[*3]
Procedure for installing front seal (5)
a Before installing the seal, check the rims of
the crankshaft end, sliding surfaces of the lip,
and housing for a flaw, burr, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
a Never remove the internal plastic cylinder of
the spare seal before installing the seal.
1) Put large inside diameter side b of internal

plastic cylinder (6) to the end of crankshaft
(7).
a Take care not to mistake the direction of the
2 Lip: Lithium grease (G2-LI)

plastic internal cylinder.
2) Evenly push in the metallic ring of front seal

(5) with both hands, getting over the large
diameter side of the internal plastic cylinder.
3) After pushing in front seal (5), remove inter-

nal plastic cylinder (6).
a When removing, take care not to damage the

seal lip.
30-36-14 HD255-5
(11)
4-1) Serial No.: 1001 – 1599

a Using tool A3, press fit the oil seal.
Oil seal press-fitting tolerance a: +10 mm
2 seal lip: Fill 50 – 80% of space at lip
with heat-resistant long-life grease
(G2-LI-S) (Kyodo Grease Martemp
ET-130 or equivalent)
4-2) Serial No.: 1601 and up

Tighten the bolt of tool A5-2 evenly until the
end of tool A3 touches the end of crankshaft
(7) to press fit front seal (5).
a When press fitting the seal, take care not
to damage the lip on the pulley side with
the tool, etc.
a After press fitting the seal, remove the
red sealant layer on its periphery.
a Fitting dimension a of seal: 16 +10 mm
HD255-5 30-36-15
(11)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove output shaft. For details, see REMOVAL
OF OUTPUT SHAFT.
2. Using eyebolts, sling flywheel (1), remove

mounting bolts, then lift off. [*1]
k The flywheel pilot is shallow and it may come
off suddenly, so be careful not to get your fin-
gers caught.
3. Hook puller tip of tool A4 to metal ring of seal (2)

and use impact force of a slide hammer to pull
out. [*2]
a Before pulling out, knock the oil seal in
slightly. This separates the seal from the
housing and makes it easier to pull out the
seal.
a Be extremely careful not to damage the
crankshaft.
a Do not use a drill. The metal powder will get
inside the engine.
• For a vehicle, Serial No.: 1601 and up, which

does not have a metallic ring, set the drill-
type tip to tool A4, make a hole on the rail,
and pull out the seal with impact forces of a
slide hammer.
a Remove all the metal powder.
30-36-16 HD255-5
(13)
REAR SEAL
removal.
[*1]
a Tighten the flywheel mounting bolts as fol-
2 Flywheel mounting bolt thread:

lows in the order shown in the diagram.
3 Flywheel mounting bolt :

Lubricating oil (E030)
1st step : 147.0 ± 19.6 Nm{15 ± 2.0 kgm}

2nd step: 289.1 ± 19.6 Nm{29.5 ± 2.0 kgm}
• Using dial gauge [1], measure radial and
face runout of flywheel.
Face runout : 0.2 mm
Radial runout: 0.15 mm
[*2]
a With the Teflon seal (lay-down lip seal),
check the condition of the wear of the crank-
shaft, then select either a standard seal or a
seal with a sleeve, and assemble the seal.
The condition of wear of the crankshaft is
judged by the luster (no wear can be felt
when touched with the flat of a finger, depth
of wear less than 10 um). If there are no
scratches, assemble a standard seal; in all
other cases, assemble a seal with a sleeve.
• Procedure for assembling standard seal

a Before assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the cor-
ner of the end face of the crankshaft.
a When assembling the seal, do not coat the
crankshaft and seal lip with oil or grease.
Wipe off all the oil from the crankshaft.
a Do not remove the internal plastic tube from
the standard seal until the seal is assembled.
HD255-5 30-36-17
(11)
1) Put large inside diameter end of internal

plastic tube (3) in contact with end of crank-
shaft (4).
a Be particularly careful to assemble facing
in the correct direction.
2) Hold metal ring of seal (2) with both hands

and push in uniformly with sudden force.
3) After pushing seal in, remove internal plastic

tube (3).
a When removing the internal plastic tube,
be careful not to damage the seal lip.
4) Tighten bolts of tool A5-1 uniformly until end

face of tool A5-1 contacts end face of crank-
shaft (4) to press fit seal (2).
a When press fitting the seal, be extremely
careful not to damage the lip at the clutch
end when setting the tool.
a After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.
• Assembly procedure for seal with sleeve

a Before assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the cor-
ner of the end face of the crankshaft.
a When assembling the seal, do not coat the
crankshaft and the area between the sleeve
and seal lip with oil or grease; wipe off all oil
or grease from the crankshaft.
a Always handle the seal and sleeve as a set.
Never disassemble it.
30-36-18 HD255-5
(11)
2 Sleeve inside circumference:

1) Set sleeve and seal (2) to tool A5-1.
Gasket sealant (LG-7)
2) Put sleeve of seal in contact with end face of

crankshaft, then tighten bolts of tool A5-1
uniformly until end face of tool A5-1 contacts
end face of crankshaft (4) to press fit sleeve
assembly (2).
3) Remove tool A5-1, and install tool A5-4.
4) Tighten bolts of tool A5-4 uniformly until end

face of tool A5-4 contacts end face of crank-
shaft (4) to press fit sleeve and seal (2).
a After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.
HD255-5 30-36-19
(11)
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
Serial No.: 1001 – 1599
k Stop the machine on level ground, and put

blocks under the wheels.

pin.
1. Collect the air conditioner refrigerant. For details,

see REMOVAL OF AIR CONDITIONER COM-
PRESSOR ASSEMBLY.
2. Remove the radiator assembly and radiator guard

together. For details, see REMOVAL OF RADIA-
TOR ASSEMBLY.
a Remove the fan and put it on top of the
shroud.
3. Disconnect 2 heater hoses (1) and 2 aeration

hoses (2).
4. After removing radiator assembly, remove cross

bar (3).
a Loosen the R.H. support mounting bolts.
5. Disconnect heater wiring (4) and (5).
6. Disconnect ground (6) and connector (7) of

exhaust brake solenoid.
7. Remove clamp (8), and move wiring towards

chassis end.
8. Disconnect alternator wiring (9), and remove

clamp (10).
30-36-20 HD255-5
(11)
9. Disconnect starting motor wiring (11).
10. Remove water temperature sensor wiring (12).
11. Disconnect connector (13).
12. Disconnect fuel hoses (14).
13. Disconnect engine oil pressure sensor wiring

(15).
14. Disconnect accelerator rod (16).
15. Disconnect engine lubrication oil hose (17).
16. Disconnect air compressor unload tube (18).
17. Disconnect exhaust brake air hose (19).
18. Remove bolt (20), then remove exhaust pipe

(21).
a There is a mount inside the fender and dump
body joint, so remove it.
19. Remove fuel hose clamp (22).

21. Remove wiring harness clamp (24).
22. Disconnect spill hose (25) and remove clamp
(26).
23. Remove air hose clamp (27).
24. Disconnect 2 connectors (28).
a After disconnecting the hoses and wiring har-
nesses, move them towards the chassis and
make it easy to assemble them again.
HD255-5 30-36-21
(11)
25. Disconnect drive shaft (29) between damper and

transmission. [*1]
26. Disconnect ground (30) between engine and

chassis.
27. Remove 4 mount bolts (31). [*2]
28. Maintain balance of engine assembly (32) with a

chain block and wire, and lift off.
4 Engine assembly : 1,300 kg
30-36-22 HD255-5
(11)
ASSEMBLY
Serial No.: 1001 – 1599
removal.
• Install the radiator assembly and radiator guard
together. For details, see INSTALLATION OF
RADIATOR ASSEMBLY.
• Connect the hoses and wiring harnesses, and
charge with gas. For details, see INSTALLA-
TION OF AIR CONDITIONER COMPRESSOR
ASSEMBLY.
2 Drive shaft mounting bolt :

[*1]

Thread tightener (LT-2)
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
3 Engine mount bolt (front):

[*2]
3 Engine mount bolt (rear) :

926.1 ± 102.9 Nm {94.5 ± 10.5 kgm}
384.65 ± 41.65 Nm {39.25 ± 4.25 kgm}

a When installing the engine assembly, assem-
ble the cushions.
a When centering, see the procedure for cen-
tering the engine assembly and torque con-
verter, transmission assembly.

Refill with water to the specified level and run the
HD255-5 30-36-23
(11)
REMOVAL OF ENGINE
ASSEMBLY
k Stop the vehicle on level ground and the tires

with chocks.

pin.
1. Lift off engine hoods (1) and (2).
2. Remove the mounting bolts of air cleaner (3).
3. Remove air cleaner hose (4). [*1]
4. Collect the air conditioner refrigerant. For

details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
5. Remove the radiator guard (G) and radiator

assembly separately. For details, see
REMOVAL OF RADIATOR ASSEMBLY.
a Lift off the air conditioner condenser assem-
bly (C), and air aftercooler (A) together with
the radiator assembly.
6. After removing the radiator assembly, remove

hose (5) and air tube (6) for the air-to-air cooler.
[*2]
7. Disconnect aeration hose (7).
8. Remove cross bar (8).

a Loosen the right support mounting bolts.
9. Disconnect alternator wiring (9) and remove

clamp (10).
10. Disconnect 2 heater hoses (11) and (12).
30-36-24 HD255-5
(11)
11. Disconnect starting motor wiring (13).
12. Disconnect retarder oil temperature sensor wir-

ing (14).
13. Disconnect connector SR (15).
14. Disconnect connectors ER2 (16) and ER3 (17).
15. Disconnect wiring harness clamps (21) (Note

that there is a clamp below).
a Spacers are used.
17. Disconnect exhaust brake air hose (23).
18. Remove fuel hose clamp (24).
19. Disconnect speed sensor connector E12 (25).

a Move the disconnected hoses and wiring
harnesses toward the chassis and arrange
them so that you can install them easily.
20. Remove exhaust pipe (26).

a Remove the mounting parts at the dump
body joint and on the inside of the fender.
HD255-5 30-36-25
(11)
21. Remove the clamp and disconnect fuel hoses

(27) and (28).
a Disconnect fuel return hose and spill hose.
22. Disconnect ground wire (30) between the engine

and chassis.
23. Remove spider (31) and disconnect the drive

shaft between the damper and transmission. [*3]
24. Disconnect unload hose (33) of air conditioner

compressor (32).
25. Remove 6 mounting bolts (34). [*4]

a There are 2 bolts on the rear side.
26. Using a chain block and wires, lift off engine

assembly (35). When slinging the engine
assembly, balance it carefully.
4 Engine assembly: 1,700 kg
a If you remove the mounting bracket at the
right rear of the engine and move it toward
the right of the engine while slinging the
engine, you can remove the engine without
removing the engine oil filter and fuel filter
from the engine.
30-36-26 HD255-5
(11)
ASSEMBLY
removal.
• Install the radiator assembly. For details, see
INSTALLATION OF RADIATOR ASSEMBLY.
• Connect the hoses and wiring harnesses, and
charge with gas. For details, see INSTALLA-
TION OF AIR CONDITIONER COMPRESSOR
ASSEMBLY.
3 Air cleaner hose clamp:

[*1]
8.8 ± 0.5 Nm {90 ± 5 kgcm}
3 Clamp for air-cooled aftercooler hose:

[*2]
9.8 ± 0.5 Nm {100 ± 5 kgcm}
2 Drive shaft mounting bolt:

[*3]
3 Drive shaft mounting bolt:

110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
3 Engine mount bolt (front):

[*4]
3 Engine mount bolt (rear):

662 – 829 Nm {67.5 – 84.5 kgm}
343 – 425 Nm {35.0 – 43.5 kgm}

a When installing the engine assembly, install
the cushions. Note that different cushions
are used on the front side and rear side.
a When centering, see the procedure for cen-
tering the engine assembly and torque con-
verter, transmission assembly.

HD255-5 30-36-27
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
Serial No.: 1001 – 1599
1. Drain the freon gas from the air conditioner. For
details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
2. Using transmission jack, support underguard,

then remove front mounting bolts.
3. Drain coolant.
4. Lift off engine hood (1).
5. Remove radiator grille (2).
7. Disconnect hose (4) between sub tank and radi-

ator at water filler end.
8. Remove brackets (5) and (6) of heater hose

clamp.
9. Disconnect hose (7) at radiator end.
10. Remove both fan guard (8).
11. Remove fan (9) and place it inside shroud (10),

taking care not to damage the core.
12. Disconnect air conditioner wiring harness (11).

a The connectors are the same, so make dis-
tinguishing marks on them.
14. Disconnect hose (13) at cab end.
30-36-28 HD255-5
(11)
15. Disconnect radiator bottom L.H. hose (14).
16. Disconnect radiator bottom R.H. hose (15).
17. Disconnect horn hose (16) at horn end.
18. Remove fan guard mounting bolts (17). [*1]

a There are 4 mounting bolts each on the left
and right.
19. Lift off radiator assembly (18) while still installed

to guard (19).
4 Guard assembly : 130 kg
20. Remove fan (9) from inside shroud.
HD255-5 30-36-29
(11)
21. Remove shroud (10).
22. Sling core (20), and remove mount (21).

4 Core : 46 kg
INSTALLATION OF RADIATOR
ASSEMBLY
Serial No.: 1001 – 1599
removal.
3 Mounting bolt :
[*1]
274.4 ± 29.4 Nm {28.0 ± 3.0 kgm}

30-36-30 HD255-5
(11)
REMOVAL OF RADIATOR
ASSEMBLY
1. Drain coolant.
2. Lift off engine hood (1).
3. Remove radiator grille (2).
4. Using transmission jack, support underguard (3),

then remove front 3 mounting bolts.
5. Disconnect lower hoses (4) and (5) the radiator.
7. Disconnect hose (7) between sub tank and radi-

ator at water filler end.
8. Disconnect bracket (8) of heater hose clamp.
9. Disconnect hose (9) at radiator end.
10. Remove the air aftercooler tube mounting bracket

and clamp (10) and (11).
11. Remove both fan guard (12).
12. Disconnect air conditioner connector COMP (15)

and clip (16).
13. Disconnect air conditioner hoses (17) and (18).
HD255-5 30-36-31
(11)
14. Disconnect horn connectors HN1 (19) and HN2

(20).
15. Remove mounting bolts (21) and lift off radiator

guard (22). [*1]
a There are 3 mounting bolts each on the right
and left sides.
a Part A is the air aftercooler.
4 Radiator guard: 65 kg
16. Remove the mounting bolts of air conditioner

condenser assembly (23) and bind it to the chas-
sis.
a Do not remove the piping of the air condi-
tioner condenser assembly. When removing
it, collect the air conditioner refrigerant with
tool X1.
17. Remove aftercooler hoses (24) and (25).
18. Lift off radiator assembly (26).

4 Radiator assembly: 95 kg
30-36-32 HD255-5
(11)
INSTALLATION OF RADIATOR
ASSEMBLY

removal.
3 Mounting bolt :
[*1]
235 – 285 Nm {23.5 – 29.5 kgm}

HD255-5 30-36-33
(11)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE CONVERTER,

TRANSMISSION ASSEMBLY
b Stop the machine on level ground, and put blocks
b
under the wheels.
Raise the dump body and lock with the safety
pin.
1. Underguard
Support underguard with transmission jack and
remove mounting bolts.
2. Draining oil
1) Drain transmission oil.
6 : Approx. 50 l
2) Drain hydraulic oil.

6 : Approx. 70 l
3. Front of transmission
1) Disconnect delivery hoses (1) and (2) of work
equipment and steering.
2) Disconnect emergency pump suction tube (3),
then remove clamp (4), and move tube to-
wards chassis.
3) Disconnect delivery hoses (5) and (6) of re-
tarder cooling and transmission control.
4) Disconnect suction tube (7) of work equipment
and steering pump.
5) Disconnect suction tube (8) of retarder cool-
s Disconnect transmission lower tank end

ing and transmission control pump.
also.
6) After removing mounting bolts, lift off retarder
cooling and transmission control pump (9)
and work equipment and steering pump (10).
7) Disconnect front drive shaft (11). [*1]
HD255-5 30-45
(11)
4. Rear of transmission
1) Disconnect rear drive shaft (12). [*2]
2) Disconnect pilot hose clamp (13).
3) Disconnect speedometer cable (14).
4) Disconnect transmission lubrication tube (15)
at transmission inlet port.
5) Disconnect return hoses (16) and (17).
5. Top of transmission
1) Remove clamps of rear brake hoses (19) and
front brake hose (18), and move towards out-
side.
2) Remove breather tube clamp (20) of fuel tank.
3) Remove cover (21).
4) Disconnect wiring connectors (22), (23), and
s Connector No. TM2, TM3, TM4.

(24).
5) Remove rear brake hose clamp (25) and move

towards outside.
6) Disconnect retarder cooling hoses (26) and
(27).
7) Disconnect retarder cooling return tube (28)
and move towards frame end.
8) Disconnect oil pressure hose (29) for trans-
mission control.
s The oil filler is installed to the transmis-

9) Remove oil filler (30).
sion lower tank and by a U-bolt.
6. Mounts
1) Front
Loosen 4 mounting bolts (31) and make sup-
port (32) free. [*3]
2) Rear
Remove mounting bolts (33). [*4]
30-46 HD255-5
(11)
7. Transmission assembly
s Using a lever block, adjust the assembly when

Lift off transmission assembly (34).
lifting off to prevent interference with other

parts. [*5]
4 Torque converter, transmission as-
sembly : 1,050 kg
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
[*1] Front drive shaft (11) mounting bolt

2 Mounting bolt : Thread tightener (LT-2)
3 Mounting bolt :
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
[*2] Rear drive shaft (12) mounting bolt

3 Mounting bolt :
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
[*3]
3 Front mount mounting bolt (31) :
177 ± 19 Nm {18.0 ± 2.0 kgm}
[*4]
3 Rear mount mounting bolt (33):
279 ± 30 Nm {28.5 ± 3 kgm}
[*5]
See the procedure for centering the engine as-
sembly with the torque converter and transmis-
sion assembly.
s Add oil to the specified level. Run the engine

• Refilling with oil
to circulate the oil through the system. Then

check the oil level again.
5 Transmission oil : 50 l
Hydraulic oil : 70 l
HD255-5 30-47
(11)
PROCEDURE FOR CENTERING THE ENGINE

ASSEMBLY WITH THE TORQUE CONVERTER
AND TRANSMISSION ASSEMBLY
• If the engine assembly, torque converter and trans-

mission assembly, or drive shaft have been re-
moved, use tool A6 to center the assemblies as
follows.
1. Install flange (1) and collar (2) to coupling (3) at

engine end, then lock flange and collar with bolt
s Look at the collar counter mark from above

(4).
and install so that it is on the center line.
2. Install flange (5) and collar (6) to coupling (7) at

torque converter end.
3. Slide collar (6) at torque converter end and align

collar (2) at engine end and counter mark, then
put a scale in contact and measure the stepped
difference at the top and bottom, left and right.
s Check that the place with the largest opening

at both the top and bottom, and left and right
is within 3 mm.
30-48 HD255-5
DISASSEMBLY AND ASSEMBLY TRANSMISSION
7. Speedometer gear
1) Set transmission assembly with oil pan at
bottom.
2) Remove cover (9), then remove speedometer
gear (10).
3) Remove plug (11), then remove collar (12).
8. Oil pan assembly

Lift off oil pan assembly (13).
9. Disassembly of oil pan assembly

1) Remove baffle plate (14).
2) Remove plug (15).
3) Remove valve (15a) and body (15b). (Serial
No.: 1601 and up)
4) Remove block (16), then remove valves (17)
and (18).
5) Remove cover (19a), then remove magnet
s A vehicle, Serial No.: 1601 and up, has a

assembly (19).
double strainer, while a vehicle, Serial No.:

1001 – 1600, does not. (See mark *)
HD255-5 30-48-19
(11)
10. Check operation of piston
s Air pressure : 0.29 – 0.59 MPa (3 – 6 kg/cm2)

Using tool C1, check operation of piston.
11. No. 1, 2 clutch, input shaft assembly

Lift off No. 1 and 2 clutch assembly (20).
• Disassembly of No. 1, 2 clutch, input shaft assem-

bly
1) Set with No. 2 clutch at bottom.
2) Cover
Remove cover (21).
3) No. 1 disc, plate, pin, spring

Remove No. 1 plate (22), disc (23), pin (24),
and spring (25).
30-48-20 HD255-5
(2)
11) Cover
Install cover (21).
26. No. 1, 2 clutch assembly

Raise No. 1 and 2 clutch assembly (20) and in-
stall.
27. No. 1, 2 clutch assembly
s Air pressure : 0.29 – 0.59 MPa (3 – 6 kg/cm2)

Using tool C1, check operation of piston.
s Standard piston stroke

No. 1 piston 4 mm
No. 2 piston 3.4 mm
28. Assembly of oil pan assembly

1) Assemble magnet assembly (19), then fit O-
s A vehicle, Serial No.: 1601 and up, has a

ring and install cover (19a).
double strainer, while a vehicle, Serial No.:

1001 – 1600, does not. (See mark *)
2) Assemble valves (17) and (18), then fit O-ring
and install block (16).
3) Install body (15b) and valve (15a). (Serial No.:
1601 and up)
4) Install plug (15).
5) Install baffle plate (14).
HD255-5 30-48-51
(11)
29. Oil pan assembly

Fit gasket, then raise oil pan assembly (13) and
install.
8 Mounting surface: Gasket sealant (LG-1)
30. Speedometer gear

1) Set transmission assembly so that oil pan is
at bottom.
2) Install collar (12), then install plug (11).
3) Fit O-ring and install speedometer gear (10)

and cover (9).
31. Torque converter oil temperature sensor

Install torque converter oil temperature sensor (8).
32. Transmission input shaft speed sensor, interme-

diate shaft speed sensor
Install transmission input shaft speed sensor (6)
and intermediate shaft speed sensor (7).
30-48-52 HD255-5
(2)
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
(ECMV ASSEMBLY)
b Raise the dump body and lock with the safety Cover
pin.
1. Remove cover.
2. Disconnect wiring connectors (1) and (2).
1 2
3. Remove 4 mounting bolts (3), then remove ECMV
assembly (4).
INSTALLATION OF TRANSMIS-
SION CONTROL VALVE
ASSEMBLY (ECMV ASSEMBLY)
moval.
1
Before removing the ECMV assembly, clean the
area around the valve thoroughly, and make sure
that no dirt or dust gets in.
2
3 ECMV assembly mounting bolt (3):
7.8 – 9.0 Nm {0.8 – 1.0 kgm}
HD255-5 30-49
(11)
DISASSEMBLY AND ASSEMBLY TRANSMISSION, MAIN RELIEF VALVE
REMOVAL OF TRANSMISSION,
MAIN RELIEF VALVE ASSEMBLY
b Raise the dump body and lock with the safety
pin. Cover
1. Remove transmission top cover.
1
2. Remove 4 mounting bolts (1), then remove main
s Before removing, clean the area around the

relief valve assembly (2).
valve.
INSTALLATION OF
TRANSMISSION, MAIN RELIEF
VALVE ASSEMBLY
moval.
1
3 Mounting bolt :
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
30-50 HD255-5
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL OF DIFFERENTIAL
ASSEMBLY
b
under the wheels.
Raise the dump body and lock with the safety
pin.
1. Drain oil.
6 Final drive gear case : 10 l (each side)
6 Differential case : 15 l
3. Remove snap ring (2), then remove sun gear (3).
s Installing an eyebolt makes it easier to pull

4. Pull out shaft (4).
the shaft out.
5. Disconnect drive shaft (5). 1
s Release the parking brake.

6. Remove pin (6).
s Completely release the compressed air in the

air tank.
8. Remove parking brake chamber (8).
9. Remove 20 mounting bolts (9). 2
10. Using forcing screws, screw in differential assem-
s To ensure safety, support with a transmission

bly (10) until U-bolt is installed.
jack.
4 Differential, parking brake assembly :
290 kg
HD255-5 30-51
INSTALLATION OF DIFFERENTIAL
ASSEMBLY
moval.
1

110.25 ± 1.25 Nm {11.25 ± 1.25 kgm}
2
3 Differential mounting bolt :
176.5 ± 19.5 Nm {18.0 ± 1.98 kgm}

Add oil until oil flows out from the oil filler.
5 Differential case : 15 l
5 Final drive case : 10 l (each side)
30-52 HD255-5
(11)
12. Lock plate

After completion of adjustment of tooth contact,
wipe off minium and install lock plate (1).
3 Mounting bolt:
176.4 ± 19.6 Nm {18.0 ± 2.0 kgm}
13. Adjustment bolt

After adjusting, screw in adjustment bolt (29) un-
til it contacts rear face of ring gear, then turn back
adjustment bolt 1/2 turns and tighten locknut (30).
2 Adjustment bolt: Gasket sealant (LG-5)
3 Locknut : 225.4 ± 19.6 Nm {23.0 ± 2.0 kgm}
HD255-5 30-63
(11)
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL OF FRONT WHEEL

ASSEMBLY
on both sides of the rear wheels.
1. Set jack (294 kN {30 ton}) under arm (1), and jack
up front wheel assembly.
2. After jacking up wheels, support with stand.
3. Remove 12 hub nuts (2). 1
4. Remove wheel assembly (3) with forklift.

4 Wheel assembly : 260 kg
s Remove with forklift (5 ton).
s Be careful not to damage the air valve.
INSTALLATION OF FRONT
WHEEL ASSEMBLY
s If any stud bolt is broken, replace all of the stud
s When a tire is removed and installed, if a stud has

bolts.
come out, be sure to remove that stud and install

it again.
2 Stud: Adhesive (LT-2)
3 Stud bolt mounting torque
Serial No.: 1001 – 1200:
167 ± 29 Nm {17 ± 3 kgm}
Serial No.: 1201 and up:
284 ± 49 Nm {29 ± 5 kgm}
moval.
1
s Do not apply LT-2, grease, or oil to the threads
of the hub nuts. (If any of them is applied, the
s Tighten the hub nuts evenly in the following

axial tension is increased too much.)
order.
s After lowering the chassis, tighten the hub

[1] – [6]
nuts permanently.
3 Hub nut
Serial No.: 1001 – 1200:
470 ± 49 Nm {48 ± 5 kgm}
823 ± 89 Nm {84 ± 9 kgm}
• After installing the wheel assembly, travel for
approx. 5 – 6 km, then check the tightening torque
again without fail.
30-64 HD255-5
(14)
DISASSEMBLY AND ASSEMBLY REAR WHEEL
REMOVAL OF REAR WHEEL

ASSEMBLY
b Stop the machine on level ground and put blocks
b
on both sides of the front wheels.
Put hydraulic jack [1] (294 kN {30 ton}) under the
rear axle, and jack up the rear wheel assembly.
1. Loosen locknut of air valve and remove lock plate
1
(1).
2. Remove 12 hub nuts (2).
3. Remove outside wheel assembly (3) with forklift.
b After removing the wheel assembly, stand it
in a safe place leaning against a secure sur-
face and block the wheel to prevent it from
2
falling over.
4. Remove 12 inside hub nuts (4).
5. Remove inside wheel assembly (5) with forklift.
INSTALLATION OF REAR
WHEEL ASSEMBLY
s If any stud bolt is broken, replace all of the stud
s When a tire is removed and installed, if a stud has

bolts.
come out, be sure to remove that stud and install

it again.
2 Stud: Adhesive (LT-2)
3 Stud bolt mounting torque
Serial No.: 1001 – 1200:
167 ± 29 Nm {17 ± 3 kgm}
284 ± 49 Nm {29 ± 5 kgm}
moval.
12
s Do not apply LT-2, grease, or oil to the threads
of the hub nuts. (If any of them is applied, the
s Tighten the hub nuts evenly in the order

axial tension is increased too much.)
shown in the right top figure.
s After lowering the chassis, tighten the hub

[1] – [6]
3 Hub nut
nuts permanently.
Serial No.: 1001 – 1200:

470 ± 49 Nm {48 ± 5 kgm}
823 ± 89 Nm {84 ± 9 kgm}
• After installing the wheel assembly, travel for
approx. 5 – 6 km, then check the tightening
torque again without fail.
HD255-5 30-65
(13)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER PAD
REMOVAL OF FRONT BRAKE

CALIPER PAD
1. Remove front wheel assembly.
• For details, see REMOVAL OF FRONT WHEEL
ASSEMBLY.
1
s Loosen pin fixing bolt (2), and pull out torque
2. Pull out torque pin (1).
pin (1) to a point where the pads can be re-

moved.
3. Remove pads (3) and (4). 2

1) Install vinyl hose to bleeder screw (5) and set
so that the brake oil can be discharged.
2) Loosen bleeder screw and use a bar to return
piston (6) to bottom of cylinder.
BRAKE CALIPER PAD
moval.
1
s Push in the torque pin and lock it securely with
s Make a clearance of 1.5 – 3 mm between the

the bolt.
torque pin and the disc.

3 Torque pin fixing bolt (2) :
s For precautions for installing the pin fixing

51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
bolt, see ASSEMBLY OF FRONT BRAKE CALI-

PERS ASSEMBLY.
2
3 Bleeder screw :
s Bleed the air from the front brake circuit. For

25.48 ± 2.94 Nm {2.6 ± 0.3 kgm}

Bleeding air from brake circuit.
30-66 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER
REMOVAL OF FRONT BRAKE

CALIPER ASSEMBLY
1. Remove front wheel assembly. For details, see
REMOVAL OF FRONT WHEEL ASSEMBLY.
2. Disconnect tube (1).
3. Sling caliper assembly and remove bolts (2). 1
s Use a lever block to adjust the assembly when

4. Remove caliper assembly (3).
lifting off.
4 Caliper assembly : 45 kg
BRAKE CALIPER ASSEMBLY
moval.
1
3 Mounting bolt :
Target 382 Nm {39 kgm}
s Bleed the air from the front brake circuit. For

(332 – 441 Nm {33 – 45 kgm})

Bleeding air from brake circuit.
HD255-5 30-67
(11)
DISASSEMBLY OF FRONT
BRAKE CALIPER ASSEMBLY
1. Remove caliper assembly. For details, see RE-
MOVAL OF FRONT BRAKE CALIPER ASSEMBLY.
2. Pin fixing bolt (1) and pull out torque pin (2) to a
point where pads can be removed, then remove
pads (3) and (4).
3. Remove plate (5), then remove plug (6) and backup

ring (7).
4. Remove dust seal (8), then remove piston (9).
s Disassemble the other side in the same way.

5. Remove seal (10) and backup ring (11).
30-68 HD255-5
(8)
ASSEMBLY OF FRONT BRAKE

CALIPER ASSEMBLY
1. Install backup ring (11), seal (10), and dust seal
s When installing seal (10), assemble with the

(8) securely in groove of caliper (12).
notched side facing pad (6).
s Insert the dust seal lip in the groove of the

2. Install piston (9).
piston.
3. Fit backup ring (7) and plug (6), and install plate
(5).
4. Insert pads (3) and (4) in caliper, then insert torque

pin (2) and lock with pin fixing bolt (1).
2 Torque pin: Grease (G2-LI)
3 Torque pin fixing bolt (1):
51.5 ± 2.5 Nm {5.25±0.25 kgm}
HD255-5 30-68-1
(11)
• Lock bolts (1) are different from the normal

bolts: the tip (portion a) cuts into the surface
of the torque pin. (Creates plastic deforma-
s When tightening, even when resistance

tion.)
is felt, it is necessary to tighten further in

order to cut into the surface. For this rea-
son, if the tightening is less than the speci-
fied tightening torque, the bolt will not cut
in sufficiently and it will not hold in posi-
tion properly.
b : Cut-in point
s For tightening the pin fixing bolt, move

c : Cut-in mark
the pin in the axial direction and check that

the bolt enters the torque pin groove se-
s Assemble the other side in the same way.

curely.
5. Referring to INSTALLATION OF FRONT BRAKE

CALIPERS ASSEMBLY, install the calipers assem-
s Install so that clearance d between disc (13)

bly.
and torque pin (2) is 1.5 – 3.0 mm.
30-68-2 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB
7. Support wheel hub assembly (6) with transmis-

sion jack, insert in spindle, then install bearing (5).
2 Fill the hatched portion completely with
(Fill amount: Approx. 2.5 l/each side)

grease.
s Select the type of grease from Table A.
Table A
No. Maker Brand of grease
1 Caltex Hilex HD-2
2 MOBIL Mobilgrease HP-2
3 SHELL Super Duty Grease 2
4 ESSO RONEX MP
5 BP Energrease LS-EP2
s Be careful not to damage the dust seal inside

the hub.
8. Adjust preload of bearing as follows.

1) Install retainer (3) with 3 mounting bolts (A)
without installing any shim, then rotate hub
20 - 30 times while tightening mounting bolts
uniformly to specified tightening torque.
3 Mounting bolt (A) (when adjusting):
49 ± 5.0 Nm {5.00 ± 0.51 kgm}
2) Measure dimension C from retainer to end
face of axle with depth micrometer [3].
3) Remove retainer (3) and measure retainer
thickness T, then select shim thickness of 0.3
mm greater than difference d in measured
s Measure 2 places and take the average.

value [(d = C – T) + 0.3 mm].
s Select the combination of shims that gives
s When removing the retainer, be careful

the minimum number of shims.
that the bearing does not come out.
HD255-5 30-71
(11)
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB
9. Fit shim (4) and retainer (3), rotate hub 20 – 30

turns, and tighten with mounting bolt (2) uni-
formly until specified tightening torque is reached.
3 Mounting bolt :
277.0 ± 32.0 Nm {28.26 ± 3.26 kgm}
10. Fit O-ring (13) and install cover (1).

2 Fill the inside of the cover (shaded por-
tion) with grease (See Table A).
11. Install front brake caliper assembly. For details,

see INSTALLATION OF FRONT BRAKE CALIPER
s If the grease is mixed with another type of

ASSEMBLY.
grease, it may swell or the composition may

deteriorate. When changing the grease or fill-
ing with grease, remove all the old grease,
clean the inside surface of the hub and the
bearing, and be careful not to let the new
grease mix with any other type of grease.
30-72 HD255-5
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
REMOVAL OF FINAL DRIVE

CARRIER ASSEMBLY
1. Remove rear wheel assembly. For details, see RE-
MOVAL OF REAR WHEEL ASSEMBLY.
2. Remove drain plug (1) and drain oil. 1

6 Final drive case : 10 l (each side)
4. Remove snap ring (3), then remove sun gear (4)

together with torque shaft.
2
5. Remove 24 bolts (5), then lift off carrier assembly
(6).
INSTALLATION OF FINAL DRIVE

CARRIER ASSEMBLY
moval.
1
3 Drain plug : 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
2
3 Mounting bolt (5) :
735 – 912 Nm {75 – 93 kgm}
HD255-5 30-73
(11)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
DISASSEMBLY OF FINAL DRIVE

CARRIER ASSEMBLY
1. Remove final drive carrier assembly. For details,
see REMOVAL OF FINAL DRIVE CARRIER ASSEM-
BLY.
s Always remove from the inside to the outside.

2. Remove shaft (1).
3. Remove gear (2), then remove bearing (3) from

gear.
4. Remove ball (4).
Be careful not to lose the ball when removing the
shaft.
ASSEMBLY OF FINAL DRIVE

CARRIER ASSEMBLY
s Clean all parts, and check for dirt or damage. Coat
the sliding surfaces of all parts with #30 engine
oil before installing.
1. Set bearing (3) to gear (2).
2. Insert gear set in carrier assembly (5).
s Insert the shaft so that ball (4) can be installed.

3. While inserting shaft (1), install ball (4).
30-74 HD255-5
DISASSEMBLY AND ASSEMBLY REAR WHEEL BRAKE
INSTALLATION OF REAR
WHEEL BRAKE ASSEMBLY
moval.
1
1. Adjust the preload of the bearing as follows.
1) Without fitting shims, temporarily install re-
tainer (4) with 3 bolts.
3 Mounting bolt :
s
78.5 ± 4.5 Nm {8.0 ± 0.45 kgm}
Rotate the wheel hub 20 – 30 turns while tight-
ening the bolts to the specified tightening
torque.
2) Using depth micrometer E3, measure distance
c between end face of retainer and end face
s
of axle housing.
Measure 2 places and take the average.
3) Remove retainer and measure retainer thick-
ness a, then select shim thickness of 0.3 mm
greater than difference b in measured value
[(b = c – a) + 0.3 mm].
2. Insert shim, then fit retainer (4) and tighten mount-
s When tightening the mounting bolts, rotate

ing bolts.
the wheel hub 20 – 30 turns while tightening

uniformly to the specified tightening torque.
2 Bolt thread : Thread tightener (LT-2)
3 Mounting bolt :
s After tightening the bolts, rotate the wheel

276.5 ± 31.5 Nm {28.21 ± 3.21 kgm}
hub, and check that the rotation is normal.
2
3 Wheel hub mounting nut :
176.5 ± 19.5 Nm {18.0 ± 1.98 kgm}
HD255-5 30-77
(11)
DISASSEMBLY AND ASSEMBLY REAR WHEEL BRAKE
3
3 Eyebolt (I) :
11.25 ± 1.45 Nm {1.15 ± 0.15 kgm}
4
2 Bolt (14) thread : Thread tightener (LT-2)
3 Mounting bolt (14) :

549.0 ± 59.0 Nm {56.02 ± 6.02 kgm}
30-78 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY REAR BRAKE
DISASSEMBLY OF REAR BRAKE

ASSEMBLY
1. Outer gear, disc, plate
1) Remove tool E1.
2) Using eyebolts [1] (14mm, Pitch=2.0), raise

outer gear (1) together with disc and plate,
s Be careful not to damage the floating seal

and lift off.
when removing.
2. Retainer
Remove retainer (2) together with floating seal (3).
3. Floating seal
1) Remove floating seal (3) from retainer (2).
2) Remove floating seal (4) from inner gear.
HD255-5 30-79
(11)
4. Disc, plate, damper

Remove disc (5), plate (6), and damper from outer
gear.
5. Hub
1) Remove mounting bolts, then remove hub (7)
from outer gear (1).
2) Remove oil seal (8) and floating seal (9) from
hub.
30-80 HD255-5
ASSEMBLY OF REAR BRAKE

ASSEMBLY
1. Hub
1) Using tool E2-3, install floating seal (9) and
s For how to use tool E2-3, see step 3.

oil seal (11) to hub (7).
2) Install hub (7) to outer gear (1).

2 Hub mounting bolt :
3 Hub mounting bolt :
176.0 ± 19.6 Nm {18.0 ± 2.0 kgm}
2. Floating seal
Using tool E2-1, install floating seal (4) to inner
gear.
3. Retainer
1) Using tool E2-3, install floating seal (2) to re-
tainer (3).
HD255-5 30-81
(11)
2) Fit dowel pin and assemble retainer (2) to in-

ner gear.
4. Outer gear
1) Using eyebolts [1] (14mm, Pitch=2.0), as-
s Coat the sliding surface of the floating seal

semble outer gear (1) to inner gear.
s Coat the lip surface of the oil seal with

thinly with engine oil.
s When assembling the outer gear, as-

grease (G2-LI).
semble carefully and take care not to dam-

age the floating seal.
2) Align center of outer gear (1) and inner gear
(10), then using tool E1, secure inner gear and
outer gear.
30-82 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
REMOVAL OF AIR GOVERNOR

s Serial No.: 1001 – 1599
ASSEMBLY
b Release pressure inside the air tank.
2. Disconnect tubes (1) and (2).
3. Remove air governor assembly (3).
s Serial No.: 1601 and up

INSTALLATION OF AIR GOVER-
NOR ASSEMBLY
moval.
HD255-5 30-91
(11)
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
DISASSEMBLY OF AIR
GOVERNOR ASSEMBLY
2. Remove snap ring (2), then remove adjusting

screw and spring assembly (3).
3. Pull out piston assembly (4), then remove stem

(5) and spring (6).
ASSEMBLY OF AIR GOVERNOR

ASSEMBLY
s Clean all parts, and check for dirt or damage, then
coat all parts with grease before installing.
1. Fit O-ring and install spring (6) and stem (5) to

piston (7).
2. Fit O-ring and install piston assembly (4) to body

(8).
3. Fit adjusting screw and spring assembly (3) to
s Check dimension A of the adjusting screw.

body (8), then install snap ring (2).
Dimension A : 50 mm
4. Install cover (1).
s After installing to the chassis, measure the air

pressure. For details, see TESTING AND ADJUST-
ING, Measuring air pressure.
30-92 HD255-5
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
DISASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
1. Remove cylinder (1), then remove spring (2) and
piston (3).
2. Remove seal (4) from piston (3).
3. Remove cap (5), then remove spring (6) and valve

(7).
ASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
moval.
s Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil and
coat the springs with grease (G2-LI) before install-
ing.
1. Fit O-ring and install valve (7).
2. Install spring (6).
3. Fit O-ring and install cap (5).

2 Spring, O-ring : Fill with lithium grease
2 Cap thread portion :
3 Cap : 57.5 ± 7.5 Nm {5.86 ± 0.76 kgm}

Coat with Cemedyne 366
4. Fit seal (4) to piston (3) and install to cylinder (1).
5. Fit O-ring to body (8) and install spring (2) and

cylinder assembly.
3 Mounting bolt :
67.5 ± 7.5 Nm {6.88 ± 0.8 kgm}
HD255-5 30-115
(13)
DISASSEMBLY AND ASSEMBLY AIR DRIER (DESICCANT TYPE)
REMOVAL AND INSTALLATION

OF AIR DRIER (DESICCANT TYPE)
(IF EQUIPPED)
b Stop the engine, apply the parking brake, and

put chocks under the tires.
REMOVAL
1. Open the drain valve of the air tank to release the
air in the brake piping.
2. Remove air hoses (1) – (4).
3. Disconnect wiring (5) of air drier (6) from rear of

the left front wheel.
4. Remove air drier (6).
INSTALLATION
moval.
30-115-1 HD255-5
(13)
DISASSEMBLY AND ASSEMBLY

OF AIR DRIER (DESICCANT TYPE)
(IF EQUIPPED)
s When disassembling the air drier, prepare the fol-

lowing repair kit for replacement.
Repair kit
234-44-42150
No. Part name Q’ty
3 O-ring 1
4 O-ring 1
6 O-ring 1
7 Valve 1
11 O-ring 1
14 Oil filter 1
15 Gasket ring 1
16 Gasket ring 1
19 O-ring 1
21 Filter 2
22 Desiccant 1
24 O-ring 1
27 Check valve 1
30 O-ring 1
34 O-ring 1
s Prepare NABCO Grease Pack, part No. 454-990-
s Prepare 3 fully threaded bolts of 6 mm nominal

30090 (about 10 g) in advance.
diameter and 80 mm nominal length and their nuts

and tweezers in advance.
HD255-5 30-115-2
(14)
Component parts of desiccant-type air drier

No. Part No. Part name Q’ty
234-44-42100 Air drier assembly
1 ✩ • Body 1
2–9 234-44-42110 • Valve body assembly (1)
2 ✩ • • Valve body 1
3 ✩ • • O-ring (kit) 1
4 ✩ • • O-ring (kit) 1
5 ✩ • • Piston 1
6 ✩ • • O-ring (kit) 1
7 ✩ • • Valve (kit) 1
8 ✩ • • Valve spring 1
9 ✩ • • Bolt and washer 1
10 ✩ • Exhaust body 1
11 ✩ • O-ring (kit) 1
12 ✩ • Retaining ring 1
13 – 29 234-44-42120 • Cartridge (1)
13 ✩ • • Case 1
14 ✩ • • Oil filter (kit) 1
15 ✩ • • Gasket ring (kit) 1
16 ✩ • • Gasket ring (kit) 1
17 ✩ • • Filter plate (1) 1
18 ✩ • • Bolt 1
19 ✩ • • O-ring (kit) 1
20 ✩ • • Spacer 1
21 ✩ • • Filter (kit) 2
22 ✩ • • Desiccant (kit) 1
23 ✩ • • Filter plate (2) 1
24 ✩ • • O-ring (kit) 1
25 ✩ • • Set spring 1
26 ✩ • • Case cover 1
27 ✩ • • Check valve (kit) 1
28 ✩ • • Bolt 6
29 ✩ • • Nut and washer 7
30 ✩ • O-ring (kit) 1
31 ✩ • Bolt and washer 4
32 ✩ • Purge chamber 1
33 ✩ • Plug 1
34 ✩ • O-ring (kit) 1
35 ✩ • Stopper ring 1
36 ✩ • Bolt and washer 2
37 ✩ • Stopper plate (1) 1
38 ✩ • Stopper plate (2) 1
39 – 43 234-44-42130 • Thermostat assembly (1)
39 ✩ • • Thermostat 1
40 ✩ • • Heater boot 2
41 ✩ • • Terminal 2
42 ✩ • • Terminal cover 1
43 ✩ • • Terminal 1
44 234-44-42140 • Heater 2
45 ✩ • Gasket 2
46 ✩ • Screw 2
47 ✩ • Cord clamp 1
48 ✩ • Rolling screw 1
49 ✩ • Bracket 2
50 ✩ • Bolt 2
51 ✩ • Nut and washer 2
52 ✩ • Terminal and cord 1
53 ✩ • Rolling screw 1
54 ✩ • Nut 1
234-44-42150 Repair kit containing 1 set of above parts
✩ : These parts are not supplied loose and do not
have Komatsu part Nos.
30-115-3 HD255-5
(13)
s The No. in ( ) after each part name is the No. of

that part in the above component parts table.
DISASSEMBLY
• Disassembly of air drier cartridge
1. Disconnect ground wire (52) from bolt (50) of
bracket (49) and then loosen bolts (36) having 10-
mm width across flats to remove stopper plates
(37) and (38).
2. Remove stopper ring (35) from purge chamber
s Insert a flat-head screwdriver [1] in the cut of

(32) with a flat-head screwdriver.
purge chamber (32) and hitch stopper ring

(35), and you can remove the stopper ring (35)
easily.
3. Pull body (1) out of purge chamber (32).
HD255-5 30-115-4
(13)
4. Remove 4 bolts (31) with a cross-head screwdriver

[2] and remove cartridge assembly (60) from body
(1).
5. Remove 3 of 6 nuts (29) alternately. (Use a 10-

mm spanner.)
6. Install 3 M6 x 80 bolts [3] to the holes from which
b Spring (25) is compressed about 40 mm

the bolts were removed.
when installed. Be sure to hold it tempo-

rarily with M6 full thread bolts having stems
of about 80 mm long and nuts. If you do not
hold it, it may shoot case cover (26) with its
spring force (approx. 725 N {74 kg}), and that
is dangerous.
7. Remove left 3 nuts (29).
8. Loosen the 3 nuts of bolts [3] gradually in order

until spring (25) expands fully, and then remove
cover (26) and spring (25).
30-115-5 HD255-5
(13)
9. Take out filter plate (23), filter (21), desiccant (22),

and filter (21) in order from above.
HD255-5 30-115-6
(13)
10. Put case (13) upside down and insert 12-mm

socket [4] in the head of bolt (18) at the center
and grip its knob with vise [5].
11. Remove nut and washer (29) from above case (13)
with a 10-mm ring wrench or socket wrench [6].
12. Remove filter plate (17), gasket ring (16) and (15),
oil filter assembly (14), spacer (20), and O-ring (19)
in order.
30-115-7 HD255-5
(13)
• Component parts of cartridge

From left of upper line: Case (13), desiccant (22), and
filter
From left of middle line: Case cover (26), set spring

(25), O-ring (24), and filter plate (23)
From left of lower line: Filter plate (17), gasket ring

(16), check valve (27), and oil filter assembly (14)
Upper line of right lower part: Spacer (20), gasket ring

(15), and O-ring
Middle line of right lower part: Nut and washer (29)
and bolt (18)
Lower line of right lower part: Nut, washer, and bolt
• Disassembly of body
1. Direct heater (44) installed to body (1) up, remove
retaining ring (12) with C-snap ring pliers (for hole)
[7], and remove exhaust body (10) and ring (11).
b When removing retaining ring (12), hold it

(See the sectional view.)
securely with C-snap ring pliers (for hole) so

that it will not jump out toward your face.
HD255-5 30-115-8
(13)
2. Hold the head of bolt (9) with pliers and pull out
valve body assembly (61).
3. Put a 10-mm hexagonal wrench in hexagonal hole

H of piston (5) in valve body assembly (61) to fix
the piston and loosen bolt (9) which is tightening
b While holding valve assembly (7), loosen the

valve assembly (7).
bolt (9) gradually. If you do not hold the valve

assembly (7), valve spring (8) may shoot it
toward your face with its spring force (Set
load: Approx. 49 N {5 kg}), and that is dan-
gerous.
4. Take piston (5), valve spring (8), and valve assem-

bly (7) out of valve body (2).
5. Remove O-rings (3), (4) and (6).
30-115-9 HD255-5
(13)
• Component parts of body

Left upper line: Retaining ring (12), exhaust body (10)
Left lower line: O-ring (11), valve body assembly (61)
Right: Body (1)
• Component parts of valve body assembly

Left upper line: Piston (5), valve spring (8), valve body
(2), valve assembly (7), bolt and washer (9)
Left lower line: O-rings (3), (4) and (6)
ASSEMBLY
s Clean all the disassembled parts, except the rub-
ber parts and desiccant, with clear cleaning oil.
Wipe off sticking matter from them and dry them.
If a part has a flaw or it is worn, replace it with
s When reusing the rubber parts, wipe them thor-

new one.
s Replace the desiccant with new one.

oughly with cloth.
b If you touch the desiccant with the bare hand

or put it in your mouth, it will heat and burn
b • Be sure to use the regular desiccant.

you. Never do it.
• Do not use a desiccant other than the ones

we specify. (If you do so, the desiccant
may become powder and flow out. As a
result, the brake piping may be clogged
with desiccant and the brake may not work
normally, and that is dangerous.)
• Different types of desiccant are used for
different models, even if they are made by
the same manufacturer. Take care not to
mistake one for another.
HD255-5 30-115-10
(13)
• Assembly of cartridge
1. Put O-ring (19) in the groove of spacer (20) and
cover it with gasket ring (15).
2. While pressing spacer (20), O-ring (19), and gas-

ket ring (15) against the hollow part of oil filter
assembly (14), set filter plate (17) and gasket ring
(16) to the opposite side and insert bolt (18) from
the filter plate (17) side. (Install bolt (18) in next
step 3. Use it to position the other parts in this
s When setting filter plate (17), direct its pro-

step.)
jected center side toward the oil filter (14).
30-115-11 HD255-5
(13)
3. Insert bolt (18) in the hole at the center of case

(13) and fix the assembly made in step 2 to the
3 Nut (29): 3.9 – 6.9 Nm {40 – 70 kgcm}

opposite side with nut and washer (29).
4. Push in filter (21) into the bottom of case (13) with

the softer side up, and then put desiccant (22) in
s The refill capacity of desiccant (22) is about

case (13).
1.1 kg. Put all of 1 bag of the repair kit in des-
b If the quantity of the supplied desiccant is

iccant (22).
less than the specification, it may become

powder and flow out. As a result, the brake
piping may be clogged with desiccant and
the brake may not work normally. Accord-
ingly, be sure to supply the specified quan-
tity of the desiccant.
HD255-5 30-115-12
(13)
5. While turning case (13), hit its periphery lightly

with a plastic hammer to settle the desiccant.
6. Place the second filter (21) with the softer side

down.
b If the desiccant is not tapped, it may become

7. Place filter plate (23) and tap the desiccant.
powder and flow out. As a result, the brake

piping may be clogged with desiccant and
the brake may not work normally. Accord-
ingly, be sure to tap the desiccant according
to the following procedure.
• Method of tapping
1. Place 2 – 3 pieces of soft cloth [8] on a surface
which you will tap the case against so that
the bottom of the case will not be damaged
when you tap.
2. Holding filter plate (23) with both hands, raise
whole case (13) to a height of about 100 mm.
3. Tap whole case (13) lightly. Do not release
case (13) but lower your hands and case (13)
together.
4. Repeat steps 1 – 3 about 30 times. Stop tap-
ping after filter plate (23) lowers about 4 – 6
mm from the initial position.
30-115-13 HD255-5
(13)
8. Install O-ring (24) and check valve (27) to case
s Apply grease to the projection at the center

cover (26).
of check valve (27) so that you can set check

valve (27) easily.
2 Projection at center of check valve (27):
Grease (NABCO Grease)
s Part No. of NABCO Grease Pack:
454-990-30090 (Approx. 10 g)
9. Place set spring (25) on filter plate (containing the

desiccant) (23).
HD255-5 30-115-14
(13)
10. Place case cover (26) on the top, press it with puller
[9] from above, and fix them with bolts (28) and
3 Nut (29): 3.9 – 6.9 Nm {40 – 70 kgcm}

nuts and washers (29).
b When the above parts are set, the spring load

is about 725 N {74 kg}. Take care.
s Replace O-rings (3), (4) and (6) with new one.

• Assembly of body
1. Coat O-ring (6) with grease and fit it to piston (5).

2 O-ring (6): Grease (NABCO Grease)
(Part No. of NABCO Grease Pack: 454-990-30090,
Weight of grease: Approx. 10 g)
2. Apply grease (see above) to the O-ring sliding part

of valve body (2) and guide of piston (5) and put
valve spring (8) in valve body (2).
3. While pushing in piston (5) having O-ring (6) from

the valve spring (8) side, fix valve assembly (7) on
3 Bolt (9): 3.9 – 6.9 Nm {40 – 70 kgcm}

the opposite side with bolt and washer (9).
30-115-15 HD255-5
(13)
4. Put valve body assembly (61), O-ring (11), and ex-

haust body (10) in body (1) in order, and then fit
s When putting valve body assembly (61) in the

retaining ring (12) to the groove of body (1).
body (1), take care that O-ring (3) will not be

caught in the cut of the body.
• Assembly of body
1. Coat O-rings (34) and (30) with grease and fit them
to the grooves of body (1).
2 O-rings (34), (30): Grease (NABCO Grease)
HD255-5 30-115-16
(13)
2. Insert cartridge assembly (60) in the guide of body

(1).
3. Using with a cross-head screwdriver [2], tighten
3 Bolt (31): 3.9 – 6.9 Nm {40 – 70 kgcm}

bolts (31).
4. Push body (1) in purge chamber (32) and fit stop-
s Pry stopper ring (35) into the groove by ap-

per ring (35) to the groove of purge chamber (32).
plying a flat-head screwdriver [1] outward.
5. Tighten stopper plates (37) and (38) with bolts and

washers (36).
30-115-17 HD255-5
(13)
6. Fix one end (the crimp terminal of the smaller

mounting hole) of terminal and code assembly
3 Screw (53): 2.0 – 3.9 Nm {20 – 40 kgcm}

(52) with screw (53).
7. Insert the other end of terminal and code assem-

bly (52) in the threaded part of bolt (50) of bracket
3 Bolt (50): 4.9 – 8.8 Nm {50 – 90 kgcm}

(49) and fix it.
• Inspection after installing to machine

1. Start the engine. After the air pressure reaches
the maximum level, check that air is discharged
from the exhaust port of the air drier when the
load state changes to the unload state.
Much air is discharged first. After about 3 sec-
onds, however, the discharge rate is so lowered
that you cannot hear the discharge sound.
2. After the air pressure lowers to the minimum level

and the unload state changes to the load state,
check the leakage through the exhaust port of the
air drier.
The leakage must not exceed 20 cc/min. (The di-
ameter of a soap water bubble must not exceed
15 mm in 6 seconds.)
3. Check each pipe joint for leakage.
4. Check that the thermostat and heater are wired

normally.
HD255-5 30-115-18
(13)
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING MOTOR PUMP
REMOVAL OF EMERGENCY
Serial No.: 1001 – 1199
STEERING MOTOR PUMP
ASSEMBLY
Serial No.: 1001 – 1199
b
pin.
Disconnect the cable from the negative (–) ter-
1. Remove ground cable (1).
2. Disconnect wiring harness (2).
3. Remove suction tube (3).
4. Remove delivery tube (4).
5. Remove mounting bolts (5), then remove motor

assembly (6).

b Disconnect the cable from the negative (–) ter-
1. Remove cover (2) above hydraulic tank (1).

2. Remove ground cable (3).
3. Disconnect wiring harness (4).
4. Remove suction tube (5).
5. Remove delivery tube (6).
6. Remove mounting bolts, then remove motor as-

sembly (7).
INSTALLATION OF EMERGENCY
STEERING MOTOR PUMP
ASSEMBLY
moval.
HD255-5 30-117
(11)
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VALVE

ASSEMBLY
b Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank.
1. Disconnect boot (1) from cover (2).
3. Disconnect 4 hoses (3) from steering valve assem-

bly (7).
4. Remove lock bolt (4), then remove column yoke
s If the column yoke is left free, it will come out,

(5).
so after removing it, secure it to the frame.
5. Remove 4 bolts (6), then remove steering valve

assembly (7).
INSTALLATION OF STEERING
VALVE ASSEMBLY
moval.
• Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the system.
Then check the oil level again.
30-118 HD255-5
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
s Use a wire brush to remove any dirt or dust stuck
around the connections on the outside circum-
s Carry out the operation in a clean place to pre-

ference of the unit.
s As far as possible, hold the parts in a vice when

vent dirt or dust from sticking to the parts.
s After disassembly, wash the parts in a clean pe-

carrying out the disassembly operation.
troleum-base solvent, then blow with clean air to

dry.
Preparatory work
1) Fit blind plugs in 4 housing ports, wash out-
side of valve to clean it, then remove blind
plugs.
2) Remove steering column from steering unit
and install unit (1) to tool F1-1 [A].
s One of the 7 plugs is bolt (2-1) (bolt with roll

1. Remove 7 mounting bolts (2) of end cover.
pin).
2. Slide end cover (3) to side and remove.
3. Remove rotor (4) and rim (5) from spacer (6), then
remove 2 O-rings (7) from rim.
HD255-5 30-119
(11)
• Components in Steps 1 – 3.
4. Remove Cardan shaft (8).
5. Remove distributor plate (9).
6. Remove bushing (10) inside check valve with

screwdriver.
30-120 HD255-5
(11)
7. Remove O-ring (11).
8. Remove check valve ball (12).
9. Keep cross pin (15) (inserted into sleeve (13) and

spool (14)) horizontal, and remove spool (14),
sleeve (13), ring (16), bearing race (17), and needle
bearing (18) from housing (19).
HD255-5 30-121
(11)
10. Remove ring (16), bearing race (17), and needle
s The outer bearing race (the thinner of the 2

bearing (18) from sleeve (13) and spool (14).
races (17)) may remain stuck to the housing,

so check that it has been removed.
11. Using bolt (2-1) (bolt with roll pin) removed in Step
1, push out cross pin (15).
s Be extremely careful not to damage the sleeve

12. Remove spool (14) from sleeve (13).
and spool when removing.
s Before removing the spool from the sleeve,

check that the marks on the sleeve and the
spool are aligned. If there are no marks, make
marks before removing.
30-122 HD255-5
(11)
4. Align neutral position spring (20) with groove of

sleeve (13) and fit in position.
5. Align both ends of 4 springs.
s Check that the ring can rotate freely.

6. Install ring (16) to sleeve (13).
7. Insert cross pin (15).
HD255-5 30-125
8. Install bearing race (17) and needle bearing (18)
s Install so that the chamfered portion of the

as shown in diagram on in right.
inner bearing race faces the sleeve.
9. Coat lip seal (21) with hydraulic oil (EO-30 or

equivalent), and install to assembly jig F3-1 (B).
10. Insert jig F3-1 (B) in housing (19).
30-126 HD255-5
(11)
11. Push in a jig F3-1 (B), and rotate to install lip seal
(21) to housing (19).
12. Rotate spool and sleeve assembly (23) lightly
s When doing this, install so that cross pin (15)

when inserting into housing (19).
is horizontal.
13. Stand housing (19) upright, and insert check valve

ball (12) in hole indicated by arrow.
HD255-5 30-127
(11)
s When doing this, make sure that the head of

14. Screw bushing (10) into check valve hole.
the helisert does not protrude from the sur-

face of housing (19).
15. Coat O-ring (11) with hydraulic oil (EO-30 or

equivalent), and assemble to housing (19).
16. Align holes of housing (19) and distributor plate

(9), and set in position.
17. Insert into housing (19) so that slot of Cardan shaft

(8) is parallel to surface with port.
30-128 HD255-5
(11)
18. Coat 2 O-rings (7) with hydraulic oil (EO-30 or
s Set rotor (4) as shown below, then set the rim

equivalent), and install in groove of rim (5).
in position so that the 7 bolt holes are aligned

with the holes in housing (19).
s Always be sure to assemble so that the posi-

tion of Cardan shaft (8) and the bottom of the
teeth of rotor (4) maintains the relationship
shown in the diagram on the right.
19. Install spacer (6) to rotor (4).
20. Put end cover (3) in specified position.
HD255-5 30-129
(11)
21. Insert bolt (2-1) (bolt with roll pin) and washer in
hole shown in diagram on right.
22. Insert remaining 6 bolts (2) and washers, then

tighten.
3 Bolt (2) : 30.38 ± 0.98 Nm {3.1 ± 0.1 kgm}
23. Install dust seal (22) to housing (19).
24. Using jig F2 (C) and plastic hammer, install dust

seal (22) to housing.
30-130 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY DEMAND VALVE
REMOVAL OF DEMAND VALVE

ASSEMBLY
pin.
• Loosen the oil filler cap slowly to release the pres-
s After disconnecting the piping, fit blind plugs.

sure inside the hydraulic tank.
sLoosen 2 clamps at the frame end.

3. Disconnect tube (4).
5. Remove 3 mounting bolts (7), then lift off demand

valve assembly (8).
4 Demand valve assembly : 30 kg
INSTALLATION OF DEMAND
VALVE ASSEMBLY
moval.

Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the system.
Then check the oil level again.
• Bleed the air.
30-132 HD255-5
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROLLER
REMOVAL OF TRANSMISSION
CONTROLLER ASSEMBLY
b
Always turn the starting switch OFF.
s Serial No.: 1001 – 1599

1. Disconnect 5 connectors CN1 - CN5.
2. Remove 4 bolts (1), then remove transmission
controller assembly (2).

1. Remove cover (1) from the rear of the operator's
seat.
2. Disconnect connectors CN1 (2), CN2 (3), CN3 (4),
and CN5 (5).
3. Remove the 4 bolts and transmission controller
assembly (6).
INSTALLATION OF TRANSMIS-
SION CONTROLLER ASSEMBLY
moval.
30-151-1 HD255-5
(11)
DISASSEMBLY AND ASSEMBLY ENGINE CONTROLLER
REMOVAL OF ENGINE CON-

TROLLER ASSEMBLY
b
Be sure to keep the starting switch in the OFF
position.

1. Remove cover (1) from the rear of the operator's
seat.
2. Disconnect connectors CN1 (2), CN2 (3), CN4 (4),
CN6 (5), and CN7 (6).
3. Remove the 4 bolts and engine controller assem-
bly (7).
CONTROLLER ASSEMBLY

moval.
HD255-5 30-151-2
(11)
DISASSEMBLY AND ASSEMBLY SHIFT INDICATOR CONTROLLER
REMOVAL OF SHIFT INDICATOR

CONTROLLER ASSEMBLY
b
Always turn the starting switch OFF.
2. Disconnect connector (2).
3. Disconnect connectors (3) and (4).
4. Remove 4 bolts (5), then remove shift indicator

controller assembly (6).
INSTALLATION OF SHIFT
INDICATOR CONTROLLER
ASSEMBLY
moval.
30-152 HD255-5
(11)
40 MAINTENANCE STANDARD
Damper ......................................................... 40-1-2

Torque converter ......................................... 40- 2
Transmission ................................................ 40- 4
Main relief valve .......................................... 40- 7
Transmission valve, ECMV ......................... 40- 8
Front axle ..................................................... 40-8-1
Differential ................................................... 40-8-3
Final drive ................................................... 40-8-6
Front brake ................................................... 40-8-7
Rear brake .................................................... 40-8-8
Parking brake ............................................. 40-8-10
Rear brake chamber .................................... 40- 9
Front brake chamber ................................... 40- 10
Slack adjuster .............................................. 40- 11
Hydraulic pump .......................................... 40- 12
Steering, hoist pump ................................... 40- 13
Steering cylinder ......................................... 40- 14
Demand valve .............................................. 40- 15
Crossover relief valve ................................. 40- 15
Hoist valver .................................................. 40- 16
Hoist cylinder .............................................. 40- 17
Steering linkage ........................................... 40- 18
Rear axle support ........................................ 40- 19
Front suspension cylinder .......................... 40- 20
Rear suspension cylinder ........................... 40- 21
HD255-5 40-1
(9)
90 OTHERS
Air circuit diagram (Standard specification Serial No.: 1001 – 1200) ................................................... 90- 3
Air circuit diagram (Standard specification Serial No.: 1201 – 1600) ................................................... 90- 5
Air circuit diagram (Emergency brake specification Serial No.: 1001 – 1200) ..................................... 90- 7
Air circuit diagram (Emergency brake specification Serial No.: 1201 – 1600) ..................................... 90- 9
Air circuit diagram (Emergency brake specification Serial No.: 1601 and up) .................................... 90-11
Hydraulic circuit diagram for torque converter, transmission, and brake cooling .............................. 90-13
Steering, hoist hydraulic circuit diagram (Serial No.: 1001 – 1200) ...................................................... 90-15
Steering, hoist hydraulic circuit diagram (Serial No.: 1201 and up) ..................................................... 90-17
Electric circuit diagram (1/2) (Serial No.: 1001 – 1200) ........................................................................... 90-19
Electric circuit diagram (1/4) (Serial No.: 1686 and up) ....................................................................... 90-34-1
Electric circuit diagram for transmission controller system .................................................................. 90-35
Electric circuit diagram of air conditioner (Serial No.: 1001 – 1200) ..................................................... 90-37
Electric circuit diagram of air conditioner (Serial No.: 1201 – 1600) ..................................................... 90-38
Electric circuit diagram of air conditioner (Serial No.: 1601 and up) .................................................... 90-39
HD255-5 90-1
(15)
AIR CIRCUIT DIAGRAM
STANDARD SPECIFICATION
Serial No.: 1001 – 1200
1. Front brake chamber 14. Exhaust brake 27. Brake valve

2. Front brake chamber 15. Rear relay valve 28. Cooling line
3. Brake oil tank 16. Front relay valve 29. Sub tank
4. Front brake 17. Front relay valve 30. Rear brake chamber
5. Front brake 18. Rear relay valve 31. Rear brake chamber
6. Compressor 19. Quick release valve 32. Slack adjuster
7. Air governor 20. Parking brake chamber 33. Rear brake
8. Air gauge 21. Low-pressure switch 34. Rear brake
9. Valve 22. Brake lamp switch 35. Check valve
10. Safety valve 23. Parking pilot switch 36. Horn
11. Wet air tank 24. Retarder lamp switch 37. Drain valve
12. Dry air tank 25. Parking brake valve
13. Double check valve 26. Hand brake valve
HD255-5 90-3
(9)
AIR CIRCUIT DIAGRAM
STANDARD SPECIFICATION
Serial No.: 1201 – 1600
1. Front brake chamber 14. Exhaust brake 28. Cooling line

2. Front brake chamber 15. Rear relay valve 29. Sub tank
3. Brake oil tank 16. Front relay valve 29A. Brake oil tank
12. Dry air tank 25. Parking brake valve
12A. Pilot air tank 26. Hand brake valve
13. Double check valve 27. Brake valve
HD255-5 90-5
(9)
AIR CIRCUIT DIAGRAM
EMERGENCY BRAKE SPECIFICATION
Serial No.: 1001 – 1200

3. Brake oil tank 16. Front relay valve 30. Rear brake chamber
5. Front brake 18. Rear relay valve 32. Slack adjuster
6. Compressor 19. Quick release valve 33. Rear brake
8. Air gauge 21. Low-pressure switch 35. Check valve
9. Valve 22. Brake lamp switch 36. Horn
10. Safety valve 23. Parking pilot switch 37. Drain valve
11. Wet air tank 24. Retarder lamp switch 38. Emergency brake valve
12. Dry air tank 25. Parking brake valve 39. Emergency brake switch
12A. Pilot air tank 26. Hand brake valve
HD255-5 90-7
(9)
AIR CIRCUIT DIAGRAM
Serial No.: 1201 – 1600

3. Brake oil tank 16. Front relay valve 29A. Brake oil tank
12. Dry air tank 25. Parking brake valve 38. Emergency brake valve
12A. Pilot air tank 26. Hand brake valve 39. Emergency brake switch
HD255-5 90-9
(9)
AIR CIRCUIT DIAGRAM

3. Brake oil tank 17. Front relay valve 31. Brake oil tank
10. Safety valve 24. Parking pilot switch 38. Drain valve
11. Wet air tank 25. Retarder lamp switch 39. Emergency brake valve
12. Dry air tank 26. Parking brake valve 40. Emergency brake switch
13. Pilot air tank 27. Hand brake valve
HD255-5 90-11
(9)
HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER,
TRANSMISSION, AND BRAKE COOLING
1. Transmission oil pan

2. Strainer
3. Hydraulic pump
4. Oil filter
5. Filter
6. ECMV for lock-up clutch
7. Lock-up clutch
8. ECMV for High clutch
9. ECMV for Low clutch
10. ECMV for 3rd clutch
11. ECMV for 2nd clutch
12. ECMV for R clutch
13. ECMV for 1st clutch
14. High clutch
15. Low clutch
16. 3rd clutch
17. 2nd clutch
18. R clutch
19. 1st clutch
20. Main relief valve
21. Torque converter relief valve
22. Hydraulic pump
23. Retarder relief valve
24. Retarder (rear brake)
25. Oil cooler
26. Oil filter
27. Transmission lubrication
28. Transmission lubrication relief valve
HD255-5 90-13
(9)
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM
Serial No.: 1001 – 1200
1. Hydraulic tank
2. Hydraulic pump (SAR056+045)
3. Emergency steering pump (SAL014)
4. Demand valve
4A. Demand spool
4B. Relief valve
5. Steering valve
6. Crossover relief valve
7. Steering cylinder
8. Hoist control valve
8A. Relief valve
8B. Spool
9. Slow return valve
10. Hoist cylinder
11. Oil filter
12. Bypass valve
HD255-5 90-15
(9)
STEERING, HOIST HYDRAULIC CIRCUIT DIAGRAM
1. Hydraulic tank
2. Hydraulic pump (SAR056+045)
3. Emergency steering pump
4. Demand valve
4A. Demand spool
4B. Relief valve
5. Steering valve
6. Crossover relief valve
7. Steering cylinder
8. Hoist control valve
8A. Relief valve
8B. Spool
9. Slow return valve
10. Hoist cylinder
11. Oil filter
12. Bypass valve
HD255-5 90-17
(9)
ELECTRIC CIRCUIT DIAGRAM (1/2)
Serial No.: 1001 – 1200
HD255-5 90-19
(9)
Serial No.: 1001 – 1200
HD255-5 90-21
(9)
Serial No.: 1201 – 1600 fl In case that local option is attached to the electrical circuit of the machine, spare fuse (in the fuse box FB1) of sutable capacity should be used for safety.
fl In this case, terminal of part number below should be provided.
Part number Part name
08021-00400 Terminal
HD255-5 90-23
(9)
Serial No.: 1201 – 1600
HD255-5 90-25
(9)
Serial No.: 1601 – 1685
HD255-5 90-27
(15)
Serial No.: 1601 – 1685
HD255-5 90-29
(15)
Serial No.: 1601 – 1685
HD255-5 90-31
(15)
Serial No.: 1601 – 1685
HD255-5 90-33
(15)
HD255-5 90-34-1
(15)
HD255-5 90-34-3
(15)
HD255-5 90-34-5
(15)
HD255-5 90-34-7
(15)
ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
HD255-5 90-35
(9)

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SEBM009115

MACHINE MODEL SERIAL NUMBER

• HD255-5 mount the SA6D125E-2 or SAA6D125E-3 engine.

01 GENERAL ............................................................................................................ 01-1

10 STRUCTURE AND FUNCTION ........................................................... 10-1

20 TESTING AND ADJUSTING ................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40 MAINTENANCE STANDARD ............................................................... 40-1

90 OTHERS ............................................................................................................... 90-1

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

20-132 (10) 20-219-5 (10) 20-247 20-316 20-375 (10)

20-405 20-451 (4) 20-552 20-726 (10) 30-27 (11)

30-48 30-49 (11) 30-101 30-138 90-5 (9)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

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

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

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