HD785-7 SEN01274-15 Shop Manual-1005-1205

SEN01943-03 40 Troubleshooting
Circuit diagram related
34 HD785-7
40 Troubleshooting SEN01943-03
Failure code [DB19KQ] Disagreement of model selection (Retarder

controller) 1
Action code Failure code Disagreement of model selection (Retarder controller)
Trouble
E03 DB19KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in retarder controller.
Action of • Turns all outputs OFF.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • When operator performs starting operation, machine does not start.
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.
information • Method of reproducing failure code: Turn starting switch ON.
Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DB19KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
machine monitor After replacing machine monitor or retarder controller, set them
value in normal
correctly according to Testing and adjusting volume.
state
Defective transmission con- Wrong reterder controller may be installed. Check its part No. and
2
troller install correct reterder controller.
HD785-7 35
Failure code [DB1RKR] CAN communication (retarder controller):

Communication disabled 1
Action code Failure code Abnormal CAN communication (retarder controller): Communication
disabled
Trouble
E03 DB1RKR (Between retarder controller – transmission controller)
(Transmission controller system)
Contents of
trouble • Updating of received data from retarder controller has stopped.
• AISS is locked in LOW. (until starting switch is turned OFF.)

Action of
controller • Keep the information at the time when abnormality occurred.
• Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • The information and special functions which are retrieved from retarder controller do not work or
machine display.
• Method of reproducing failure code: Turn the starting switch to ON position.

• Start of CAN communication is recognized by each controller when the ACC signal of the starting
switch is received.
• If a failure code for [D**RKR], [dB2RKR] or [DBBQKR] is additionally displayed, write down every
failure code displayed.
Related • The fact that a failure code for [DB2RKR] is displayed means that CAN communication is estab-
information lished at least between the transmission controller and the machine monitor.
Therefore, there is no short circuit, ground fault or hot short circuit in the CAN communication line.
• Since power to each controller and machine monitor is fed directly from the battery, supply of their
power remains uninterrupted even when the starting switch is turned OFF.
• Since the signals in operation are constructed with pulse voltage, they cannot be measured by
using a multimeter.

Defective power supply to
1 Perform troubleshooting for [DB13KK]
retarder controller
1) Turn the starting switch to OFF position
2) Disconnect connector CAN2 and CAN3, and connect the T-adpter
Defective CAN terminating to male side.
resistor
2 Between CAN3 (male) (A) and (B) (engine Resis-
(Internal open or short cir- side) 120 ± 12 z
tance
cuit)
Between CAN2 (male) (A) and (B) (engine Resis-
120 ± 12 z
cab) tance
• CAN communication line
a CAN terminating resistors of 120 z are connected in parallel.
Possible causes Therefore, an disconnection has not occurred in the communica-
and standard
tion line when the combined resistance of 60 z is measured
value in normal
state from any connector.
1) Turn the starting switch to OFF position and disconnect the bat-
tery ground cable.
2) Disconnect either one of the following connectors ATC2, J2P,
Disconnection or short cir- J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
3 adapter to the female side of the disconnected connector.
cuit in wiring harness
a If a short circuit is detected (resistance between terminals is 1 z
or less), disconnect all CAN communication connectors on each
controller. Then, identify whether the failure is short circuit
between wiring harnesses or inside the controller.
Resis- Approx. 60
Between ATC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
Between J2P (female) (46) and (47)
tance Mz
36 HD785-7

Resis- Approx. 60
Between J2C (female) (46) and (47)
tance Mz
Resis- Approx. 60
Between DPC4 (female) (3) and (8)
tance Mz
Disconnection or short cir- Resis- Approx. 60
3 Between BRC2 (female) (32) and (22)
cuit in wiring harness tance Mz
Resis- Approx. 60
Between HM-CN4A (female) (4) and (12)
tance Mz
Resis- Approx. 60
Between ABS2 (female) (32) and (22)
tance Mz
1) Turn the starting switch to OFF position and disconnect the battery
ground cable.
2) Insert the T-adapter into connectors ATC3, J2P, J3P, J2C, J3C,
DPC1, BRC3, HM-CN1 and ABS3.
3) Connect the battery ground cable and turn the starting switch to
ON position.
Between ATC3(14) and (21) Voltage 20 - 30 V
Defective ACC signal from Between J2P (39) and J3P (1) Voltage 20 - 30 V
starting switch
4
(Start of CAN communica- Between J2C (39) and J3C (1) Voltage 20 - 30 V
tion is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Between DPC1 (7) and (10) Voltage 20 - 30 V
Between BRC3 (14) and (21) Voltage 20 - 30 V
Possible causes
and standard Between BRC3 (24) and (31) Voltage 20 - 30 V
value in normal Between HM-CN1 (17) and (19) Voltage 20 - 30 V
state
Between ABS3 (14) and (21) Voltage 20 - 30 V
a If no failure is found by check on cause 4, this check is not
required.
tery ground cable.
2) Disconnect the connectors ATC2, J2P, J2C, DPC4, BRC2, HM-
CN4A, CAN2, CAN3 and ABS2, and connect the T-adapter to
their female side.
Between ATC2 (female) (32) and CAN2 Resis-
Max. 1 z
(female) (A) tance
Max. 1 z
Disconnection in wiring har- (female) (B) tance
ness
5 (Wire breakage or defective Between ATC2 (female) (32) and BRC2 Resis-
Max. 1 z
(female) (32) tance
contact of connector)
Between ATC2 (female) (22) and BRC2 Resis-
Max. 1 z
(female) (22) tance
Between ATC2 (female) (32) and DPC4 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Between ATC2 (female) (32) and J2P Resis-
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
HD785-7 37

Between ATC2 (female) (32) and J2C Resis-
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Between ATC2 (female) (32) and DL (male) Resis-
Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Between ATC2 (female) (32) and ABS2 Resis-
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Between ATC2 (female) (32) and HM- Resis-
Max. 1 z
CN4A (female) (4) tance
Disconnection in wiring har- Between ATC2 (female) (22) and HM- Resis-
ness Max. 1 z
5
(Wire breakage or defective
Possible causes a If no failure is found by check on cause 5, this check is not
and standard required.
value in normal 1) Turn the starting switch to OFF position and disconnect the bat-
state tery ground cable.
2) Disconnect connectors ATC3, J2P, J2C, DPC1, BRC3, HM-CN1
and ABS3, and connect the T-adapter to their female side.
Between starting switch (ACC) and ATC3 Resis-
Max. 1 z
(female) (14), (24) tance
Between starting switch (ACC) and DPC1 Resis-
Max. 1 z
Between starting switch (ACC) and J2P Resis-
Max. 1 z
(female) (39) tance
Between starting switch (ACC) and J2C Resis-
Max. 1 z
(female) (39) tance
Between starting switch (ACC) and BRC3 Resis-
Max. 1 z
Between starting switch (ACC) and HM- Resis-
Max. 1 z
CN1 (female) (17) tance
Between starting switch (ACC) and ABS3 Resis-
Max. 1 z
a If no abnormality is found in the above troubleshooting, the
Defective retarder control-
6 machine monitor may be defective. (Since this is an internal
ler
defect, troubleshooting cannot be performed.)
7 Defective machine monitor machine monitor may be defective. (Since this is an internal
38 HD785-7
HD785-7 39
Failure code [DB1RMA] Disagreement of option setting (Retarder

controller) 1
Action code Failure code Disagreement of option setting (Retarder controller)
Trouble
E03 DB1RMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in retarder controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • None in particular.
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.

Possible causes Option may be set wrongly in machine monitor. When machine
Wrong option setting in
and standard 1 monitor or retarder controller is replaced, set it correctly according
machine monitor
value in normal to Testing and adjusting.
state If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)
40 HD785-7
Failure code [DB2RKR] CAN communication (engine controller):

Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 DB2RKR (Transmission controller system)
• Updating of received data from engine controller has stopped.
Contents of • The transmission controller cannot recognize the engine controller of left bank in the CAN commu-
trouble nication.
1) CAN communication circuit error
• keep the current gear speed.
Action of • Set the gearshift lever in the "N" position to keep the transmission in neutral.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.

switch is received.
• The fact that a failure code for [DB2RKR] is displayed means that CAN communication is estab-
Related
lished at least between the transmission controller and the machine monitor.
information
Therefore, there is no short circuit, ground fault or hot short circuit in the CAN communi-
cation line.
using a multimeter.

1) Turn the starting switch to OFF position.
2) Remove fuses at the 5th and 6th from the bottom of BT3 and
1 Blowout of fuse the top fuse of BT2.
Between fuse terminals Continuity
a If fuse is not brown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J3P and connect T-adapter to male side.
Defective engine controller of a Measured value: Approx. 9-20 kz
2 left bank a If measured value is below 10 kz, engine controller is defec-
Possible causes (Internal short circuit) tive (internal short circuit).
and standard
Resis-
value in normal Between J3P (male) (3) and (1) Max. 10 z
tance
state
tery ground cable.
2) Insert the T-adapter into connector J3P
3) Perform troubleshooting by connecting the battery ground
Defective power supply to cable.
3
engine controller a If abnormality is found, perform troubleshooting for Detail of
failure 2) "Abnormality in input power supply circuit for engine
controller of left bank".
Between J3P (3) and (1) Voltage 20 - 30 V
Between J3P (4) and (2) Voltage 20 - 30 V
HD785-7 41

2) Disconnect connector CAN2 and CAN3, and connect the T-
Defective CAN terminating adapter to male side.
resistor
(Internal open or short cir- 120 ± 12 z
side) tance
cuit)
Between CAN2 (male) (A) and (B) (inside Resis-
120 ± 12 z
cab) tance
Therefore, an disconnection has not occurred in the communi-
cation line when the combined resistance of 60 z is measured
from any connector.
tery ground cable.
J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
adapter to the female side of the disconnected connector.
a If a short circuit is detected (resistance between terminals is 1
z or less), disconnect all CAN communication connectors on
each controller. Then, identify whether the failure is short cir-
cuit between wiring harnesses or inside the controller.
Disconnection or short circuit
5 Resis- Approx. 60
in wiring harness Between ATC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
tance Mz
Possible causes Resis- Approx. 60
and standard tance Mz
value in normal
Resis- Approx. 60
state Between DPC4 (female) (3) and (8)
tance Mz
Resis- Approx. 60
Between BRC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
6
(Start of CAN communication Between J2C (39) and J3C (1) Voltage 20 - 30 V
is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Between HM-CN1 (17) and (19) Voltage 20 - 30 V
42 HD785-7

required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Max. 1 z
(female) (46) tance
Possible causes Between ATC2 (female) (22) and J2C Resis-
Disconnection in wiring har- Max. 1 z
and standard (female) (47) tance
value in normal ness
7 (Wire breakage or defective Between ATC2 (female) (32) and DL (male) Resis-
state Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Max. 1 z
required.
tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
HD785-7 43

Max. 1 z
(female) (39) tance
ness (female) (14), (24) tance
7
(Wire breakage or defective Between starting switch (ACC) and HM- Resis-
contact of connector) Max. 1 z
Possible causes
and standard Max. 1 z
value in normal (female) (14), (24) tance
state a If no abnormality is found in the above check and in the trou-
bleshooting for Detail of failure 2, "Abnormality in input power
8 Defective engine controller supply circuit for engine controller of left bank", the engine con-
troller may be defective. (Since this is an internal defect, trou-
bleshooting cannot be performed.)
44 HD785-7
HD785-7 45
Contents of • The transmission controller cannot recognize the engine controller in the CAN communication.
trouble 2) Abnormality in input power supply circuit for engine controller of left bank.

Defective circuit breaker (60 If a circuit breaker is tripped, the circuit probably has a ground
1
A) fault. (See cause 3.)
2 Blowout of fuse 2) Remove the 5th fuse from the bottom of BT3.
tery ground cable.
2) Perform troubleshooting with the switch turned OFF.
Possible causes Disconnection in wiring har-
Between circuit breaker (60 A) terminal and Resis-
and standard ness Max. 1 z
3 BT3 (21) tance
value in normal (Wire breakage or defective
Between BT3(22) and J3P (female) (3) or Resis-
state contact of connector) Max. 1 z
(4) tance
Between J3P (female) (1), (2) and ground Resis-
Max. 1 z
(GS) tance
tery ground cable.
Ground fault in wiring har- 2) Perform troubleshooting with the switch turned OFF.
4 ness Resis-
Between ground and BT3 (21) Min. 1 z
(Contact with ground circuit) tance
Between ground and BT3 (22) or J3P Resis-
Min. 1 z
(female) (3) or (4) tance
46 HD785-7
Failure code [dB2RKR] CAN communication (engine controller):

Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 dB2RKR (Transmission controller system)
• Updating of received data from engine controller has stopped.
Contents of • The transmission controller cannot recognize the engine controller of right bank in the CAN commu-
trouble nication.
1) CAN communication circuit error
• keep the current gear speed.
Action of • Set the gearshift lever in the "N" position to keep the transmission in neutral.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.

switch is received.
• If a failure code for [D**RKR] or [DBBQKR] is additionally displayed, write down every failure code
displayed.
Related
information
cation line.
using a multimeter.

2) Remove fuses at the 3th and 6th from the bottom of BT3 and
1 Blowout of fuse the top fuse of BT2.
a If fuse is not brown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J3C and connect T-adapter to male side.
Defective engine controller of a Measured value: Approx. 9-20 kz
2 right bank a If measured value is below 10 kz, engine controller is defec-
Possible causes (Internal short circuit) tive (internal short circuit).
and standard
Resis-
value in normal Between J3C (male) (3) and (1) Max. 10 z
tance
state
tery ground cable.
2) Insert the T-adapter into connector J3C
3) Perform troubleshooting by connecting the battery ground
Defective power supply to cable.
3
engine controller a If abnormality is found, perform troubleshooting for Detail of
failure 2) "Abnormality in input power supply circuit for engine
controller of right bank".
Between J3C (3) and (1) Voltage 20 - 30 V
Between J3C (4) and (2) Voltage 20 - 30 V
HD785-7 47

Defective CAN terminating adapter to male side.
resistor
side) tance
cuit)
Between CAN2 (male) (A) and (B) (inside Resis-
120 ± 12 z
cab) tance
Therefore, an disconnection has not occurred in the communi-
from any connector.
tery ground cable.
J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
adapter to the female side of the disconnected connector.
each controller. Then, identify whether the failure is short cir-
cuit between wiring harnesses or inside the controller.
5 Resis- Approx. 60
in wiring harness Between ATC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
tance Mz
Possible causes Resis- Approx. 60
and standard tance Mz
value in normal
Resis- Approx. 60
state Between DPC4 (female) (3) and (8)
tance Mz
Resis- Approx. 60
Between BRC2 (female) (32) and (22)
tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
6
(Start of CAN communication Between J2C (39) and J3C (1) Voltage 20 - 30 V
is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Between HM-CN1 (17) and (19) Voltage 20 - 30 V
48 HD785-7

required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Max. 1 z
(female) (46) tance
Possible causes Between ATC2 (female) (22) and J2C Resis-
and standard (female) (47) tance
value in normal ness
7 (Wire breakage or defective Between ATC2 (female) (32) and DL (male) Resis-
state Max. 1 z
(3) tance
Max. 1 z
(10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Max. 1 z
required.
tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
HD785-7 49

Max. 1 z
(female) (39) tance
ness (female) (14), (24) tance
7
(Wire breakage or defective Between starting switch (ACC) and HM- Resis-
contact of connector) Max. 1 z
Possible causes
value in normal (female) (14), (24) tance
state a If no abnormality is found in the above check and in the trou-
bleshooting for Detail of failure 2, "Abnormality in input power
8 Defective engine controller supply circuit for engine controller of right bank", the engine
controller may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
50 HD785-7
HD785-7 51
Contents of • The transmission controller cannot recognize the engine controller in the CAN communication.
trouble 2) Abnormality in input power supply circuit for engine controller of right bank.

Defective circuit breaker (60 If a circuit breaker is tripped, the circuit probably has a ground
1
A) fault. (See cause 3.)
2 Blowout of fuse 2) Remove the 3th fuse from the bottom of BT3.
tery ground cable.
2) Perform troubleshooting with the switch turned OFF.
Possible causes Disconnection in wiring har-
Between circuit breaker (60 A) terminal and Resis-
and standard ness Max. 1 z
3 BT3 (25) tance
value in normal (Wire breakage or defective
Between BT3(26) and J3C (female) (3) or Resis-
state contact of connector) Max. 1 z
(4) tance
Between J3C (female) (1), (2) and ground Resis-
Max. 1 z
(GS) tance
tery ground cable.
Ground fault in wiring har- 2) Perform troubleshooting with the switch turned OFF.
4 ness Resis-
Between ground and BT3 (25) Min. 1 z
(Contact with ground circuit) tance
Between ground and BT3 (26) or J3C Resis-
Min. 1 z
(female) (3) or (4) tance
52 HD785-7
HD785-7 53
Failure code [DBB0KK] or VHMS_LED display: "n9" o "01" 1

VHMS controller: Low power supply voltage (input)
Action code Failure code VHMS controller: Low power supply voltage (input)
Trouble
– DBB0KK (VHMS controller system) (Display: PLM)
Contents of
• Voltage of VHMS controller switch fell to below 19.5 V while the engine speed is above 500 rpm.
trouble
Action of • None in particular.
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays "n9" o "01".
• Method of reproducing failure code: Start engine and raise the engine speed above 500 rpm

Defective fuse No.(19), (20) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT1 (See cause 3.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring har- ing without turning starting switch ON.
ness Between fuse No.10 (20) of fuse box BT1 Resis-
2 Max. 1 z
(Disconnection or defective and HM-CN1 (female) (8), (9) tance
contact) Between HM-CN1 (female) (11), (12), (19), Resis-
Possible causes Max. 1 z
(20) and chassis ground tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state Grounding fault in wiring har- ing without turning starting switch ON.
3 ness Between fuse No.10 (20) of fuse box BT1 or
(Contact with ground circuit) HM-CN1 (female) (8), (9) and chassis Resis- Min. 1
tance Mz
ground
ing after starting engine and raising the engine speed above
Defective VHMS & PLM con- 500 rpm
4
troller
Between HM-CN1 (8), (9) and (11), (12),
Voltage 20 – 30 V
(19), (20) or chassis ground
54 HD785-7
HD785-7 55
Failure code [DBB0KQ] (or VHMS_LED display: "nF" o "11")

VHMS controller: Disagreement of model selection signals 1
Action code Failure code VHMS controller: Disagreement of model selection signals
Trouble
— DBB0KQ (VHMS controller system) (Display: PLM)
Contents of
• Improperly connected connectors were detected.
trouble
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The system may not work properly.
machine
information • The LED of the VHMS controller displays "nF" o "11".
• Method of reproducing failure code: Turn the starting switch ON.

Possible Improperly connected con-
Check connection between HM-CN2A and HM-CN3A connectors,
causes and 1 nectors in VHMS controller
and HM-CN2B and HM-CN3B connectors for abnormality.
standard value (when the system is normal)
in normal state Defective VHMS & PLM If the above is normal, VHMS & PLM controller may be defective.
2
controller (Since trouble is in system, troubleshooting cannot be carried out.)
56 HD785-7
HD785-7 57
Failure code [DBB3KK] (or VHMS_LED display: "n9" o "05")

VHMS controller battery power supply: Low power supply voltage (input) 1
Action code Failure code VHMS controller: Low power supply voltage (input)
Trouble
Contents of
• Constant voltage of VHMS controller fell to below 10 V.
trouble
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on –
machine
• Method of reproducing failure code: Keep the starting switch turned OFF

Defective fuse No.(29), (30) If the fuse is burn, the circuit probably has a grounding fault, etc.
1
of fuse box BT2 (See cause 3.)
Disconnection in wiring har- ing without turning starting switch ON.
ness Between fuse No.25 (30) of fuse box BT2 Resis-
2 Max. 1 z
(Disconnection or defective and HM-CN1 (female) (6), (7) tance
Possible causes contact) Between HM-CN1 (female) (11), (12), (19), Resis-
Max. 1 z
and standard (20) and chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Grounding fault in wiring har-
3 ness Between fuse No.25 (30) of fuse box BT2 or
(Contact with ground circuit) HM-CN1 (female) (6), (7) and chassis Resis- Min. 1
tance Mz
ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective VHMS & PLM con- and carry out troubleshooting
4
troller Between HM-CN1 (6), (7) and (11), (12),
Voltage 20 – 30 V
(19), (20) or chassis ground
58 HD785-7
HD785-7 59
Failure code [DBB5KP] (or VHMS_LED display: "n9" o "04")

VHMS controller 5 V power supply output: Low output voltage 1
Action code Failure code VHMS controller 5 V power supply output: Low output voltage
Trouble
Contents of
• VHMS controller 5 V sensor power supply is shorted with the chassis ground.
trouble
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked
Related by downloading data stored in the VHMS controller).

Grounding fault in wiring har- ing without turning starting switch ON.
Possible causes 1 ness
and standard (Contact with ground circuit) Between HM-CN1 (female) (4), (5) or HM12 Resis- Min. 1 Mz
(female) (B) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
2
troller Between HM-CN1 (female) (4), (5) and
Voltage 4.5 – 5.5 V
HMCN2A (female) (12) or chassis ground
60 HD785-7
HD785-7 61

Trouble
– DBB6KP (VHMS controller system) (Display: PLM)
Contents of • VHMS controller 24 V sensor and VHMS indicator lamp power supply is shorted with the chassis
trouble ground.
Problem that
appears on –
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked
Related by downloading data stored in the VHMS controller).

Possible causes 1 ness Between HM-CN1 (female) (2) or HN25
(Contact with ground circuit) (female) (2), or HM-23A (female) (A), or Resis-
and standard Min. 1 Mz
tance
value in normal HM-23B (female) (A) and chassis ground
2
troller Between HM-CN1 (2) and (11), (12), (19),
Voltage 20 – 30 V
(20) or chassis ground
62 HD785-7
HD785-7 63

Trouble
– DBB7KP (VHMS controller system) (Display: PLM)
Contents of
• VHMS controller 12 V indicator lamp power supply is shorted with the chassis ground.
trouble
Problem that
appears on –
machine

Possible causes 1 ness
and standard (Contact with ground circuit) Between HM-CN1 (female) (3) or LM1 and Resis-
Min. 1 Mz
chassis ground tance
value in normal
2
troller Between HM-CN1 (3) and (11), (12), (19), 11.5 – 12.5
Voltage
(20) or chassis ground V
64 HD785-7
Failure code [DBBQKR] (or VHMS_LED display: "n8" o "02")

VHMS controller CAN communication: Defective communication
(Abnormality in target component system) 1
Action code Failure code VHMS controller CAN communication: Defective communication
Trouble (Abnormality in target component system)
– DBBQKR (VHMS controller system) (Display: PLM)
Contents of
• CAN communication information from each controller cannot be received.
trouble
Action of
• None in particular.
machine monitor
Problem that
appears on • The system may not work properly.
machine
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [DAQRKR], [DB1RKR], [DB2RKR] or [DBCRKR].
state
Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 1

Action code Failure code Abnormality in CAN communication (VHMS)
Trouble
E03 DBBRKR (Machine monitor system)
Contents of • Machine monitor cannot obtain information from VHMS controller through CAN communication cir-
trouble cuit.
Action of
• Keeps information at time of occurrence of abnormality.
machine monitor
Problem that
• System may not operate normally.
appears on
machine • Information from VHMS controller is not displayed.
Related
• Method of reproducing failure code: Turn starting switch ON.
information

and standard Defetive power supply for Carry out troubleshooting for failure code [DBB0KK] and
1
value in normal VHMS controller [DBB3KK].
state 2 Carry out troubleshooting for failure code [DAQRKR] (Cause 2 and after)
HD785-7 65
Failure code [DBC2KK] ABS controller solenoid power supply: Power

supply system trouble 1
Action code Failure code ABS controller solenoid power supply: Power supply system trou-
Trouble ble
E03 DBC2KK (ABS controller system)
Contents of • While controller direct power supply voltage is normal, solenoid power supply voltage has become
trouble below 18 V.
Action of • Turn OFF all of output circuits.
controller • Turn OFF sensor 24 V power supply.
Problem that
appears on • All systems of ABS controller do not operate.
machine
Related
• If the fuse is blown, check for ground fault of line between fuse and ABS3 (female) (2), (12), (22).
information

Defective circuit breaker If a circuit breaker is tripped, the circuit probably has a ground
1
(FuB2) fault. (See cause 4.)
2) Remove No.30 of fuse BT3 (5th fuse from the top).
2 Defective No.30 of fuse BT3
If the fuse is blown, the circuit probably has a ground fault. (See
cause 4).
1) Turn starting switch OFF.
2) Disconnect negative (–) terminal of battery and connector ABS3
and connect T-adapter to ABS3 (female).
3) Connect negative (–) terminal of battery.
4) Turn starting switch ON.
Between battery terminal M and ground Voltage 20 – 30 V
Disconnection in wiring Between ABS3 (2), (12), (22) and ground Voltage 20 – 30 V
harness If voltage at fuse BT3 No.30 (9) is normal and voltage at ABS3 (2),
3
(Disconnection or defective (12), (22) is abnormal, wiring harness between fuse No.30 (10)
Possible causes contact) and ABS3 (female) (2), (12), (22) has disconnection.
and standard
value in normal
2) Disconnect negative (–) terminal of battery and connector ABS3,
state
and connect connect T-adapter to ABS3 (female).
Between ABS3 (female) (21), (31), (32),
Resis-
(33) and ground Max. 1 z
tance
a Looseness or rusting on ER1 terminal
tery ground cable.
Ground fault in wiring har- 2) If No.30 of fuse BT3 is blown, replace it with a new one.
4 ness 3) Disconnect connector ABS3 and connect the T-adapter to
(Contact with ground circuit) female side.
Between ground and ABS3 (female) (2), Resis-
Min. 1 z
(12), (22) tance
2) Disconnect negative (–) terminal of battery and insert T-adapter
in ABS3.
5 Defective ABS controller 3) Connect negative (–) terminal of battery.
Between ABS3 (2), (12), (22) and ground Voltage 20 – 30 V
66 HD785-7
HD785-7 67
Failure code [DBC3KK] ABS controller battery direct power supply:

Power supply voltage too low 1
Action code Failure code ABS controller battery direct power source: Power supply voltage
Trouble too low
E03 DBC3KK (ABS controller system)
Contents of
• Controller power supply voltage is below 18 V.
trouble
Action of
• Turns all output OFF.
controller
Problem that
appears on • ABS does not operate.
machine
Related
• When the fuse is blown, check the ground faulf of line between fuse and ABS3 (female) (1), (11).
information

a Check battery voltage and electrolyte specific gravity.
Battery voltage Voltage Min. 24 V
1 Defective battery
Specific
Battery electrolyte specific gravity Min. 1.26
gravity
Defective circuit breaker If a circuit breaker is tripped, the circuit probably has a ground
2
(FuA2) fault. (See cause 4.)
2) Remove No.21 of fuse BT2 (5th fuse from the bottom).
3 Defective No. 21 of fuse BT2
If the fuse is blown, the circuit probably has a ground fault. (See
cause 4).
2) Disconnect battery (–) terminal and connector ABS3, and con-
nect T-adapter to ABS3 (female).
Between ABS3 (female) (21), (31), (32),
Resis-
(33) and ground Max. 1 z
tance
a Looseness or rusting on ER1 terminal
Possible causes Disconnection in wiring har- 1) Turn starting switch OFF.
and standard ness 2) Disconnect battery (–) terminal and connector ABS3, and con-
value in normal 4 (Disconnection in wiring or nect T-adapter in ABS3 (female).
state defective contact in connec- 3) Connect battery (–) terminal.
tor)
Between battery relay terminal B and
Voltage 20 – 30 V
ground
Between ABS3 (1), (11) and ground Voltage 20 – 30 V
If there is voltage between battery relay terminal B and ground but
not between ABS3 (1), (11) and ground, wiring harness or fuse is
broken.
tery ground cable.
Ground fault in wiring har- 2) If No.21 of fuse BT2 is blown, replace it with a new one.
5 ness 3) Disconnect connector ABS3 and connect the T-adapter to
(Contact with ground circuit) female side.
Between ground and ABS3 (female) (1), Resis-
Min. 1 z
(11) tance
Defective transmission con- 2) Disconnect battery (–) terminal and insert T-adapter to ABS3.
6 3) Connect battery (–) terminal.
troller
Between ABS3 (1), (11) and ground Voltage 20 – 30 V
68 HD785-7
HD785-7 69
Failure code [DBC9KQ] Disagreement of model selection (ABS

controller) 1
Action code Failure code Disagreement of model selection (ABS controller)
Trouble
E03 DBC9KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in ABS controller.
Action of • Turns all outputs OFF.
Problem that
• ABS does not operate.
appears on
• All ABS output is turned OFF.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBC9KQ] is not displayed.
Possible causes
Wrong model selection in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
Installation of wrong ABS Wrong ABS controller may be installed. Check part No. of installed
2
controller ABS controller and install normal ABS controller.
70 HD785-7
Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1

Action code Failure code Abnormality in CAN communication (ABS)
Trouble
E03 DBCRKR (Transmission controller system)
Contents of • Machine monitor cannot obtain information from ABS controller through CAN communication cir-
trouble cuit.
Action of
• Keeps information at time of occurrence of abnormality.
machine monitor
Problem that
• System may not operate normally.
appears on
• Information from ABS controller is not displayed.
machine
switch is received.
Related
information
cation line.
using a multimeter.

Defective power supply to
1 Perform troubleshooting for [DB13KK]
retarder controller
1) Turn the starting switch to OFF position
Defective CAN terminating adpter to male side.
resistor
side) tance
cuit)
Between CAN2 (male) (A) and (B) (engine Resis-
120 ± 12 z
cab) tance
Possible causes Therefore, an disconnection has not occurred in the communi-
and standard
value in normal
state from any connector.
tery ground cable.
Disconnection or short cir- J2C, DPC4, BRC2, HM-CN4A and ABS2, and connect the T-
3 adapter to the female side of the disconnected connector.
cuit in wiring harness
each controller. Then, identify whether the failure is short circuit
between wiring harnesses or inside the controller.
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
HD785-7 71

Resis- Approx. 60
tance Mz
Resis- Approx. 60
Between DPC4 (female) (3) and (8)
tance Mz
Disconnection or short cir- Resis- Approx. 60
3 Between BRC2 (female) (32) and (22)
cuit in wiring harness tance Mz
Resis- Approx. 60
tance Mz
Resis- Approx. 60
tance Mz
tery ground cable.
ON position.
starting switch
4 Between J2C (39) and J3C (1) Voltage 20 - 30 V
(Start of CAN communica-
tion is not detected) Between DPC1 (6) and (9) Voltage 20 - 30 V
Possible causes
and standard Between BRC3 (24) and (31) Voltage 20 - 30 V
value in normal Between HM-CN1 (17) and (19) Voltage 20 - 30 V
state
required.
tery ground cable.
their female side.
Max. 1 z
(female) (A) tance
Max. 1 z
ness
5 (Wire breakage or defective Between ATC2 (female) (32) and BRC2 Resis-
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (8) tance
Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
72 HD785-7

Max. 1 z
(female) (46) tance
Max. 1 z
(female) (47) tance
Between ATC2 (female) (32) and DL Resis-
Max. 1 z
(male) (3) tance
Between ATC2 (female) (22) and DL Resis-
Max. 1 z
(male) (10) tance
Max. 1 z
(female) (A) tance
Max. 1 z
(female) (B) tance
Max. 1 z
(female) (32) tance
Max. 1 z
(female) (22) tance
Max. 1 z
Disconnection in wiring har- Between ATC2 (female) (22) and HM- Resis-
ness Max. 1 z
5
Possible causes a If no failure is found by check on cause 5, this check is not
value in normal 1) Turn the starting switch to OFF position and disconnect the bat-
state tery ground cable.
Max. 1 z
Max. 1 z
Max. 1 z
(female) (39) tance
Max. 1 z
(female) (39) tance
Max. 1 z
Between starting switch (ACC) and HM- Resis-
Max. 1 z
Max. 1 z
6 Defective ABS controller ABS controller may be defective. (Since this is an internal
HD785-7 73
74 HD785-7
Failure code [DBCRMA] Disagreement of option setting (ABS controller) 1

Action code Failure code Disagreement of option setting (ABS controller)
Trouble
E03 DBCRMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in ABS controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Non in particular.
machine
Related • Perform initial setting and adjustment of ABS controller to be performed after replacement.

Failure code [DBCRMA] is not displayed.
Possible causes
Wrong option setting in a Machine model may not be set correctly in machine monitor.
and standard 1
value in normal
state
If cause 1 is not detected, machine monitor may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
HD785-7 75
Failure code [DBG2KK] Solenoid power supply: Low voltage

Action code Failure code Solenoid power supply: Low voltage
Trouble
E03 DBG2KK (Pre-lubrication controller system)
Contents of
• During starting switch is ON, solenoid supply voltage below 18 V is detected.
trouble
• Turns pre-lubrication relay output OFF.
Action of
• Turns pre-heating relay output OFF.
controller
• Turns engine start relay output OFF.
Problem that • The engine does not start.
appears on • No pre-lubrication effected
machine • No pre-heating effected
• Engine can be started by bypassing pre-lubrication controller.
1) Disconnect connectors PER1 and PRE2 from near pre-librication controller.
Related
2) Connect PRE1 (male) connector and PRE2 (female) connector.
information
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power sup- 2) Disconnect PRE5 and connect T-branch.
1
ply pin voltage is 3) Start the engine and carry out troubleshooting.
normal) Between PRE5 (30) – (31) Voltage 20 – 30 V
2 Fuse disconnection Fuse box BT2: Fuse (11) Continuity Yes
3 Circuit breaker operated Between circuit breaker (62) – (63) Continuity Yes
Possible causes 1) Turn starting switch OFF.
and standard 2) Disconnect PRE5 and alternator terminal B and carry out trou-
Disconnection in wiring har- bleshooting.
value in normal ness (Disconnection or
state 4 Between PRE5 (female) (30) – alternator Resis-
defective contact in Max. 1 z
terminal B tance
connector)
Between PRE5 (female) (21), (31) and Resis-
Max. 1 z
Ground fault in wiring 2) Disconnect PRE5 and alternator terminal B and carry out trou-
5 harness (Contact with bleshooting.
ground circuit) Between PRE5 (female) (30) and chassis Resis- Min. 1
ground tance Mz
76 HD785-7
Related electrical circuit diagram
a Prelube controller is the same as pre-lubrication controller.
HD785-7 77
Failure code [DBG3KK] Battery direct power supply: Low voltage

Action code Failure code Battery direct power supply: Low voltage
Trouble
E03 DBG3KK (Pre-lubrication controller system)
Contents of
• Supply voltage of controller is low.
trouble
Action of
• Stops judging other errors caused by low voltage
controller
Problem that
appears on • Engine may not be able to start.
machine
• Engine can be started by bypassing pre-lubrication controller.
1) Disconnect connectors PER1 and PRE2 from near pre-librication controller.
Related
2) Connect PRE1 (male) connector and PRE2 (female) connector.
information
• The output state (ON/OFF) of the pre-lubrication start relay can be checked with the monitoring
code: 40974, "D-OUT-1" (1: ON, 0: OFF).

Defective pre-lubrication 1) Turn starting switch OFF.
controller (When power 2) Disconnect PRE5 and connect T-branch.
supply pin (40) voltage is 3) Start the engine and carry out troubleshooting.
normal)
1
a Check which path Between PRE5 (1) and (11) – (31) Voltage 20 – 30 V
poses problem since
each pin (1) and pin (2) Between PRE5 (2) and (12) – (31) Voltage 20 – 30 V
have different path.
Fuse box BT2: Fuse (19) Continuity Yes
2 Fuse disconnection
Fuse box BT2: Fuse (29) Continuity Yes
Circuit breaker(30A) oper- Directly check circuit breaker (30A). (If the circuit breaker is shut
3
ated down, the circuit probably has a grounding fault, etc.)
1) Check starting switch unit.
4 Defective starting switch 2) Turn starting switch ON position,Then carry out troubleshooting.
Possible causes Between terminal B – terminal ACC Continuity Yes
and standard 1) Turn starting switch OFF.
value in normal 2) Disconnect PRE5.
state 3) Turn starting switch ON and carry out troubleshooting.
Between PRE5 (female) (1), (11) and chassis
Disconnection in wiring Voltage 20 – 30 V
ground
harness (Disconnection or
5 Between PRE5 (female) (2), (12) and chassis
defective contact in Voltage 20 – 30 V
ground
connector)
2) Disconnect PRE5.
Between PRE5 (female) (21), (26), (31) and Resis-
Max. 1 z
2) Disconnect battery ground and PRE6.
Ground fault in wiring 3) Turn starting switch OFF and carry out troubleshooting.
6 harness (Contact with Between PRE5 (female) (1), (11) and chassis Resis-
Min. 1 Mz
ground circuit) ground tance
Between PRE5 (female) (2), (12) and chassis Resis-
Min. 1 Mz
ground tance
78 HD785-7
HD785-7 79
Failure code [DBG9KQ] Model selection signal: Abnormal

Action code Failure code Model selection signal: Abnormal
Trouble
E01 DBG9KQ (Pre-lubrication controller system)
Contents of • Because pre-lubrication controller model selection signal is not specified as GND, the system
trouble judged the signal as for different model.
Action of
• Pre-lubrication controller operates under the program for a different model.
controller
Problem that
appears on
machine
• Input state of model selection signal can be checked with monitoring code: 40973 (1: 24 V, 0:
GND)
Related
[D-IN-4]: PRE5 (35)=Machine select1
information
[D-IN-5]: PRE5 (26)=Machine select2 (NC: Internal pull-up)
[D-IN-6]: PRE5 (36)=Machine select3 (NC: Internal pull-up)

False connection of the
1 Choice and connect the connector for HD785-7.
machine select connector
2) Disconnect PRE5 and carry out troubleshooting.
Possible causes Disconnection in wiring Between connectors PRE5 (female) (35) – Resis-
Min. 1 Mz
and standard harness (Disconnection or (21), (26), (31) tance
2
value in normal defective contact in Between connectors PRE5 (female) (36) – Resis-
state connector) Min. 1 Mz
(21), (26), (31) tance
Between connectors PRE5 (female) (21), Resis-
Max. 1 z
(26), (31) – ground tance
If causes 1, 2 is not detected, the pre-lubrication controller may be
Defective pre-lubrication
3 defective. (Since trouble is in system, troubleshooting cannot be car-
controller
ried out.)
80 HD785-7
HD785-7 81
Failure code [DDD7KX] Trouble in travel speed setting switch system:

Out of input signal range 1
Action code Failure code Trouble in travel speed setting switch system: Out of input signal
range
Trouble
E03 DDD7KX (When ARSC is set and ARSC system switch is ON)
(Retarder controller system)
Contents of
trouble • The input signal circuit voltage of the travel speed set switch is below 0.15 V.
Action of
controller • When ARSC operates, the controller releases the brake gradually.
Problem that
appears on • This failure does not have a serious effect on the machine.
machine
Related
information • None in particular.

1) Turn the starting switch OFF.
2) Replace the travel speed set switch (ARSC SET switch).
Defective travel speed set
1 Replace the travel Failure is not
switch (ARSC SET switch) Switch is normal
speed set switch repaired.
(ARSC SET switch). Failure is repaired. Switch is defective
2) Disconnect connector RE3.
2 Defective register (250 z) 3) Connect T-adapter (female).
Resis- 250 ± 25
Between RE3 (female) (1) and (2)
tance z
Possible causes 2) Disconnect connector RE4.
and standard 3 Defective resistor (1,020 z) 3) Connect T-adapter (female).
value in normal Resis- 1,020 ±
state Between RE4 (female) (1) and (2)
tance 102 z
2) Disconnect connectors BRC1, ARC, RE3, and RE4.
3) Connect T-adapter to BRC1 (female), ARC (female), RE3 (male)
and RE4 (male).
Between BRC1 (female) (22) and RE3 Resis-
ness (male) (1) tance
4
(Disconnection or defective Between BRC1 (female) (13) and RE3 Resis-
Max. 1 z
contact) (male) (2) and ARC (female) (1) tance
Between RE4 (male) (1) and ARC (female) Resis-
Max. 1 z
(3) tance
Between RE4 (male) (2) and ARC (female) Resis-
Max. 1 z
(2) tance
82 HD785-7

2) Disconnect connector BRC1.
3) Insert T-adapter.
4) Turn the starting switch ON.
Between BRC1 (22) and (21) Voltage Approx. 5 V
2) Disconnect connectors BRC1.
3) Connect T-adapter (female).
5 Defective retarder controller
When set switch is Resis- 1,020 ±
ON tance 102 z
When set switch is Resis- 68 ± 6.8
Between BRC1 TOUCH UP tance z
(female) (13) – (21) When set switch is Resis- 198 ±
TOUCH DOWN tance 19.8 z
When set switch is Resis- 418 ±
CANCEL tance 41.8 z
HD785-7 83
Failure code [DDD8KA] ARSC system switch system: Disconnection (If

equipped) 1
Action code Failure code ARSC system switch system: Disconnection
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KA (Retarder controller system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

Disconnection in wiring har- 2) Disconnect connectors ARSC and DPC2B.
ness 3) Connect T-adapter (female).
1
(Disconnection or defective
Between DPC2B (female) (1) and ARSC Resis-
contact) Max. 1 z
(female) (3) tance
2) Replace the ARSC system switch with normal one.
Defective ARSC system
2 System switch is nor-
Possible causes switch When the ARSC system switch No
mal
and standard is replaced with normal one, is
value in normal failure repaired? System switch is
Yes
state defective
2) Disconnect connector DPC2B.
Turn the ARSC sys-
tem switch ON Voltage 20 – 30 V
Between DPC2B (1) (Press it up).
and ground Turn the ARSC sys-
tem switch OFF Voltage Max. 1 V
(Press it down).
84 HD785-7
HD785-7 85
Failure code [DDD8KB] ARSC system switch system: Short circuit

(If equipped) 1
Action code Failure code ARSC system switch system: Short circuit
Trouble (When ARSC is set and ARSC system switch is ON)
E03 DDD8KB (Machine monitor system)
Contents of
• The ON input of the ARSC system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ARSC operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
• Condition of ARSC switch can be checked with monitoring function (Code: 37701 (V)).
information

2) Disconnect connectors ARSC and DPC2B.
Hot short in wiring harness 3) Connect T-adapter (female).
1 4) Turn the starting switch ON.
(Contact with 24V circuit)
Between ARSC (female) (3) and ground Voltage Max. 1 V
Between ARSC (female) (2) and ground Voltage Max. 1 V
2) Replace the ARSC system switch with normal one.
Possible causes ARSC system switch defec-
and standard tive When the ARSC system switch No
mal
value in normal is replaced with normal one, is
failure repaired? System switch is
state Yes
defective
Turn the ARSC sys-
3 Machine monitor defective
– ground Turn the ARSC sys-
(Press it down).
86 HD785-7
HD785-7 87
Failure code [DDD9KA] ABS system switch system: Disconnection 1

Action code Failure code ABS system switch system: Disconnection
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KA (ABS controller system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
controller
Problem that
machine
Related
information

2) Disconnect connectors ABS and DPC2B.
Disconnection in wiring har- 3) Connect T-adapter (female).
ness
1 Between DPC2B (female) (2) and ABS Resis-
(Disconnection or defective Max. 1 z
(female) (3) tance
contact)
Between DPC2B (female) (8) and ABS Resis-
Max. 1 z
(female) (2) tance
2) Replace the ABS system switch with normal one.
Possible causes
and standard 2 Defective ABS system switch System switch is nor-
When the ABS system switch is No
value in normal mal
replaced with normal one, is fail-
state ure repaired? System switch is
Yes
defective
Turn the ABS sys-
and ground Turn the ABS sys-
(Press it down).
88 HD785-7
HD785-7 89
Failure code [DDD9KB] ABS system switch system: Short circuit 1

Action code Failure code ABS system switch system: Short circuit
Trouble (When ABS is set and ABS system switch is ON)
E03 DDD9KB (Machine moniter system)
Contents of
• The ON input of the ABS system switch is ON and the OFF input of the system switch is ON.
trouble
Action of
• When ABS operates, the controller releases the brake gradually.
machine moniter
Problem that
machine
Related
information

2) Disconnect connectors ABS.
Between ground and ABS (female) (3) Voltage Max. 1 V
Between ground and ABS (female) (2) Voltage Max. 1 V
2) Replace the ABS system switch with normal one.
Possible causes 2 Defective ABS system switch System switch is nor-
and standard When the ABS system switch is No
mal
value in normal replaced with normal one, is fail-
ure repaired? System switch is
state Yes
defective
Turn the ABS sys-
and ground Turn the ABS sys-
(Press it down).
90 HD785-7
HD785-7 91
Failure code [DDDAKA] ASR system switch: Disconnection 1

Action code Failure code ASR system switch: Disconnection
Trouble
E01 DDDAKA (Machine monitor system)
Contents of
• The ON input of the ASR system switch is OFF and the OFF input of the system switch is OFF.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected seriously.
appears on
machine • ASR control cannot be continued.
Related
information

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring har- Between DPC2B (female) (3) and ASR Resis-
ness Max. 1 z
(female) (3) tance
1 (Disconnection in wiring or
defective contact in connec- 1) Turn starting switch OFF.
tor) 2) Disconnect connectors ASR and DPC2B.
Between DPC2B (female) (9) and ASR Resis-
Max. 1 z
(female) (2) tance
2) Replace ASR system switch with normal switch.
Possible causes 3) Turn starting switch ON.
Defective ASR system
and standard 2 System switch is nor-
switch When ASR system switch is No
value in normal mal
state replaced with normal switch,
does condition become normal? System switch is
Yes
abnormal
ASR system switch
Voltage 20 – 30 V
Between DPC2B (3) "ON"
3 Defective machine monitor and ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
and ground ASR system switch
Voltage 20 – 30 V
"OFF"
92 HD785-7
HD785-7 93
Failure code [DDDAKB] ASR system switch: Short circuit 1

Action code Failure code ASR system switch system: Short circuit
Trouble
E01 DDDAKB (Machine monitor system)
Contents of
• ASR system switch ON input is turned ON and system switch OFF input is turned ON.
trouble
Action of
• Resets ASR control.
machine moniter
Problem that
• Machine is not affected particularly.
appears on
machine • ASR control cannot be continued.
Related
information

2) Disconnect connectors ASR.
1 4) Turn starting switch ON.
Between ground and ASR (female) (3) Voltage Max. 1 V
Between ground and ASR (female) (2) Voltage Max. 1 V
2) Replace ASR system switch with normal switch.
Defective ASR system
switch When ASR system switch is No
Possible causes mal
replaced with normal switch, is
and standard System switch is
condition normal? Yes
value in normal defective
state
ASR system switch
Voltage 20 – 30 V
3 Defective machine monitor and ground ASR system switch
Voltage Max. 1 V
"OFF"
ASR system switch
Voltage Max. 1 V
and ground ASR system switch
Voltage 20 – 30 V
"OFF"
94 HD785-7
HD785-7 95
Failure code [DDE2KB] Engine oil pressure switch error: Grounding

fault
Action code Failure code Engine oil pressure switch: Grounding fault
Trouble
E01 DDE2KB (Pre-lubrication controller system)
Contents of • Engine oil pressure switch detected low oil pressure (switch closed) when engine speed is Min.
trouble 500 rpm and engine oil pressure is over 100 kPa (communication from engine controller).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related
• Engine oil pressure: 37200 (kPa)
information
• State of the engine oil pressure switch can be monitored with 40973 "D-IN-1" (ON: 1, OFF: 0).

Ground fault in wiring 2) Disconnect connector PRE5 and terminal PRE16, then carry out
1 harness (Contact with troubleshooting.
ground circuit) Between terminal PRE16 (harness side) and Resis-
Min. 1 Mz
Possible causes 2) Disconnect terminal PRE16.
and standard 3) Start the engine and carry out troubleshooting.
value in normal Between terminal PRE16 (oil pressure switch Resis-
state Defective engine oil Min. 1 Mz
2 side) and chassis ground tance
pressure switch
2) Disconnect terminal PRE16 and carry on troubleshooting.
Between terminal PRE16 (oil pressure switch Resis-
Max. 1 z
side) and chassis ground tance
If causes 1 – 2 are not detected, pre-lubrication controller may be
controller
ried out.)
96 HD785-7
HD785-7 97
Failure code [DDE2L6] Engine oil pressure switch error: Disconnection

or hot short circuit
Action code Failure code Engine oil pressure switch error: Disconnection or hot short circuit
Trouble
E01 DDE2L6 (Pre-lubrication controller system)
• After starting switch is ON, no terminal C signal is input and engine oil pressure switch detected
Contents of
"OPEN" state although the engine speed is under 500 rpm (communication from engine control-
trouble
ler).
Action of
controller
Problem that
appears on
machine
• Engine speed: 01002 (rpm)
Related • Engine oil pressure switch: 40973 "D-IN-1" (ON: 1, OFF: 0).
information • Oil pressure can be monitored with engine starting switch terminal C signal: 40973 "D-IN-3" (ON:
1, OFF: 0).

Disconnection in wiring 2) Disconnect connector PRE5 and terminal PRE16, then carry out
harness (Disconnection or troubleshooting.
1
defective contact in
Between connector PRE5 (5) – terminal Resis-
connector) Max. 1 z
PRE16 tance
2) Disconnect connector PRE5 and terminal PRE16.
Hot short circuit in wiring
3) Connect T-branch to connector PRE5 (female).
2 harness (Contact with
4) Turn starting switch ON and carry out troubleshooting.
power supply circuit)
Between PRE5 (female) (5) and chassis
Voltage Max. 1 V
Possible causes ground
value in normal 2) Disconnect terminal PRE16.
state 3) Start the engine and carry out troubleshooting.
Engine starting.
Resis-
Between terminal PRE16 (oil pressure switch Min. 1 Mz
Defective engine oil tance
3 side) and chassis ground
pressure switch
2) Disconnect terminal PRE16 and carry out troubleshooting.
While engine is starting
Resis-
Between terminal PRE16 (oil pressure switch Max. 1 z
tance
side) and chassis ground
If causes 1 – 3 are not detected, pre-lubrication controller may be
controller
ried out.)
98 HD785-7
HD785-7 99
Failure code [DDP6L4] Service brake pressure switch trouble (Rear) 1

Action code Failure code Service brake pressure switch trouble (Rear)
Trouble
E03 DDP6L4 (Retarder controller system)
Contents of
• When brake pedal is pressed, signal is not sent from service brake pressure switch.
trouble
Action of
controller
Problem that
appears on • When brake pedal is pressed, brake lamp (rear center lamp) does not light up.
machine
Related
information

1) Remove relay cover.
Defective stop lamp relay 2) Turn starting switch ON (Do not start engine).
1 3) Turn foot brake ON and OFF to check relay.
(R08)
R08 Turning ON/OFF sound is heard.
a Turn starting switch OFF and disconnect D09, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
Forward direction:
Between D09 (male) There is continuity
Continuity
(1) (-) and (2) (+) Backward direction:
There is not continuity
2 Defective diode
a Turn starting switch OFF and disconnect D10, then carry out
troubleshooting without turning starting switch ON (Measure in
diode check mode).
Forward direction:
Possible causes Between D10 (male) There is continuity
Continuity
and standard (1) (-) and (2) (+) Backward direction:
value in normal There is not continuity
state a Connect wires to T-adapter for DT-T-3.
2) Disconnect S01 and connect T-adapter (male).
Defective service brake 3) Turn starting switch ON.
3
switch When brake pressed:
Between S01 (male) There is continuity
Continuity
(A) and (B) When brake is released:
There is not continuity
a Turn starting switch OFF and disconnect BRC1, S01 and
D10,then carry out troubleshooting without turning starting
switch ON.
Disconnection in wiring har- Between S01 (female) (A) and D10 (female) Resis-
ness (Disconnection in wiring (1) Max. 1 z
4 tance
or defective contact in con-
Between BRC1 (female) (17) and D10 Resis-
nector) Max. 1 z
(female) (2) tance
Resis-
Between S01 (female) (B) and ground Max. 1 z
tance
100 HD785-7

a Turn starting switch OFF and disconnect BRC1, S01, D09 and
D10, then carry out troubleshooting without turning starting
Grounding fault in wiring har- switch ON.
5 ness (Contact with ground Resis-
Between D10 (female) (1) and ground Min. 1 Mz
Possible causes circuit) tance
and standard Resis-
value in normal Between D10 (female) (2) and ground Min. 1 Mz
tance
state
Trouble in hydraulic system
6 (when electrical system is Hydraulic system may have trouble. Remove cause of trouble.
normal)
If causes 1 – 5 are not detected, retarder controller may be defec-
7 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
HD785-7 101
Failure code [DDTHKA] Hi clutch fill switch: Disconnection 1

Action code Failure code Hi clutch fill switch: Disconnection
(Command is Holding pressure, fill switch is OFF, and slip is not
Trouble
E03 DDTHKA sensed)
Contents of • When the output to the Hi clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
trouble from the fill switch is not turned ON.
Action of • The controller keeps the current gear speed.
controller • If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that
• The gear cannot be shifted.
appears on
machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
• The signal from the fill switch can be checked in the monitoring function (Code: 38919) (0: OFF, 1:
ON).
• Method of reproducing failure code: Start the engine and travel at F3 (2nd: Hi).
k Lift the body to the maximum position, set the dump lever to HOLD and install a body lock
pin on the both sides of the body.
k Insertion and removal of the body lock pins must be carried out by at least two workers.
(Drop down of the body during the operation can cause serious personal injury or death.)
• Installation of body lock pin
Related 1. Start the engine.
information 2. Lift the body to the maximum position and set the dump lever to HOLD.
3. Be sure to insert the body lock pin into both sides of the body.
4. Set the dump lever to FLOAT and lock the lock knob.
5. Turn the starting switch to OFF position and stop the engine.
• Removal of body lock pin
1. Start the engine.
2. Set the dump lever to HOLD.
3. Pull out the body lock pins, store them inside the body and lock them with the fixing pin.
4. Set the dump lever to LOWER to seat the body.

1) Start the engine.
a Make sure beforehand that failure code [DDTJKA] does not
appear when you set shift lever to D and gear speed to F2 (Lo:
2nd) while depressing brake pedal.
2) Lift the body to the maximum position and install body lock pins
(see the above "Related information").
4) Swap connectors of Hi clutch and Lo clutch.
Possible causes
q L.PS (CN17) < – – –> H.PS (CN19)
and standard
q L.SW (CN18) < – – –> H.SW (CN20)
value in normal 1 Defective Hi clutch fill switch 5) Start the engine.
state
6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTJKA] appears, Hi clutch fill switch remains OFF.
a Check the oil pressure. If oil pressure is normal, Hi clutch fill
switch is defective.
a If failure code [DDTJKA] does not appear, disconnection in wir-
ing harness or defective transmission controller.
a After completing the above check, lift the body again and return
connectors to their original positions.
102 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and H.SW (CN20).
Possible causes ness 3) Connect T-adapters (female).
2
and standard (Disconnection or defective
Between ATC3 (female) (30) and H.SW Resis-
value in normal contact) Max. 1 z
state (CN20) (female) (1) tance
If no abnormality is found in the above troubleshooting, the trans-
Defective transmission con-
3 mission controller is defective. (Since this is an internal defect,
troller
HD785-7 103
Failure code [DDTJKA] Lo clutch fill switch: Disconnection 1

Action code Failure code Lo clutch fill switch: Disconnection
Trouble
E03 DDTJKA sensed)
Contents of • When the output to the Lo clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F1 (1st: Lo).
a Make sure that the body is seated (the condition for F1 travel).

4) Swap connectors of Lo clutch and Hi clutch.
q L.PS (CN17) < – – –> H.PS (CN19)
q L.SW (CN18) < – – –> H.SW (CN20)
Possible causes
and standard
6) Set shift lever to D, gear speed to F2 (Lo: 2nd) while depressing
value in normal 1 Defective Lo clutch fill switch brake pedal.
state
If failure code [DDTJKA] does not appear, Lo clutch fill switch
remains OFF.
a Check the oil pressure. If oil pressure is normal, Lo clutch fill
a If failure code [DDTJKA] does appear, disconnection in wiring
harness or defective transmission controller.
104 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and L.SW (CN18).
2
Between ATC3 (female) (10) and L.SW Resis-
troller
HD785-7 105
Failure code [DDTKKA] 1st clutch fill switch: Disconnection 1

Action code Failure code 1st clutch fill switch: Disconnection
Trouble
E03 DDTKKA sensed)
Contents of • When the output to the 1st clutch ECMV soleniod is turned ON, the clutch is engaged but the signal
controller • If the shift lever is set in the "N" position, the controller keeps the gear in neutral.
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F1 (1st: Lo).

a Make sure beforehand that failure code [DDTLKA] does not
4) Swap connectors of 1st clutch and 2nd clutch.
Possible causes q 1.PS (CN6) < – – –> 2.PS (CN8)
and standard q 1.SW (CN7) < – – –> 2.SW (CN9)
value in normal 1 Defective 1st clutch fill switch 5) Start the engine.
state 6) Set shift lever to D, gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, 1st clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 1st clutch fill
a If failure code [DDTKKA] does appear, disconnection in wiring
106 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and 1.SW (CN7).
2
Wiring harness between ATC3 (female) (40) Resis-
state and 1.SW (CN7) (female) (1) tance
troller
HD785-7 107
Failure code [DDTLKA] 2nd clutch fill switch: Disconnection 1

Action code Failure code 2nd clutch fill switch: Disconnection (KA)
Trouble
E03 DDTLKA sensed)
Contents of • When the output to the 2nd clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F3 (2nd: Hi).

a Make sure beforehand that failure code [DDTKKA] does not
appear when you set shift lever to L and gear speed to F1 (Lo:
1st) while depressing brake pedal.
4) Swap connectors of 2nd clutch and 1st clutch.
q 2.PS (CN8) < – – –> 1.PS (CN6)
Possible causes
q 2.SW (CN9) < – – –> 1.SW (CN7)
and standard
Defective 2nd clutch fill 5) Start the engine.
value in normal 1
switch 6) Set the dump lever to LOWER to seat the body.
state
7) Set shift lever to L, gear speed to F1 (Lo: 1st) while depressing
brake pedal.
If failure code [DDTKKA] appears, 2nd clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 2nd clutch fill
a If failure code [DDTKKA] does appear, disconnection in wiring
108 HD785-7

Possible causes ness 3) Connect T-adapter.
2
Between ATC3 (female) (9) and 2.SW Resis-
troller
HD785-7 109
Failure code [DDTMKA] 3rd clutch fill switch: Disconnection 1

Action code Failure code 3rd clutch fill switch: Disconnection
Trouble
E03 DDTMKA sensed)
Contents of • When the output to the 3rd clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F4 (3rd: Lo).

4) Swap connectors of 3rd clutch and 2nd clutch.
Possible causes q 3.PS (CN10) < – – –> 2.PS (CN8)
and standard q 3.SW (CN11) < – – –> 2.SW (CN9)
value in normal Defective 3rd clutch fill 5) Start the engine.
1
state switch 6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, 3rd clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 3rd clutch fill
a If failure code [DDTLKA] does not appear, disconnection in wir-
110 HD785-7

2
troller
HD785-7 111
Failure code [DDTNKA] R clutch fill switch: Disconnection 1

Action code Failure code R clutch fill switch: Disconnection
Trouble
E03 DDTNKA sensed)
Contents of • When the output to the R clutch ECMV solenoid is turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at R.

4) Swap connectors of R clutch and 2nd clutch.
Possible causes
q R.PS (CN12) < – – –> 2.PS (CN8)
and standard
q R.SW (CN13) < – – –> 2.SW (CN9)
value in normal 1 Defective R clutch fill switch 5) Start the engine.
state
6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTLKA] appears, R clutch fill switch remains OFF.
a Check the oil pressure. If oil pressure is normal, R clutch fill
a If failure code [DDTLKA] does not appear, disconnection in wir-
112 HD785-7

Disconnection in wiring har- 2) Disconnect connectors ATC3 and R.SW (CN13).
Possible causes ness 3) Connect T-adapter.
2
Wiring harness between ATC3 (female) (29) Resis-
state and R.SW (CN13) (female) (1) tance
troller
HD785-7 113
Failure code [DDTPKA] 4th clutch fill switch: Disconnection 1

Action code Failure code 4th clutch fill switch : Disconnection
Trouble
E03 DDTPKA sensed)
Contents of • When the output to the 4th clutch ECMV is solenoid turned ON, the clutch is engaged but the signal
Problem that
appears on
ON).
• Method of reproducing failure code: Start the engine and travel at F6 (4th: Lo).

a Make sure beforehand that failure code [DDTJKA] does not
4) Swap connectors of 4th clutch and Lo clutch.
Possible causes q L.PS (CN17) < – – –> 4.PS (CN14)
and standard q L.SW (CN18) < – – –> 4.SW (CN15)
value in normal 1 Defective 4th clutch fill switch 5) Start the engine.
state 6) Set shift lever to D , gear speed to F2 (Lo: 2nd) while depressing
brake pedal.
If failure code [DDTJKA] appears, 4th clutch fill switch remains
OFF.
a Check the oil pressure. If oil pressure is normal, 4th clutch fill
a If failure code [DDTJKA] does not appear, disconnection in wir-
114 HD785-7

2
troller
HD785-7 115
Failure code [DF10KA] Gear shift lever: Disconnection 1

Action code Failure code Gear shift lever: Disconnection
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• Gear shift lever signal is not input at all.
trouble
Action of
• Controls according to previous gear shift lever information before abnormality occurs.
controller
Problem that • Gear speed is still in neutral and cannot start vehicle.
appears on • Cannot shift between forward and reverse positions.
machine • All gear shift lever position lamps go out.
Related infor-
• Non in particular.
mation

• Gear shift lever is being pushed even though it is not operated.
1 Operational error • Gear shift lever has been stopped at the midway point between
each of the gear positions.
2) Remove fuse BT3 No.14
3) Connect T-adapters to connector SF1, ATC1, ATC2 and ATC3
(female).
Resis-
Between BT3 (14) and SF1 (female) (1) Max. 1 z
tance
Between ATC2 (female) (35) and SF1 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (5) tance
Max. 1 z
Disconnection in wiring (female) (4) tance
harness Between ATC2 (female) (15) and SF1 Resis-
2 Max. 1 z
(Disconnection or defective (male) (6) tance
contact of connectors) Between ATC2 (female) (5) and SF1 Resis-
Max. 1 z
(female) (7) tance
Possible causes Between ATC2 (female) (36) and SF1 Resis-
(female) (8) tance
value in normal Between ATC2 (female) (26) and SF1 Resis-
state Max. 1 z
(female) (9) tance
Max. 1 z
(female) (10) tance
Max. 1 z
(female) (11) tance
Between ATC3 (female) (21) (31), (32), Resis-
Max. 1 z
(33) and SF1 (female) (2) tance
2) Connect T-adapters to connectors ATC1 (female), ATC2
(female), and SF1 (female).
Between ground and ATC2 (female) (35) or Resis-
Min. 1 Mz
SF1 (female) (3) tance
Ground fault in wiring har-
3 ness Min. 1 Mz
(Contact with ground circuit)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
116 HD785-7

Min. 1 Mz
Ground fault in wiring har- Min. 1 Mz
3 ness
(Contact with ground circuit) Between ground and ATC2 (female) (16) or Resis-
Min. 1 Mz
Min. 1 Mz
2) Insert T-adapter in connector SF1.
4) Operate shift lever and troubleshoot.
In shift range "R" Voltage 20 – 30 V
Between SF1 (3) and
ground In shift range other
Voltage Max. 1 V
than "R"
In shift range "N" Voltage 20 – 30 V
Between SF1 (4) and
Voltage Max. 1 V
than "N"
In shift range "D" Voltage 20 – 30 V
Between SF1 (5) and
Voltage Max. 1 V
than "D"
In shift range "6" Voltage 20 – 30 V
Between SF1 (6) and
Voltage Max. 1 V
than "6"
Possible causes In shift range "5" Voltage 20 – 30 V
and standard 4 Defective gear shift lever Between SF1 (7) and
value in normal ground In shift range other
Voltage Max. 1 V
state than "5"
Between SF1 (8) and
Voltage Max. 1 V
than "4"
Between SF1 (9) and
Voltage Max. 1 V
than "3"
Between SF1 (10)
and ground In shift range other
Voltage Max. 1 V
than "2"
In shift range "L" Voltage 20 – 30 V
Between SF1 (11)
Voltage Max. 1 V
than "L"
a If wiring harness is normal and all the voltages at any selected
range are less than the standard value, the power supply line or
ground circuit in shift lever is defective.
mission controller is defective.
a Reference
Defective transmission 2) Insert T-adapter in connectors ATC1 and ATC2.
controller
Between ATC2 (35)
Voltage Max. 1 V
than "R"
HD785-7 117

In shift range "D" Voltage 20 – 30 V
Between ATC2 (25)
Voltage Max. 1 V
than “D“
Between ATC1 (6)
Voltage Max. 1 V
than "N"
Between ATC2 (15)
Voltage Max. 1 V
than "6"
Possible causes Between ATC2 (5)
and standard Voltage Max. 1 V
Defective transmission than "5"
value in normal 5
state controller In shift range "4" Voltage 20 – 30 V
Between ATC2 (36)
Voltage Max. 1 V
than "4"
Between ATC2 (26)
Voltage Max. 1 V
than "3"
Between ATC2 (16)
Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"
118 HD785-7
HD785-7 119
Failure code [DF10KB] Gear shift lever: Short circuit 1

Action code Failure code Gear shift lever: Short circuit
Trouble (Input of multiple lever signach)
E03 DF10KB (Transmission controller system)
Contents of
• Gear shift lever signals have been inputted at the same time from 2 or more systems.
trouble
• Controls according to high priority signal.
(1): N > D > 6> 5 > 4 > 3 > 2 > L
Action of
(2): N > R
controller
• Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the
same time.
• There are cases where the gear speed is shifted to a higher gear speed than that which has been
Problem that
set by the gear shift lever.
appears on
• Gear speed is still in neutral and cannot start vehicle.
machine
• Gear shift lever position lamp does not indicate actual gear shift lever position.
Related
information

2) Disconnect connector SF1.
3) Connect T-adapter to connector SF1 (female).
When not
Between ground and SF1 (female) (3) Voltage at R, Max.
1V
When not
Between ground and SF1 (female) (5) Voltage at D, Max.
1V
When not
Between ground and SF1 (female) (4) Voltage at N, Max.
1V
When not
Between ground and SF1 (female) (6) Voltage at 6, Max.
Hot short in wiring harness
1 1V
(Contact with 24 V circuit)
When not
Possible causes 1V
and standard
value in normal When not
state Between ground and SF1 (female) (8) Voltage at 4, Max.
1V
When not
1V
When not
1V
When not
Between ground and SF1 (female) (11) Voltage at L, Max.
1V
2) Disconnect connectors ATC1, ATC2 and SF1, and connect the T-
adapters to each female side.
Short circuit in wiring har- a Use the continuity range of the multimeter for the measure-
ness ment.
2
(Contact between har-
Between ATC1 (female) (6) and each pin No continuity
nesses)
other than pin (6). (No sound is heard)
120 HD785-7

Short circuit in wiring har- Between SF1 (female) (3) and each pin other No continuity
ness than (3) (No sound is heard)
2
(Contact between har- Between SF1 (female) (4) and each pin other No continuity
nesses) than (4) (No sound is heard)
Between SF1 (female) (5) and each pin other No continuity
than (5) (No sound is heard)
Possible causes than (8) (No sound is heard)
and standard Between SF1 (female) (9) and each pin other No continuity
value in normal than (9) (No sound is heard)
state
Between SF1 (female) (10) and each pin No continuity
other than (10) (No sound is heard)
Between SF1 (female) (11) and each pin No continuity
other than (11) (No sound is heard)
2) Insert T-adapter in connector SF1 (female).
Between SF1 (3) and
Voltage Max. 1 V
than "R"
Between SF1 (4) and
Voltage Max. 1 V
than "N"
In shift range"D" Voltage 20 – 30 V
3 Defective gear shift lever Between SF1 (5) and
Voltage Max. 1 V
than "D"
Between SF1 (6) and
Voltage Max. 1 V
than "6"
Between SF1 (7) and
Voltage Max. 1 V
than "5"
Between SF1 (8) and
Voltage Max. 1 V
than "4"
HD785-7 121

Between SF1 (9) and
Voltage Max. 1 V
than "3"
Between SF1 (10)
3 Defective gear shift lever In shift range other
and ground Voltage Max. 1 V
than "2"
Between SF1 (11)
Voltage Max. 1 V
than "L"
mission controller is defective.
a Reference
2) Insert T-adapter in connectors ATC1 and ATC2.
Between ATC2 (35)
Voltage Max. 1 V
than "R"
Possible causes In shift range "D" Voltage 20 – 30 V
Between ATC2 (25)
and standard and ground In shift range other
Voltage Max. 1 V
value in normal than "D"
state In shift range"N" Voltage 20 – 30 V
Between ATC1 (6)
Voltage Max. 1 V
than “N“
Defective transmission In shift range "6" Voltage 20 – 30 V
4 Between ATC2 (15)
controller and ground In shift range other
Voltage Max. 1 V
than "6"
Between ATC2 (5)
Voltage Max. 1 V
than "5"
Between ATC2 (36)
Voltage Max. 1 V
than "4"
Between ATC2 (26)
Voltage Max. 1 V
than "3"
Between ATC2 (16)
Voltage Max. 1 V
than "2"
Between ATC2 (6)
Voltage Max. 1 V
than "L"
122 HD785-7
HD785-7 123
Failure code [DGE5KX] or VHMS_LED display: "n4" o "01" 1

Atmospheric temperature sensor: Out of input signal range
Action code Failure code Atmospheric temperature sensor: Out of input signal range
Trouble
– DGE5KX (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
trouble less.
Action of
machine monitor
Problem that
appears on • Monitoring function fails to monitor the atmospheric temperature.
machine
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays "n4" o "01".
information • The input state (temperature) from the atmospheric temperature sensor can be checked with the
monitoring function (Code: 37501 ATR TEMP).
• Method of reproducing failure code: Turn the starting switch ON

ing without turning starting switch ON.
Defective atmospheric tem- Atmospheric
FL06 (male) Resistance
perature sensor temperature
1
(Internal disconnection or 25°C (Normal temp) 3.6 – 4.7 kz
short circuit)
Between (A) and (B) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz
ing without turning starting switch ON.
Atmospheric
HM-CN2A (male) Resistance
Disconnection or short circuit temperature
2
in wiring harness 25°C (Normal temp) 3.6 – 4.7 kz
Between (10) and
About 0°C 10.2 – 13.4 kz
Possible causes (12)
and standard About 40°C 2.1 – 2.6 kz
value in normal
a If no abnormality is found in check on cause 2, this check is not
state
required.
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
(Disconnection or defective Between HM-CN2A (female) (10) and FL06 Resis-
Max. 1 z
contact of connector) (female) (A) tance
Between FL06 (female) (B) and chassis Resis-
Max. 1 z
ground tance
4 ness
(Contact with ground circuit) Between HM-CN2A (female) (10) or FL06 Resis- Min. 1
(female) (A) and chassis ground tance Mz
1) Starting switch OFF
2) Insert T-adapter into connector HM-CN2A or FL06.
Hot short in wiring harness 3) Starting switch ON
5
Between HM-CN2A (10) or FL06 (A) and Max. 4.9
Voltage
chassis ground V
124 HD785-7

and standard If causes are not found by above checks, transmission controller is
value in normal Defective VHMS & PLM con-
6 defective. (Since this is an internal failure, troubleshooting can not
state troller
be performed.)
HD785-7 125
Failure code [DGF1KX] Transmission oil temperature sensor: Out of

input signal range 1
Action code Failure code Transmission oil temperature sensor: Out of input signal range
Trouble
E03 DGF1KX (Transmission controller system)
• The voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V (above
Contents of 150°C) or only transmission oil temperature is low (transmission oil temperature sensor signal cir-
trouble cuit voltage is above 4.56 V (below 15 °C) and torque converter and brake oil temperature sensor
voltage is below 3.7 V (above 55 °C).
Action of
• The controller controls the clutch oil pressure, fixing the sensed oil temperature high.
controller
Problem that
appears on • Gear shift shocks become large.
machine
• This failure can be checked in the monitoring function (Code: 32500 (°C), 32501 (V)).
Related
information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

2) Disconnect connector T/M.T (CN23).
3) Connect T-adapter (male).
Defective transmission oil Between Resis-
1 Oil temperature: 25 °C 37 – 50 kz *
temperature sensor T/M.T tance
(CN23)
(male) (1) Oil temperature: 100 °C Resis-
3.5 – 4.0 kz *
and (2) tance

2) Disconnect connector ATC1.
3) Connect T-adapter.
Disconnection or short cir- Between Resis-
2 Oil temperature: 25 °C 37 – 50 kz
cuit in wiring harness ATC1 tance
(female)
(3) and Resis-
Oil temperature: 100 °C 3.5 – 4.0 kz
(21) tance
Possible causes a If no abnormality is found in check on cause 2, this check is not
value in normal 1) Turn the starting switch OFF.
state Disconnection in wiring har- 2) Disconnect connectors ATC1 and T/M.T (CN23).
ness 3) Connect T-adapters (female).
3
Between ATC1 (female) (21) and T/M.T Resis-
contact) Max. 1 z
(CN23) (female) (2) tance
Between ATC1 (female) (3) and T/M.T Resis-
Max. 1 z
Grounding fault in wiring 2) Disconnect connector ATC1 or T/M.T (CN23).
4 harness (Contact with 3) Connect T-adapter (female).
ground) Between ground and ATC1 (female) (3) or Resis-
Min. 1 Mz
T/M.T (CN23) (female) (1) tance
2) Disconnect connector ATC1 or T/M.T (CN23).
Hot short in wiring harness 3) Insert T-adapter into it.
(Contact with 24V)
Between ground and ATC1 (3) or T/M.T
Voltage Max. 4.5 V
(CN23) (1)
126 HD785-7

value in normal Defective transmission con-
state troller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as
retarder oil temperature sensor).
HD785-7 127
Failure code [DGR2KB] Trouble in retarder oil temperature sensor (rear

wheel) system (Disconnection and short circuit) 1
Action code Failure code Trouble in retarder oil temperature sensor (rear wheel) system
Trouble (Disconnection and short circuit)
E01 DGR2KB (Retarder controller system)
Contents of
• Signal circuit voltage of retarder oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
appears on • Oil temperature gauge does not work because of failure mode of sensor.
machine
Related • Input signal from oil temperature sensor can be checked with monitoring function (codes: 30211
information (°C) and 30212 (V)).

a Prepare with starting switch OFF, disconnect connector RTR
and troubleshooting with starting switch still OFF.
Retarder oil tempera-
RTR (male) Resistance (kz)*
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) and (2) 80 6.556
90 4.925
100 3.75
a Prepare with starting switch OFF, disconnect connector BRC1
Possible causes Retarder oil tempera-
BRC1 (female) Resistance (kz)
and standard ture (°C)
value in normal Disconnection or short circuit 25 42.7
state 2
in wiring harness
30 35.13
Between (3) and (21) 80 6.556
90 4.925
100 3.75
Ground fault in wiring har- and troubleshooting with starting switch still OFF.
3 ness
(Contact with ground circuit) Resis- Min. 1
Between BRC1 (female) (3) and ground
tance Mz
a Prepare with starting switch OFF and troubleshooting with
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30203).
*: Shown are average resistance values of the sensor at each temperature level.
The values actually vary.
128 HD785-7
HD785-7 129
Failure code [DGR2KZ] Trouble in retarder oil temperature sensor (rear

wheel) system (Ground fault) 1
Action code Failure code Trouble in retarder oil temperature sensor (rear wheel) system
Trouble (Ground fault)
E01 DGR2KZ (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

and standard
value in normal Perform troubleshooting for failure code [DGR2KB].
state
130 HD785-7
Failure code [DGR4KB] Trouble in retarder oil temperature sensor (front

wheel) system (Disconnection and short circuit) 1
Action code Failure code Trouble in retarder oil temperature sensor (front wheel) system
Trouble (Disconnection and short circuit)
E01 DGR4KB (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

and standard
value in normal Perform troubleshooting for failure code [DGR4KZ].
state
HD785-7 131
Failure code [DGR4KZ] Trouble in retarder oil temperature sensor (front

wheel) system (Ground fault) 1
Action code Failure code Trouble in retarder oil temperature sensor (front wheel) system
Trouble (Ground fault)
E01 DGR4KZ (Retarder controller system)
Contents of
trouble
Action of
controller
Problem that
machine

a Prepare with starting switch OFF, disconnect connector RTF
Retarder oil tempera-
RTF (male) Resistance (kz)*
ture (°C)
Defective retarder oil temper- 25 42.7
1
ature sensor
30 35.13
Between (1) and (2) 80 6.556
90 4.925
100 3.75
Possible causes Retarder oil tempera-
BRC1 (female) Resistance (kz)
and standard ture (°C)
value in normal Disconnection or short circuit 25 42.7
state 2
in wiring harness
30 35.13
Between (9) and
80 6.556
(21)
90 4.925
100 3.75
Ground fault in wiring har- and troubleshooting with starting switch still OFF.
3 ness
(Contact with ground circuit) Resis- Min. 1
Between BRC1 (female) (9) and ground
tance Mz
a Prepare with starting switch OFF and troubleshooting with
starting switch still ON.
Defective retarder controller
4 Check with monitor-
(In normal system) Oil tem- Actual oil temperature and dis-
ing function
perature played temperature are same.
(Code: 30201).
*: Shown are average resistance values of the sensor at each temperature level.
The values actually vary.
132 HD785-7
HD785-7 133
Failure code [DGR6KX] Steering oil temperature sensor: Input signal

out of range 1
Action code Failure code Steering oil temperature sensor: Input signal out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Signal circuit voltage of steering oil temperature sensor has become below 0.97 V (more than 150
°C) or only steering oil temperature is low (signal circuit voltage of steering oil temperature sensor is
Contents of
above 4.56 V (less than 15 °C)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55 °C )
and normal.
Action of
controller
Problem that
appears on • Steering oil temperature gauge does not indicate properly.
machine
• Input signal from oil temperature sensor can be checked with monitoring function.
Related 1) Steering oil temperature sensor (codes: 32701 (°C) and 32702) (V))
information 2) Torque converter oil temperature sensor (codes: 30100 (°C) and 30101 (V))
3) Retarder oil temperature sensor (codes: 30211 (°C) and 30212 (V))

2) Connect T-adapter to connector STR (male).
Defective steering oil Between Oil temperature: Resis-
1 37 – 50 kz *
temperature sensor STR 25 °C tance
(male) (1) Oil temperature: Resis-
and (2) 3.5 – 4.0 kz *
100 °C tance
2) Connect T-adapter to connector ATC1 (female).
Disconnection or short circuit Between Oil temperature: Resis-

37 – 50 kz
2 ATC1 25 °C tance
in wiring harness
(female)
(20) and Oil temperature: Resis-
3.5 – 4.0 kz
(21) 100 °C tance
a If no abnormality is found in check on cause 2, this check is not

Possible causes required.
value in normal Disconnection in wiring 2) Connect T-adapters to connectors ATC1 (female) and STR
state harness (female).
3
Between ATC1 (female) (20) and STR Resis-
contact) Max. 1 z
(female) (1) tance
Between ATC1 (female) (21) and STR Resis-
Max. 1 z
(female) (2) tance
Ground fault in wiring har- 2) Disconnect connector ATC1 or STR.
4 ness 3) Connect T-adapter to connector ATC1 or STR (female).
Min. 1 Mz
STR (female) (1) tance
2) Disconnect connector ATC1 or STR.
Hot short in wiring harness 3) Insert T-adapter into it.
Max. 4.5
Between ground and ATC1 (21) or STR (2) Voltage
V
134 HD785-7

value in normal Defective transmission
state controller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as retarder oil tem-
perature sensor).
HD785-7 135
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of

Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Transmission controller system)
• The voltage of the signal circuit of the torque converter oil temperature sensor is below 0.97 V
Contents of (above 150°C) or when transmission valve oil temperature signal voltage is below 3.7 V (above
trouble 55C°) and there is no abnormality, torque converter oil temperature sensor signal circuit voltage is
above 4.56 V (below 15°C).
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge does not indicate normally.
machine
Related
• This failure can be checked in the monitoring function (Code: 30100 (°C), 30101 (V)).
information

2) Disconnect connector T/C.T (CN22).
Defective torque converter Between Resis-
oil temperature sensor T/C.T tance
(CN22)
(male) (1) Oil temperature: 100 Resis-
3.5 – 4.0 kz
and (2) °C tance

3) Insert T-adapter (female).
Disconnection or short circuit Between Resis-
in wiring harness AT1 tance
(female)
(9) and Resis-
Oil temperature: 100 °C 3.5 – 4.0 kz
(21) tance
Possible causes a If no abnormality is found in check on cause 2, this check is not
state Disconnection in wiring har- 2) Disconnect connectors ATC1 and T/C.T (CN22).
ness 3) Connect T-adapter.
3
Between ATC1 (female) (21) and T/C.T Resis-
contact) Max. 1 z
Between ATC1 (female) (9) and T/C.T Resis-
Max. 1 z
Grounding fault in wiring har- 2) Disconnect connectors ATC1 and T/C.T (CN22).
4 ness 3) Connect T-adapter.
Min. 1 Mz
T/C.T (CN22) (female) (1) tance
2) Disconnect connector ATC1 or T/C.T (CN22).
Defective hot short in wiring 3) Insert T-adapter into it.
5 harness 4) Turn the starting switch ON.
Between ground and ATC1 (21) or T/C.T Max. 4.5
Voltage
(CN22) (female) (2) V
136 HD785-7

value in normal Defective transmission con-
state troller
be performed.)
*: For the average resistance values of sensor at each temperature level, see [DGR2KZ] (the same as retarder oil tem-
perature sensor).
HD785-7 137
HD785-7 Dump truck

Form No. SEN01943-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
138 HD785-7
SEN01944-02
DUMP TRUCK 1SHOP MANUAL
HD785-7
Machine model Serial number

HD785-7 7001 and up
40 Troubleshooting 1
Troubleshooting by failure code, Part 7
Failure code [DGT5KA] (or VHMS_LED display: "n3" o "12")
Left bank exhaust temperature sensor system (Front): Disconnection ................................................... 3
Failure code [dGT5KA] (or VHMS_LED display: "n3" o "22")
Left bank exhaust temperature sensor system (Rear): Disconnection .................................................... 6
Failure code [DGT5KB] (or VHMS_LED display: "n3" o "11")
Left bank exhaust temperature sensor system (Front): Short circuit ....................................................... 9
Failure code [dGT5KB] (or VHMS_LED display: "n3" o "21")
Left bank exhaust temperature sensor system (Rear): Short circuit...................................................... 12
Failure code [DGT6KA] (or VHMS_LED display: "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ............................................... 15
Failure code [dGT6KA] (or VHMS_LED display: "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection................................................ 18
Failure code [DGT6KB] (or VHMS_LED display: "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit................................................... 21
Failure code [dGT6KB] (or VHMS_LED display: "n3" o "25")
Right bank exhaust temperature sensor system (Rear): Short circuit ................................................... 24
HD785-7 1
Failure code [DHE5KB] or VHMS_LED display: "n3" o "32" Blow-by pressure sensor: Short circuit .......... 27
Failure code [DHE5KY] (or VHMS_LED display: "n3" o "31")
(Blow-by pressure sensor: Short circuit with power supply line)............................................................ 30
Failure code [DHP4KY] (or VHMS_LED display: "n5" o "44")
Suspension pressure sensor system: Short circuit (Right front) ............................................................ 32
Failure code [DHP4KZ] (or VHMS_LED display: "n5" o "43")
Suspension pressure sensor system: Disconnection or ground fault (Right front) ................................ 34
Suspension pressure sensor system: Short circuit (Left front) .............................................................. 36
Suspension pressure sensor system: Disconnection or ground fault (Left front)................................... 38
Failure code [DHP6KA] Suspension pressure sensor system: Disconnection (Right rear) .......................... 40
Failure code [DHP6KX] Failure in suspension pressure sensor system trouble:
Out of input signal range (Right rear)..................................................................................................... 41
Suspension pressure sensor system: Short circuit (Right rear)............................................................. 44
Suspension pressure sensor system: Disconnection or ground fault (Right rear) ................................. 46
Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)............................. 48
Failure code [DHP7KX] Failure in suspension pressure sensor system:
Out of input signal range (Left rear) ....................................................................................................... 49
Suspension pressure sensor system: Short circuit (Left rear) ............................................................... 52
Suspension pressure sensor system: Disconnection or ground fault (Left rear) ................................... 54
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range............................. 56
Failure code [DHT5L6] Torque converter oil pressure sensor:
Disagreement of run and stop condition with signal .............................................................................. 58
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range .......................... 60
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range........................... 62
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right) .................................... 64
Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left) ...................................... 66
Failure code [DJF1KA] Fuel level sensor: Disconnection ............................................................................. 72
Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)........................................... 74
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent
with swich signal .................................................................................................................................... 75
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range ............................. 78
Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal..................... 80
Failure code [DK54KX] Body positioner sensor: Out of input signal range................................................... 82
Failure code [DKD0L6] Failure in steering speed sensor.............................................................................. 84
Failure code [DKH0KX] Clinometer sensor signal out of range .................................................................... 86
Failure code [DKH1KX] (or VHMS_LED display: "n4"o"33") Abnormality in clinometer sensor .................. 88
Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection........................................... 90
Failure code [DLF1LC] Transmission input shaft speed sensor:
Disagreement of revolution speed signal............................................................................................... 92
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection............................... 94
Failure code [DLF2LC] Transmission intermediate shaft speed sensor:
Disagreement of revolution speed signal............................................................................................... 96
2 HD785-7
Failure code [DGT5KA] (or VHMS_LED display: "n3" o "12") Left bank
exhaust temperature sensor system (Front): Disconnection
Action code Failure code Left bank exhaust temperature sensor system (Front): Disconnection
Trouble
E01 DGT5KA (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
appears on • The left bank exhaust temperature cannot be monitored with the monitoring function.
machine
• The machine monitor does not display the failure code. (If the data saved in the VHMS controller
are downloaded to a personal computer, however, the failure code can be checked.)
• The LED of the VHMS controller indicates "n3" o "12".
Related • The input state (temperature) from the exhaust gas temperature sensor (FL) can be checked with
information the monitoring function (Code: 42604 EXHAUST TEMP FL).
• If failure code [DBB6KP] (VHMS controller 24 V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.

tery ground cable.
Defective left bank sen- 2) Disconnect connector HM-23A and connect the T-adapter to
sor amplifier power sup- female side.
1 ply (defective wiring 3) Connect the battery ground cable and turn the starting switch to
harness or defective ON position.
VHMS & PLM controller) a Ignore the failure code displayed
Approx.
Between HM-23A (female) (A) and (C) Voltage
24 V
a Check that failure code [dGT5KA] is not displayed.
Defective exhaust gas 1) Turn the starting switch to OFF position.
temperature sensor on 2) Swap A and C of connector HM-21, A and C of HM-22 and A and
left bank engine front C of HM-23 sequentially one by one.
side, or defective exhaust 3) Turn the starting switch to ON position and perform troubleshoot-
2 gas temperature sensor ing.
amplifier on left bank 4) Return to step 1) and conduct the test three times to locate the
engine front side, or failed portion.
Possible causes defective intermediate If failure code [DGT5KA] changed to [dGT5KA], the defective portion
and standard wiring harness. must be ahead (on the right side of the replaced connectors in the
value in normal
related circuit diagram).
state
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Between HM-23A (female) (A) and HM-CN1 Resis-
Max. 1 z
harness (female) (2) tance
3
(Disconnection or defec- Between HM-23A (female) (B) and HM-CN2A Resis-
Max. 1 z
tive contact of connector) (female) (7) tance
Between HM-23A (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23A.
3) Start engine and carry out troubleshooting.
Defective exhaust gas Exhaust gas temper-
temperature sensor HM-23A Voltage
4 ature
amplifier on the left bank
50 - 100°C 1.0 - 1.6 V
engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
HD785-7 3

If no abnormality is found in the above troubleshooting, the VHMS &
PLM controller may be defective. (Since this is an internal defect,
a Reference
2) Insert T-adapter into connector HM-CN2A
Defective VHMS & PLM 3) Start engine and carry out troubleshooting.
5
controller Exhaust gas temper-
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
value in normal 300 - 400°C 2.1 - 2.7 V
Between (7) and (12)
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Since the sensor output voltage range is mV, actual measurement
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21A Voltage
ature
Ref ture in exhaust gas tem- 50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
4 HD785-7
HD785-7 5
Failure code [dGT5KA] (or VHMS_LED display: "n3" o "22") Left bank
exhaust temperature sensor system (Rear): Disconnection 1
Action code Failure code Left bank exhaust temperature sensor system (Rear): Disconnection
Trouble
E01 dGT5KA (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RL) can be checked with
information the monitoring function (Code: 42606 EXHAUST TEMP RL).

tery ground cable.
Defective left bank sen- 2) Disconnect connector HM-23A and connect the T-adapter to
Approx.
Between HM-23C (female) (A) and (C) Voltage
24 V
a Check that failure code [DGT5KA] is not displayed.
temperature sensor on 2) Swap A and C of connector HM-21, A and C of HM-22 and A and
left bank engine rear C of HM-23 sequentially one by one.
engine rear side, or failed portion.
Possible causes defective intermediate If failure code [dGT5KA] changed to [DGT5KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23C (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23C (female) (B) and HM- Resis-
Max. 1 z
tive contact of connector) CN2A (female) (16) tance
Between HM-23C (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23C.
temperature sensor HM-23C Voltage
4 ature
amplifier on the engine
50 - 100°C 1.0 - 1.6 V
rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
6 HD785-7

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
value in normal Between (16) and 300 - 400°C 2.1 - 2.7 V
state (12) 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21C Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 7
8 HD785-7
Failure code [DGT5KB] (or VHMS_LED display: "n3" o "11") Left bank
exhaust temperature sensor system (Front): Short circuit 1
Action code Failure code Left bank exhaust temperature sensor system (Front): Short circuit
Trouble
— DGT5KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

temperature sensor on 2) Disconnect connector HM-21A, HM-22A and HM-23A sequen-
left bank engine front tially one by one.
defective intermediate If failure code [DGT5KB] changed to [DGT5KA], the defective por-
wiring harness. tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connector HM-23A, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23A (female).
2
and standard ness
Resis-
value in normal HM-23A (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23A.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23A
3 ness (female).
(Contact with 24 V circuit) 4) Start engine and carry out troubleshooting.
Between HM-23A (female) (B) or HM-CN2A
Voltage Max. 1 V
(7) and chassis ground
2) Disconnect connectors HM-23A, HM-22A, HM-CN2A.
Grounding fault in wiring 3) Connect T-adapter to anyone (female).
harness
4 Between HM-23A(female) (B) or HM-CN2A Resis-
(Contact with ground cir- Min. 1 Mz
(female) (7) and chassis ground tance
cuit)
Between HM-22A (female) (1) or (2) and Resis-
Min. 1 Mz
HD785-7 9

2) Insert T-adapter into HM-23A
temperature sensor HM-23A Voltage
5 ature
Between (A) and (C) Always 20 - 30 V
engine front side
50 - 100°C 1.0 - 1.6 V
Between (B) and (C) 300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
a Reference
and standard 2) Insert T-adapter into connector HM-CN2A
value in normal Defective VHMS & PLM 3) Start engine and carry out troubleshooting.
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21A Voltage
ature
Ref ture in exhaust gas tem-
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
10 HD785-7
HD785-7 11
Failure code [dGT5KB] (or VHMS_LED display: "n3" o "21") Left bank
exhaust temperature sensor system (Rear): Short circuit 1
Action code Failure code Left bank exhaust temperature sensor system (Rear): Short circuit
Trouble
— dGT5KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

temperature sensor on 2) Disconnect connector HM-21C, HM-22C and HM-23C sequen-
left bank engine rear tially one by one.
defective intermediate If failure code [dGT5KB] changed to [dGT5KA], the defective portion
wiring harness. must be ahead (on the right side of the disconnected connector in
the related circuit diagram).
2) Disconnect connector HM-23C, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23C (female).
2
and standard ness
Resis-
value in normal HM-23C (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23C.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23C
3 ness (female).
Between HM-23C (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23C, HM-22C, HM-CN2A.
harness
4 Between HM-23C(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22C (female) (1) or (2) and Resis-
Min. 1 Mz
12 HD785-7

2) Insert T-adapter into HM-23C
temperature sensor HM-23C Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
Between (16) and 300 - 400°C 2.1 - 2.7 V
(12) 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21C Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 13
14 HD785-7
Failure code [DGT6KA] (or VHMS_LED display: "n3" o "24") Right bank
exhaust temperature sensor system (Front): Disconnection 1
Action code Failure code Right bank exhaust temperature sensor system (Front): Disconnec-
Trouble
— DGT6KA tion (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
appears on • The right bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (FR) can be checked with
information the monitoring function (Code: 42602 EXHAUST TEMP FR).

tery ground cable.
Defective right bank sen- 2) Disconnect connector HM-23B and connect the T-adapter to
Approx.
Between HM-23B (female) (A) and (C) Voltage
24 V
temperature sensor on 2) Swap B and D of connector HM-21, B and D of HM-22 and B and
right bank engine front D of HM-23 sequentially one by one.
amplifier on right bank 4) Return to step 1) and conduct the test three times to locate the
Possible causes defective intermediate If failure code [DGT6KA] changed to [dGT6KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23B (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23B (female) (B) and HM-CN2A Resis-
Max. 1 z
tive contact of connector) (female) (5) tance
Between HM-23B (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23B.
temperature sensor HM-23B Voltage
4 ature
amplifier on the right
50 - 100°C 1.0 - 1.6 V
bank engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
HD785-7 15

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21B Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
16 HD785-7
HD785-7 17
Failure code [dGT6KA] (or VHMS_LED display: "n3" o "26") Right bank
exhaust temperature sensor system (Rear): Disconnection 1
Action code Failure code Right bank exhaust temperature sensor system (Rear): Disconnec-
Trouble
— dGT6KA tion (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RR) can be checked with
information the monitoring function (Code: 42601 EXHAUST TEMP RR).

tery ground cable.
Defective right bank sen- 2) Disconnect connector HM-23D and connect the T-adapter to
Approx.
Between HM-23D (female) (A) and (C) Voltage
24 V
temperature sensor on 2) Swap B and D of connector HM-21, B and D of HM-22 and B and
right bank engine rear D of HM-23 sequentially one by one.
Possible causes defective intermediate If failure code [dGT6KA] changed to [DGT6KA], the defective portion
value in normal
state
Disconnection in wiring Between HM-23D (female) (A) and HM-CN1 Resis-
Max. 1 z
3
(Disconnection or defec- Between HM-23D (female) (B) and HM- Resis-
Max. 1 z
tive contact of connector) CN2A (female) (6) tance
Between HM-23D (female) (C) and HM- Resis-
Max. 1 z
2) Insert T-adapter into HM-23D.
temperature sensor HM-23D Voltage
4 ature
50 - 100°C 1.0 - 1.6 V
bank engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
18 HD785-7

a Reference
5
HM-CN2A Voltage
ature
Possible causes
50 - 100°C 1.0 - 1.6 V
and standard
state 500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21D Voltage
ature
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 19
20 HD785-7
Failure code [DGT6KB] (or VHMS_LED display: "n3" o "23") Right bank
exhaust temperature sensor system (Front): Short circuit 1
Action code Failure code Right bank exhaust temperature sensor system (Front): Short circuit
Trouble
— DGT6KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (FR) can be checked with
information the monitoring function (Code: 42602 EXHAUST TEMP FR).

temperature sensor on 2) Disconnect connector HM-21B, HM-22B and HM-23B sequen-
right bank engine front tially one by one.
defective intermediate If failure code [DGT6KB] changed to [DGT6KA], the defective por-
wiring harness. tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connector HM-23B, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23B (female).
2
and standard ness
Resis-
value in normal HM-23B (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23B.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23B
3 ness (female).
Between HM-23B (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23B, HM-22B, HM-CN2A.
harness
4 Between HM-23B(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22B (female) (1) or (2) and Resis-
Min. 1 Mz
HD785-7 21

2) Insert T-adapter into HM-23B
temperature sensor HM-23B Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
bank engine front side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21B Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
22 HD785-7
HD785-7 23
Failure code [dGT6KB] (or VHMS_LED display: "n3" o "25") Right bank
exhaust temperature sensor system (Rear): Short circuit 1
Action code Failure code Right bank exhaust temperature sensor system (Rear): Short circuit
Trouble
— dGT6KB (VHMS controller system) (Display: PLM)
Contents of
• The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (RR) can be checked with
information the monitoring function (Code: 42601 EXHAUST TEMP RR).

temperature sensor on 2) Disconnect connector HM-21D, HM-22D and HM-23D sequen-
right bank engine rear tially one by one.
defective intermediate If failure code [dGT6KB] changed to [dGT6KA], the defective portion
wiring harness. must be ahead (on the right side of the disconnected connector in
the related circuit diagram).
2) Disconnect connector HM-23D, HM-CN1 and HM-CN2A and con-
Possible causes Short circuit in wiring har- nect T-adapter to HM-23D (female).
2
and standard ness
Resis-
value in normal HM-23D (female) between (A) and (B) Min. 1 Mz
tance
state
2) Disconnect connector HM-23D.
Hot short in wiring har- 3) Insert T-adapter into HM-CN2A or connect T-adapter to HM-23D
3 ness (female).
Between HM-23D (female) (B) or HM-CN2A
Voltage Max. 1 V
2) Disconnect connectors HM-23D, HM-22D, HM-CN2A.
harness
4 Between HM-23D(female) (B) or HM-CN2A Resis-
cuit)
Between HM-22D (female) (1) or (2) and Resis-
Min. 1 Mz
24 HD785-7

2) Insert T-adapter into HM-23D
temperature sensor HM-23D Voltage
5 ature
50 - 100°C 1.0 - 1.6 V
bank engine rear side
300 - 400°C 2.1 - 2.7 V
Between (B) and (C)
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
a Reference
state 6
HM-CN2A Voltage
ature
50 - 100°C 1.0 - 1.6 V
300 - 400°C 2.1 - 2.7 V
500 - 600°C 2.9 - 3.6 V
700 - 800°C 3.8 - 4.4 V
is unavailable.
Exhaust gas temper-
Caracteristic of tempera- HM-21D Voltage
ature
50 - 100°C 1.0 - 35 mV
perature sensor
300 - 400°C 11.2 - 15.6 mV
Between (1) and (2)
500 - 600°C 19.7 - 24.2 mV
700 - 800°C 28.1 - 32.6 mV
HD785-7 25
26 HD785-7
Failure code [DHE5KB] or VHMS_LED display: "n3" o "32" Blow-by

pressure sensor: Short circuit 1
Action code Failure code Blow-by pressure sensor: Short circuit
Trouble
– DHE5KB (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 0.1 V or less.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
• The LED of the VHMS controller displays "n3" o "32".
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-
• Method of reproducing failure code: Start engine and performs troubleshooting

2) Disconnect connectors HM-CN1, HM12, and HM-CN2A, and
Ground fault in wiring har- connect T-adapters to either female side.
1 ness Between ground and HM-CN1 (female) (4), Resis-
Min. 1 Mz
(Contact with ground circuit) (5), or HM12 (female) (B) tance
Between ground and HM-CN2A (female) Resis-
Min. 1 Mz
(18), or HM12 (female) (C) tance
2) Disconnect connector HM12 and connect the T-adapter to
female side.
Defective sensor power sup- 3) Turn the starting switch to ON position.
Possible causes 2
ply system a If the power supply voltage is abnormal, go to cause 4.
and standard
value in normal 4.85 -
Between HM 12 (female) (B) and (A) Voltage
state 5.15 V
2) Insert the T-adapter into connector HM12.
3) Turn the starting switch to ON position, start the engine and then
perform troubleshooting.
Defective blowby pressure Between HM 12 (C) Sensor output Voltage 0.5 - 4.5 V
3 sensor and (A) At high idle Voltage 0.5 - 0.9 V
(Internal short circuit) 1) Turn the starting switch to OFF position.
2) Disconnect connector HM12 and connect the T-adapter to male
side.
Between ground and HM 12 (male) (A), (B), Resis-
Min. 1 Mz
(C) tance
HD785-7 27

2) Disconnect connectors HM-CN1, HM12, and HM-CN2A, and
connect T-adapters to each female side.
a If the power supply voltage in cause 2 is
normal, this check is not required. Resis-
Between HM-CN2A (female) (12) and HM12 tance
ness (female) (A)
4
contact of connector) a If the power supply voltage in cause 2 is
normal, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (4), (5) and tance
HM12 (female) (B)
Possible causes
and standard Between HM-CN2A (female) (18) and Resis-
Max. 1 z
value in normal HM12(female) (C) tance
state If no abnormality is found in the above troubleshooting, the VHMS
& PLM controller may be defective. (Since this is an internal defect,
a Reference
Defective VHMS & PLM con- 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2A.
5 3) Turn the starting switch to ON position, start the engine and then
troller
4.85 -
Between HM-CN1 (4) and HM-CN2A (12) Voltage
5.15 V
Between HM-CN2A Anytime Voltage 0.5 - 4.5 V
(18) and (12) At high idle Voltage 0.5 - 0.9 V
28 HD785-7
HD785-7 29
Failure code [DHE5KY] or VHMS_LED display: "n3" o "31" Blow-by

pressure sensor: Short circuit with power supply line 1
Action code Failure code Blow-by pressure sensor: Short circuit with power supply line
Trouble
― DHE5KY (VHMS controller system) (Display: PLM)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 4.7 V and above.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-
• Method of reproducing failure code: Start engine and performs troubleshooting

2) Disconnect connector HM12 and connect the T-adapter to
female side.
Hot short in wiring harness 3) Turn the starting switch to ON position.
1
Between HM 12 (female) (C) and (A) Voltage Max. 1 V
4.85 -
Between HM 12 (female) (B) and (A) Voltage
5.15 V
2) Disconnect connector HM12.
Defective blowby pressure 3) Turn the starting switch to ON position.
2 sensor
Possible causes (Internal short circuit) If the failure code changes from [DHE5KY] to [DHE5KB] (if LED
and standard display of VHMS controller changes from "31" to "32"), blowby
value in normal pressure sensor is defective.
state If no abnormality is found in the above troubleshooting, the VHMS
a Reference
Defective VHMS & PLM con- 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2A.
3 3) Turn the starting switch to ON position, start the engine and then
troller
4.85 -
Between HM-CN1 (4) and HM-CN2A (12) Voltage
5.15 V
Between HM-CN2A Anytime Voltage 0.5 - 4.5 V
(18) and (12) At high idle Voltage 0.5 - 0.9 V
30 HD785-7
HD785-7 31
Failure code [DHP4KY] or VHMS_LED display: "n5" o "44" Short circuit

in suspension pressure sensor system (Front right) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front right)
Trouble
E01 DHP4KY (VHMS controller system) (Display: PLM)
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front right).
trouble
Action of
• None in particular
controller
Problem that
appears on • PLM may not be displayed normally.
machine
Related
information • Suspension pressure can be checked with the monitoring function (Code: 32804 (MPa) and 32810
(V)).

2) Disconnect connector SUFR.
3) Connect T-adapter to SUFR (female) or insert T-adapter into
HM-CN2B.
Hot short in wiring harness 4) Turn the starting switch ON.
1
(Contact with 24 V circuit) a Ignore the failure code displayed
Between wiring harness HM-
CN2B (1) or SUFR (female) (C) Voltage Max. 1 V
and ground
Defective sensor power sup- 4) Turn the starting switch ON.
2 a Ignore the failure code displayed
ply
Possible causes Power
and standard Between SUFR (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
Defective suspension pres- 3) Turn the starting switch to ON position.
3
sure sensor (FR)
If failure code changes from [DHP4KY] to[DHP4KZ], suspension
pressure sensor(FR) is defective.
If no abnormality is found in the above troubleshooting, the VHMS
a Reference
Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
4 2) Insert the T-adapter into connectors HM-CN1 and HM-CN2B.
troller
3) Turn the starting switch to ON position.
Approx.
Between HM-CN1 (2) and HM-CN2B (9) Voltage
24 V
Between HM-CN2B (1) and (9) Voltage 1.0 - 5 V
32 HD785-7
HD785-7 33
Failure code [DHP4KZ] or VHMS_LED display: "n5" o "43" Disconnec-

tion or ground fault in suspension pressure sensor system(Front right)1
Action code Failure code Disconnection or ground fault in suspension pressure sensor sys-
Trouble tem (Front right)
E01 DHP4KZ (VHMS controller system) (Display: PLM)
Contents of • No signal received from the suspension pressure sensor (front right) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Ground fault in wiring har- 3) Connect T-adapter to HM-CN1 and HM-CN2B (female).
1 ness Between HM-CN2B (female) (1) or SUFR Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (C) and ground tance
Between HM-CN1 (female) (2) or SUFR Resis-
Min. 1 Mz
(female) (B) and ground tance
ply
Power
Between SUFR (female) (B) and
supply Approx. 24 V
Possible causes (A)
Voltage
and standard
value in normal 1) Turn the starting switch to OFF.
state Defective suspension pres- 2) Insert T-adapter into connector SUFR.
3 3) Turn the starting switch to ON position.
sure sensor (FR)
Between SUFR (C) and (A) Voltage 1.0 - 5 V
2) Disconnect connector SUFR, HM-CN1 and HM-CN2B.
Between HM-CN2B (female) (1) and SUFR Resis-
Max. 1 z
(female) (C) tance
Disconnection in wiring har-
ness a If no abnormality is found in checks on
4 cause 2, this check is not required. Resis-
contact of connector) Between HM-CN2B (female) (9) and SUFR tance
(female) (A)
a If no abnormality is found in checks on
cause 2, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (2) and SUFR tance
(female) (B)
34 HD785-7

Possible causes
a Reference
and standard
value in normal Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
state trollers
Between HM-CN1 (2) and HM-
Voltage Approx. 24 V
CN2B (9)
HD785-7 35
Failure code [DHP5KY] or VHMS_LED display: "n5" o "54" Short circuit

in suspension pressure sensor system (Front left) 1
Action code Failure code Short circuit in suspension pressure sensor system (Front left)
Trouble
Contents of
• Abnormal current flows to the signal circuit from the suspension pressure sensor (front left).
trouble
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFL.
3) Connect T-adapter to SUFL (female) or insert T-adapter into
Hot short in wiring harness HM-CN2B.
a Ignore the failure code displayed
Between wiring harness HM-CN2B (2) or
Voltage Max. 1 V
SUFL (female) (C) and ground
ply
Between SUFL (female) (B) and
and standard supply Approx. 24 V
(A)
value in normal Voltage
state 1) Turn the starting switch to OFF position.
3
sure sensor (FL)
pressure sensor(FL) is defective.
a Reference
Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
troller
CN2B (9)
36 HD785-7
HD785-7 37
Failure code [DHP5KZ] or VHMS_LED display: "n5" o "53" Disconnec-

tion or ground fault in suspension pressure sensor system(Front left) 1
Action code Failure code Disconnection or ground fault in suspension pressure sensor sys-
Trouble tem (Front left)
Contents of • No signal received from the suspension pressure sensor (front left) or the sensor signal system is
trouble grounded fault (shorted).
Action of
controller
Problem that
machine
Related
(V)).

2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Ground fault in wiring har- 3) Connect T-adapter to HM-CN1 and HM-CN2B (female).
1 ness Between HM-CN2B (female) (2) or SUFL Resis-
Min. 1 Mz
Between HM-CN1 (female) (2) or SUFL Resis-
Min. 1 Mz
3) Connect T-adapter.(female)
ply
Power
Between SUFL (female) (B) and
supply Approx. 24 V
Possible causes (A)
Voltage
and standard
value in normal 1) Turn the starting switch to OFF.
state Defective suspension pres- 2) Insert T-adapter into connector SUFL.
3 3) Turn the starting switch to ON position.
sure sensor (FL)
Between SUFL (C) and (A) Voltage 1.0 - 5 V
2) Disconnect connector SUFL, HM-CN1 and HM-CN2B.
Between HM-CN2B (female) (1) and SUFL Resis-
Max. 1 z
(female) (C) tance
ness a If no abnormality is found in checks on
4 cause 2, this check is not required. Resis-
contact of connector) Between HM-CN2B (female) (9) and SUFL tance
(female) (A)
a If no abnormality is found in checks on
cause 2, this check is not required. Resis-
Max. 1 z
Between HM-CN1 (female) (2) and SUFL tance
(female) (B)
38 HD785-7

Possible causes
a Reference
and standard
value in normal Defective VHMS & PLM con- 1) Turn the starting switch to OFF position.
state trollers
CN2B (9)
HD785-7 39
Failure code [DHP6KA] Suspension pressure sensor system:

Disconnection (Right rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection rear right
Trouble
E01 DHP6KA (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
appears on • There is no great influence of machine.
machine
• The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32816 (MPa), 32817 (V)).
information
• This failure occurs only when the built-in PLM function is installed.

and standard
value in normal Carry out troubleshooting for failure code [DH6KX].
state
40 HD785-7
Failure code [DHP6KX] Failure in suspension pressure sensor system

trouble: Out of input signal range (Right rear) 1
Action code Failure code Failure in suspension pressure sensor system trouble: Out of input
Trouble signal range (Right rear)
E03 DHP6KX (Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (Right rear) is below 1.0 V or
trouble above 4.7 V.
Action of • Does not operate auto suspension.
controller • Dose not operate ARSC.
Problem that
machine
Related • The suspension pressure sensor (Right rear) input signal can be checked with the monitoring func-
information tion (Code: 32816 (MPa), 32817 (V)).

2) Disconnect connectors BRC1, SURR, PM6.
Grounding fault in wiring 3) Connect T-adapter to BRC1 or SURR (female).
1 harness Between BRC1 (female) (7) or SURR Resis-
Min. 1 Mz
Between ground and BRC1 (female) (21) or Resis-
Min. 1 Mz
SURR (female) (A) tance
2) Disconnect connector SURR.
3) Connect T-adapter to SURR (female) or insert T-adapter into
Hot short in wiring harness BRC1.
2
Possible causes (Contact with 24V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and BRC1 (female) (7) or
Voltage Max. 1 V
state SURR (female) (C)
2) Disconnect connector SURR and connect T-adapter to it
(female)
Defective sensor power sup- 3) Turn starting switch ON.
3
plly
Power
Between SURR (female) (B) and
supply 18 ± 3 V
(A)
Voltage
Defective suspension 3) Insert T-adapter.
4
pressure sensor (Right rear) 4) Turn starting switch ON.
Between SURR (C) and (A) Voltage 1.0 – 5 V
HD785-7 41

2) Disconnect connectors BRC1, SURR, and PM6.
3) Connect T-adapter.(female)
Between BRC1 (female) (7) and SURR Resis-
Max. 1 z
(female) (C) tance
Disconnection in wiring
harness a If the power supply voltage is normal,
5 this check is not required. Resis-
contact) Between BRC1 (female) (21) and SURR tance
(female) (A)
a If the power supply voltage is normal,
this check is not required. Resis-
Between PM6 (female) (2) and SURR tance
and standard (female) (B)
value in normal
2) Disconnect connector PM6 and connect the T-adapter to male
6 Defective PLM controller side.
Between PM 6 (2) and (3) Voltage 18 ± 3 V
If no abnormality is found in the above troubleshooting, the retarder
controller may be defective. (Since this is an internal defect, trou-
a Reference
2) Insert the T-adapter into connector BRC1.
Between BRC1 (7) and (21) Voltage 1.0 – 5 V
42 HD785-7
HD785-7 43
Failure code [DHP6KY] or VHMS_LED display: "n5" o "64" Suspension

pressure sensor system: Short circuit (Right rear) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Right rear)
Trouble
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor (right rear).
trouble
Action of
• Stops auto-suspension function.
controller
Problem that
appears on • Auto-suspension function does not operate.
machine
information • Suspension pressure can be checked with monitoring function (Code: 32806 (MPa), 32812 (V)).

3) Connect T-adapter to SURR (female) or insert HM-CN2B.
Hot short in wiring harness 4) Turn starting switch ON.
1
(Contact with 24V circuit) a Ignore the failure code displayed
Between ground and HM-CN2B (7) or
Voltage Max. 1 V
SURR (female) (C)
3) Connect T-adapter to it (female)
plly
and standard Between SURR (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
3
sure sensor (RR)
pressure sensor(RR) is defective.
Defective VHMS & PLM con- a Reference
4
troller 1) Turn the starting switch to OFF position.
2) Insert the T-adapter into connector HM-CN2B.
Between HM-CN2B (7) and (9) Voltage 1.0 – 5 V
44 HD785-7
HD785-7 45
Failure code [DHP6KZ] or VHMS_LED display: "n5" o "63" Suspension

pressure sensor system: Disconnection or ground fault (Right rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Right rear)
Contents of
• Signal is not sent from suspension pressure sensor (right rear) or it is grounded.
trouble
Action of
controller
Problem that
machine

2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
3) Connect T-adapter to HM-CN1(female), HM-2B (female) or
Grounding fault in wiring har- SURR (female).
1 ness
Between HM-CN2B (female) (7) or SURR Resis-
(Contact with ground circuit) Min. 1 Mz
(female) (C) and ground tance
Between ground and HM-CN1 (female) (2) Resis-
Min. 1 Mz
or SURR (female) (B) tance
3) Connect T-adapter to it (female).
Defective sensor power sup- 4) Turn starting switch ON
2
plly
Power
Between SURR (female) (B)
supply Approx. 24 V
and (A)
Voltage
Possible causes 2) Disconnect connector SURR.
and standard 3
value in normal
state Between SURR (C) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC1, SURR, HM-CN1 and HM-CN2B.
3) Connect T-adapters to them (female).
Disconnection in wiring har- Between HM-CN2B(female) (7) and SURR Resis-
ness Max. 1 z
4 (female) (C) tance
contact of connector) Between HM-CN2B (female) (9) and SURR Resis-
Max. 1 z
(female) (A) tance
Between HM-CN1 (female) (2) and SURR Resis-
Max. 1 z
(female) (B) tance
5
trollers 1) Turn the starting switch to OFF position.
46 HD785-7
HD785-7 47
Failure code [DHP7KA] Suspension pressure sensor system:

Disconnection (Left rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection (Left rear)
Trouble
E01 DHP7KA (Retarder controller system)
Contents of
• The voltage of the signal circuit of the suspension pressure sensor (Left rear) is below 0.3 V.
trouble
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

and standard
value in normal Carry out troubleshooting for failure code [DHP7KX].
state
48 HD785-7
Failure code [DHP7KX] Failure in suspension pressure sensor system

trouble: Out of input signal range (Left rear) 1
Action code Failure code Failure in suspension pressure sensor system trouble (Left rear):
Out of input signal range
Trouble
E03 DHP7KX (When ARSC is not set or ARSC system switch is "ON")
(Retarder controller system)
Contents of • The voltage of the signal circuit of the suspension pressure sensor (left) is below1.0 V or above 4.6
trouble V.
Action of
• Does not operate auto suspenshion.
controller
Problem that
machine
• The suspension pressure sensor (Left rear) input signal can be checked with the monitoring func-
Related
tion (Code: 32814 (MPa), 32815 (V)).
information

2) Disconnect connectors BRC1, SURL, and PM6.
Grounding fault in wiring 3) Connect T-adapter.
1 harness Between ground and BRC1 (female) (1) or Resis-
Min. 1 Mz
(Contact with ground circuit) SURL (female) (C) tance
Between ground and PM6 (female) (2) or Resis-
Min. 1 Mz
SURL (female) (B) tance
2) Disconnect connector SURL.
3) Connect T-adapter to connector SURL (female) or insert T-
Hot short in wiring harness adapter into BRC1
2
Possible causes (Contact with 24V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and BRC1 (1) or SURL
Voltage Max. 1 V
state (female) (C)
2) Disconnect connector SURL and connect T-adapter to it
(female)
3
ply
Power
Between SURL(female) (B) and
supply 18 ± 3 V
(A)
Voltage
4
pressure sensor (Left rear) 4) Turn starting switch ON.
Between SURL (C) and (A) Voltage 1.0 – 5 V
HD785-7 49

2) Disconnect connectors BRC1, SURL, and PM6.
3) Connect T-adapters (female).
Between BRC1 (female) (1) and SURL Resis-
Max. 1 z
(female) (C) tance
harness a If the power supply voltage is normal,
5 this check is not required. Resis-
contact) Between BRC1 (female) (21) and SURL tance
(female) (A)
Between PM6 (female) (2) and SURL tance
and standard (female) (B)
value in normal
2) Disconnect connector PM6 and connect the T-adapter to male
6 Defective PLM controller side.
Between PM 6 (male) (2) and (3) Voltage 18 ± 3 V
If no abnormality is found in the above troubleshooting, the retarder
a Reference
2) Insert the T-adapter into connector BRC1.
Between BRC1 (1) and (3) Voltage 1.0 – 5 V
50 HD785-7
HD785-7 51
Failure code [DHP7KY] or VHMS_LED display: "n5" o "74" Suspension

pressure sensor system: Short circuit (Left rear) 1
Action code Failure code Suspension pressure sensor system: Short circuit (Left rear)
Trouble
Contents of
• Abnormal current is flowing in signal circuit coming from suspension pressure sensor.
trouble
Action of
controller
Problem that
machine

3) Connect T-adapter to SURL (female) or insert HM-CN2B.
Hot short in wiring harness 4) Turn starting switch ON.
1
Between ground and HM-CN2B (8) or
Voltage Max. 1 V
SURL (female) (C)
3) Connect T-adapter to it (female)
plly
and standard Between SURL (female) (B) and
supply Approx. 24 V
value in normal (A)
Voltage
state
3
sure sensor (RL)
pressure sensor(RL) is defective.
4
troller 1) Turn the starting switch to OFF position.
Between HM-CN2B (8) and (9) Voltage 1.0 – 5 V
52 HD785-7
HD785-7 53
Failure code [DHP7KZ] or VHMS_LED display: "n5" o "73" Suspension

pressure sensor system: Disconnection or ground fault (Left rear) 1
Action code Failure code Suspension pressure sensor system: Disconnection or ground
Trouble fault (Left rear)
Contents of
• Signal is not sent from suspension pressure sensor or it is grounded (Abnormal).
trouble
Action of
controller
Problem that
machine

2) Disconnect connectors BRC1, SURL, HM-CN1 and HM-CN2B.
3) Connect T-adapter to HM-CN1(female), HM-2B (female) or
Grounding fault in wiring har- SURL (female).
1 ness
Between HM-CN2B (female) (8) or SURL Resis-
Between ground and HM-CN1 (female) (2) or Resis-
Min. 1 Mz
SURL (female) (B) tance
Defective sensor power sup- 3) Connect T-adapter to it (female).
plly
Between SURL (female) (B) and Power sup-
Approx. 24 V
(A) ply Voltage
Possible causes
value in normal 2) Disconnect connector SURL.
state 3
Between SURL (C) and (A) Voltage 1.0 – 4.6 V

2) Disconnect connectors BRC1, SURL, HM-CN1 and HM-CN2B.
3) Connect T-adapters to them (female)
Wiring harness between HM-CN2B(female) Resis-
Max. 1 z
(8) and SURL (female) (C) tance
ness a If the power supply voltage is normal, this
4 check is not required. Resis-
contact of connector) Wiring harness between HM-CN2B (female) tance
(9) and SURL (female) (A)
a If the power supply voltage is normal, this
check is not required. Resis-
Max. 1 z
Wiring harness between HM-CN1 (female) tance
(2) and SURL (female) (B)
54 HD785-7

5
trollers 1) Turn the starting switch to OFF position.
HD785-7 55
Failure code [DHT5KX] Torque converter oil pressure sensor: Out of

Action code Failure code Torque converter oil pressure sensor: Out of input signal range
Trouble
E01 DHT5KX (Transmission controller system)
Contents of • The voltage of the signal circuit of the torque converter oil pressure sensor is below 0.5 V or above
trouble 4.5 V.
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure in
controller itself.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32600 (MPa), 32605 (V)).
information

2) Disconnect connectors ATC1, ATC3 and T/C.P(CN21).
Ground fault in wiring 3) Connect T-adapter.
1 harness Between ground and ATC3A (female) (8) or T/ Resis-
Min. 1 Mz
(Contact with ground circuit) C.P(CN21) (female) (B) tance
Between ground and ATC1 (female) (1) or T/ Resis-
Min. 1 Mz
C.P(CN21) (female) (C) tance
2) Disconnect connector T/C.P(CN21).
3) Insert T-adapter into ATC1 or connect T-adapter to T/C.P(CN21)
Defective hot short in wiring (female)
Possible causes (Contact with 24V circuit)
and standard Between ground and ATC1 (1) or
value in normal between T/C.P(CN21) (female) Voltage Min. 1 V
state (C) and ground
2) Disconnect connector T/C.P(CN21) and connect T-adapter
(female).
3 a If the power supply voltage is abnormal, go to cause 5.
ply
Power
Between T/C.P(CN21) (female)
supply 20 – 30 V
(B) and (A)
Voltage
Defective torque converter 3) Insert T-adapter.
4
oil pressure sensor 4) Turn the starting switch ON.
Between T/C.P(CN21) (C) and (A) Voltage 0.8 – 2.0 V
56 HD785-7

2) Disconnect connectors ATC1, ATC3, and CN21.
3) Connect T-adapters (female)
a If no failure is found by check on cause 3,
Disconnection in wiring Max. 1 z
Between ATC3(female) (8) and T/C.P(CN21) tance
harness (female) (B)
5
contact) a If no failure is found by check on cause 3,
Between ATC1(female) (21) and T/C.P(CN21) tance
and standard (female) (A)
value in normal
Between ATC1 (female) (1) and T/C.P(CN21) Resis-
state Max. 1 z
(female) (C) tance
mission controller may be defective. (Since this is an internal
a Reference
Defective transmission con- 1) Turn the starting switch to OFF position.
6
troller 2) Insert the T-adapter into connectors ATC1 and ATC3.
Between ATC1 (1) and (21) Voltage 20 – 30 V
Between ATC3 (8) and ATC1 (21) Voltage 0.8 – 2.0 V
HD785-7 57
Failure code [DHT5L6] Torque converter oil pressure sensor:

Disagreement of run and stop condition with signal 1
Action code Failure code Torque converter oil pressure sensor: Disagreement of run and
Trouble stop condition with signal
E01 DHT5L6 (Transmission controller system)
• While the engine is stopped, the transmission controller detects oil pressure via output voltage from
Contents of
torque converter oil pressure sensor. (Output voltage of torque converter oil pressure sensor does
trouble
not decrease after engine is stopped.)
Action of • The controller controls the machine, fixing the torque converter oil pressure to the set pressure init-
controller self.
Problem that
appears on • Large shocks are made when the lockup system is operated.
machine
Related
• This failure can be checked in the monitoring function (Code: 32601 (MPa), 32602 (V)).
information

3) Insert T-adapter into connector ATC1 or connect T/C.P(CN21)
Defective hot short in wiring (female).
Between ATC1 (1) or T/C.P(CN21) (female)
Voltage Max. 1.2 V
(C) and ground
2) Disconnect connector T/C.P (CN21).
Possible causes Defective torque converter a Ignore failure code [DHT5KX]
and standard 2
oil pressure sensor If failure code [DHT5L6] disappears, torque converter oil pressure
value in normal
sensor is defective.
state
a If failure code [DHT5L6] is displayed, the wiring harness or the
transmission controller is defective.
a Reference
3 2) Insert the T-adapter into connectors ATC1 and ATC3.
troller
Between ATC3 (8) and ATC1
Voltage 20 – 30 V
(21)
Between ATC1 (1) and (21) Voltage 0.8 – 2.0 V
58 HD785-7
HD785-7 59
Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of

Action code Failure code Front accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU2KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35500 (MPa), and
Related 35504 (V)).
information • When only rear accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Disconnect connector ACCF and ATC1.
3) Connect T-adapter to connectors ATC1 (female) and ACCF
Ground fault in wiring har- (female).
1 ness
ACCF (female) (C) tance
Min. 1 Mz
ACCF (female) (B) tance
2) Disconnect connector ACCF.
3) Connect to connector ACCF (female) or insert T-adapter into
Hot short in wiring harness ATC1.
Possible causes 2
(Contact with 24 V circuit) 4) Turn starting switch ON.
and standard
value in normal Between ground and ATC1 (13) or ACCF
state Voltage Max. 1 V
(C) (female)
2) Disconnect connector ACCF.
3) Connect T-adapter to connector ACCF (female).
Defective sensor power sup- 4) Carry out troubleshooting while starting switch is ON.
3 a If the power supply voltage is abnormal, to to cause 5.
ply
Power
Between ACCF (female) (B) and (A) supply 4.6 – 5.4 V
Voltage
Defective front accumulator 2) Insert T-adapter into connector ACCF.
4 3) Carry out troubleshooting while starting switch is ON.
oil pressure sensor
Between ACCF (C) and (A) Voltage 0.3 – 4.7 V
60 HD785-7

2) Connect T-adapter to connectors ATC1 (female) and ACCF
(female).
Between ATC1 (female) (13) and ACCF Resis-
Max. 1 z
(female) (C) tance
harness a If no failure is found by check on cause
5 3, this check is not required. Resis-
(Disconnection or Max. 1 z
defective contact) Between ATC1 (female) (21) and ACCF tance
(female) (A)
Possible causes a If no failure is found by check on cause
and standard
3, this check is not required. Resis-
value in normal Max. 1 z
Between ATC1 (female) (22) and ACCF tance
state
(female) (B)
a Reference
6
troller 2) Insert the T-adapter into connector ATC1.
HD785-7 61
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of

Action code Failure code Rear accumulator oil pressure sensor: Out of input signal range
Trouble
E01 DHU3KX (Transmission controller system)
Contents of • Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5
trouble V.
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• Signal from oil pressure sensor can be checked with monitoring function (codes: 35501 (MPa),
Related and 35505 (V)).
information • When only front accumulator oil pressure sensor is has trouble, this error code may be displayed,
too.

2) Connect T-adapter to connectors ATC1 (female) and ACCR
Ground fault in wring har- (female).
1 ness Between ground and ATC1 (female) (7) or Resis-
Min. 1 Mz
(Contact with ground circuit) ACCR (female) (C) tance
Min. 1 Mz
ACCR (female) (B) tance
2) Connect T-adapter to connector ACCR (female) or insert T-
Hot short in wiring harness adapter into ATC1.
(a contact with 24V circuit)
Between ground and ATC1 (7) or ACCR
Voltage Max. 1 V
(C) (female)
2) Connect T-adapter to connector ACCR (female).
3) Carry out troubleshooting while starting switch is ON.
Defective sensor power sup- a If the power supply voltage is abnormal, go to cause 5.
Possible causes 3
ply
and standard Power
value in normal Between ACCR (female) (B) and (A) supply 4.6 – 5.4 V
state Voltage
Defective rear accumulator 2) Insert T-adapter into ACCR.
4 3) Carry out troubleshooting while starting switch is ON.
oil pressure sensor
Between ACCR (C) and (A) Voltage 0.3 – 4.7 V
2) Connect T-adapter to connectors ATC1 (female) and ACCR
(female).
Between ATC1 (female) (7) and ACCR Resis-
Max. 1 z
(female) (C) tance
harness a If no failure is found by check on cause
5 3, this check is not required. Resis-
(Disconnection or Max. 1 z
defective contact) Between ATC1 (female) (21) and ACCR tance
(female) (A)
a If no failure is found by check on cause
3, this check is not required. Resis-
Max. 1 z
Between ATC1 (female) (22) and ACCR tance
(female) (B)
62 HD785-7

Possible causes defect, troubleshooting cannot be performed.).
and standard a Reference
value in normal Defective transmission con- 1) Turn the starting switch to OFF position.
6
state troller 2) Insert the T-adapter into connector ATC1.
HD785-7 63
Failure code [DHU6KX] Trouble in ABS control valve pressure sensor

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front right)
Trouble
E01 DHU6KX (ABS controller system)
Contents of • Input voltage from ABS control valve pressure sensor (front right: FR) became 0.3 V or less or 4.7 V
trouble and over.
Action of
controller • Stop ABS control.
Problem that
• ABS does not work.
appears on
machine • Ordinary brake operation can be carried out.
Related • ABS control valve pressure sensor output can be checked with the monitoring function (Code:
information 43314 (MPa) and 43315 (V)).

2) Disconnect connector ABS1 and BPFR.
3) Connect T-adapter to ABS1 and BPFR (female).
Disconnection in wiring Between ABS1 (female) (19) and BPFR Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFR Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (22) and BPFR Resis-
Max. 1 z
(female) (B) tance
2) Disconnect connector ABS1 and BPFR.
3) Connect T-adapter to ABS1 (female) or BPFR (female).
Ground fault in wiringhar-
2 Between ABS1 (female) (19) or BPFR Resis-
ness Max. 1 z
Between ABS1 (female) (22) or BPFR Resis-
Max. 1 z
Possible causes 1) Turn the starting switch OFF.

and standard 2) Disconnect connector BPFR.
value in normal 3) Connect T-adapter to BPFR (female) or insert T-adapter into
state 3 Hot short in wiring harness ABS1.
Between ABS1 (19) or BPFR (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFR.
Defective ABS control valve 3) Replace with the front left pressure sensor. (See [DHU7KX].)
pressure sensor (FR)
If failure code [DHU6KX] does not appear, ABS control valve
pressure sensor (FR) is defective.
If no abnormality is found in the above troubleshooting, the ABS
a Reference
5 Defective ABS controller 1) Turn the starting switch to OFF position.
2) Insert the T-adapter into connector ABS1.
Between ABS1 (22) and (21) Voltage 4.6 – 5.4V
Between ABS1 (19) + and (21) Voltage 0.3 – 4.7 V
64 HD785-7
HD785-7 65

(Front left) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Front left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (front left: FL) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

2) Disconnect connector ABS1 and BPFL.
3) Connect T-adapter to ABS1 and BPFL (female).
Disconnection in wiring Between ABS1 (female) (13) and BPFL Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFL Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (22) and BPFL Resis-
Max. 1 z
(female) (B) tance
3) Connect T-adapter to ABS1 (female) or BPFL (female).
2 Between ABS1 (female) (13) or BPFL Resis-
ness Max. 1 z
Between ABS1 (female) (22) or BPFL Resis-
Max. 1 z

and standard 2) Disconnect connector BPFL.
value in normal 3) Connect T-adapter to BPFL (female) or insert T-adapter into
Between ABS1 (13) or BPFL (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the front right pressure sensor. (See [DHU6KX].)
pressure sensor (FL)
pressure sensor (FL) is defective.
a Reference
Between ABS1 (22) and (21) Voltage 4.6 – 5.4V
66 HD785-7
HD785-7 67

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear right)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear right: RR) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

2) Disconnect connector ABS1 and BPRR.
3) Connect T-adapter to ABS1 and BPRR (female).
Disconnection in wiring Between ABS1 (female) (7) and BPRR Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPRR Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (16) and BPRR Resis-
Max. 1 z
(female) (B) tance
2) Disconnect connector ABS1 and BPRR.
3) Connect T-adapter to ABS1 (female) or BPRR (female).
2 Between ABS1 (female) (7) or BPRR Resis-
ness Max. 1 z
Between ABS1 (female) (16) or BPRR Resis-
Max. 1 z

and standard 2) Disconnect connector BPRR.
value in normal 3) Connect T-adapter to BPRR (female) or insert T-adapter into
Between ABS1 (7) or BPRR (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPRR.
Defective ABS control valve 3) Replace with the rear left pressure sensor. (See [DHU9KX].)
pressure sensor (RR)
pressure sensor (RR) is defective.
a Reference
Between ABS1 (16) and (21) Voltage Approx. 24 V
68 HD785-7
HD785-7 69

(Front right) 1
Action code Failure code Trouble in ABS control valve pressure sensor (Rear left)
Trouble
Contents of • Input voltage from ABS control valve pressure sensor (rear left: RL) became 0.3 V or less or 4.7 V
trouble and over.
Action of
Problem that
appears on

3) Connect T-adapter to ABS1 and BPFL (female).
Disconnection in wiring Between ABS1 (female) (1) and BPFL Resis-
harness Max. 1 z
contact in connector) Between ABS1 (female) (21) and BPFL Resis-
Max. 1 z
(female) (A) tance
Between ABS1 (female) (16) and BPFL Resis-
Max. 1 z
(female) (B) tance
3) Connect T-adapter to ABS1 (female) or BPFL (female).
2 Between ABS1 (female) (1) or BPFL Resis-
ness Max. 1 z
Between ABS1 (female) (16) or BPFL Resis-
Max. 1 z

and standard 2) Disconnect connector BPFL.
value in normal 3) Connect T-adapter to BPFL (female) or insert T-adapter into
Between ABS1 (1) or BPFL (female) (C)
Voltage Max. 1 V
and ground
2) Disconnect connector BPFL.
Defective ABS control valve 3) Replace with the rear right pressure sensor. (See [DHU8KX].)
pressure sensor (RL)
pressure sensor (RL) is defective.
a Reference
Between ABS1 (16) and (21) Voltage Approx. 24 V
70 HD785-7
HD785-7 71
Failure code [DJF1KA] Fuel level sensor: Disconnection 1

Action code Failure code Fuel level sensor: Disconnection
Trouble
E01 DJF1KA (Transmission controller system)
Contents of
trouble • The voltage of the signal circuit of the fuel level sensor is higher than 4.0 V.
Action of
controller • None in particular.
Problem that
appears on • The fuel level gauge does not indicate normally.
machine
Related
information • This failure can be checked in the monitoring function (Code: 04200 (V), 04201 (z)).

2) Disconnect connector FUEL.
3) Connect T-adapter to male side.
1 Defective fuel level sensor Fuel level: Resis-
Max. 12 z
Between FUEL When FULL tance
(male) (1) and (2) Fuel level: Resis-
74 – 100 z
When EMPTY tance
2) Disconnect connector ATC1 and connect T-adapter (female).
2 Fuel level: Resis-
in wiring harness Max. 12 z
Between ATC1 When FULL tance
(female) (8) and (21) Fuel level: Resis-
Possible causes 74 – 100 z
When EMPTY tance
and standard
value in normal a If no abnormality is found in checks on cause 2, this check is not
state required.
Disconnection in wiring 2) Disconnect connectors ATC1and FUEL.
harness 3) Connect T-adapter.
3
contact) Between ATC1 (female) (8) and FUEL Resis-
Max. 1 z
(female) (1) tance
Between ATC1 (female) (21) and FUEL Resis-
Max. 1 z
(female) (2) tance
Defective hot short in wiring 2) Insert T-adapter connector ATC1.
Between ATC1 (female) (8) and (21). Voltage Max. 4 V
If causes are not found by above checks, transmission controller is
troller
be performed.)
72 HD785-7
HD785-7 73
Failure code [DK30KX] Steering angle potentiometer: Trouble

(Disconnection) 1
Action code Failure code Steering angle potentiometer: Trouble (Disconnection)
Trouble
E01 DK30KX (Retarder controller system)
Contents of
trouble • There is no voltage in signal coming from steering angle potentiometer.
Action of
Problem that
appears on • Since steering angle signal is not input to retarder controller, ASR may not operate normally and
machine tires may slip consequently.
Related • Input state from steering angle sensor can be checked with monitoring function (Code: 35400 (V),
information 35402(°))

Turn starting switch OFF and disconnect ASR1, then carry out
troubleshooting without turning starting switch ON.
ASR1 (Male: Sensor side) Resistance
Defective steering angle Between (A) and (C) 5 kz ± 20%
1
sensor
Between (A) and (B) 0 – 5 kz *1
Between (B) and (C) 0 – 5 kz *1
*1 Between (A) and (B) + between (B) and (C) = 5 kz ± 20%
a Turn starting switch OFF and disconnect ASR1, then carry out
troubleshooting without turning starting switch ON.
Possible causes Between ASR1 (female) (B) and BRC1 Resis-
Max. 1 z
and standard Disconnection in wiring har- (female) (2) tance
value in normal ness (Disconnection in wiring
2
state or defective contact in con- 1) Turn starting switch OFF and disconnect ASR1.
nector) 2) Turn starting switch ON and carry out troubleshooting.
ASR1 (Female: Wiring harness
Voltage
side)
Between (C: +) and (A: -) 5V
a Turn starting switch OFF and disconnect connector ASR1 and
Grounding fault in wiring har- BRC1, then carry out troubleshooting without turning starting
3 ness (Contact with ground switch ON.
circuit) Resis-
Between ASR1 (female) (B) and ground Min. 1 Mz
tance
If causes 1 – 3 are not detected, retarder controller may be defec-
4 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
74 HD785-7
Failure code [DK51L5] Retarder lever potentiometer: Potentiometer

signal is inconsistent with swich signal 1
Action code Failure code Retarder lever potentiometer: Potentiometer signal is inconsistent
Trouble with swich signal
E03 DK51L5 (Retarder controller system)
Contents of • The signal voltage of the potentiometer of the retarder lever circuit is below 0.3 V or above 4.7 V. Or,
trouble the potentiometer signal does not agree with the switch signal.
The controller acts as follows, depending on the condition of the failure.
Action of • Controls with the potentiometer signal.
controller • Limits the output for the solenoid to 70%.
• Turns the output for the solenoid OFF.
The following appear, depending on the action of the controller.
Problem that
• This failure does not have a serious effect on the machine.
appears on
• The retarder cannot control finely.
machine
• The retarder does not operate (The foot brake operates, however).
Related
• This failure can be checked in the monitoring function (Code: 33900 (V)).
information

2) Disconnect connectors BRC1, BRC3, RE1, and RTL.
3) Connect T-adapter to them (female).
Between BRC1 (female) (22) and RE1 Resis-
Max. 1 z
(female) (1) tance
Between RE1 (female) (2) and RTL Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring Between BRC1 (female) (21) and RTL Resis-
harness Max. 1 z
1 (female) (3) tance
contact) Between BRC1 (female) (14) and RTL Resis-
Max. 1 z
(female) (2) tance
Possible causes
Between BRC1 (female) (24) and RTL Resis-
(female) (4) tance
value in normal
state Between BRC1 (female) (18) and RTL Resis-
Max. 1 z
(female) (5) tance
Between RTL (female) (6) and BRC3 Resis-
Max. 1 z
(female) (21), (31), (32), (33) tance
2) Disconnect connectors BRC1, RE1, and RTL.
3) Connect T-adapter to BRC1 (female).
Grounding fault in wiring Between ground and BRC1 (female) (22) or Resis-
Min. 1 Mz
2 harness RE1 (female) (1) tance
(Contact with ground circuit) Between ground and RE1 (female) (2) or Resis-
Min. 1 Mz
RTL (female) (1) tance
Between ground and BRC1 (female) (14) Resis-
Min. 1 Mz
or RTL (female) (2) tance
HD785-7 75

2) Disconnect connector RTL.
3) Connect T-adapter to RTL (female) or insert T-adapter into
BRC1.
Hot short in wiring
3 harness
(Contact with 24V circuit) Between ground and BRC1 (22) or RTL
Voltage Approx. 5 V
(female) (1)
Between ground and BRC1 (14) or RTL
Voltage Max. 1 V
(female) (2)
2) Disconnect connector RE1.
4 Defective resistor (RE1) 3) Connect T-adapter.
Resis-
Between RE1 (male) (1) and (2) 250 ± 5 z
tance
2) Disconnect connector RTL
5) Check the potentiometer.
Between RTL (1) and (3) Voltage 4.1 – 4.8 V
Between RTL (2) and (3) Voltage 0.3 – 4.7 V
2) Disconnect connector RTL
5 Defective retarder lever 3) Connect T-adapter.
4) Check the switch.
Possible causes
and standard Lever at OFF posi- Resis-
Max. 1 z
value in normal Between RTL (male) tion tance
state (4) – (6) Resis-
Lever at ON position Min. 1 Mz
tance
Lever at OFF posi- Resis-
Min. 1 Mz
Between RTL (male) tion tance
(5) – (6) Resis-
Lever at ON position Max. 1 z
tance
2) Disconnect connectors BRC1, and BRC3.
Between BRC1 (22) and BRC3,
(21), (31), (32), (33)
Between BRC1 (14) and BRC3,
(21), (31), (32), (33)
2) Disconnect connector RTL.
6 Defective retarder controller 3) Connect T-adapter.
4) Check the switch.
Between BRC1 Max. 1 z
tion tance
(female) (24) and
ground Resis-
Lever at ON position Min. 1 Mz
tance
Between BRC1 Min. 1 Mz
tion tance
(female) (18) and
ground Resis-
Lever at ON position Max. 1 z
tance
76 HD785-7
HD785-7 77
Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of

Action code Failure code Failure in hoist lever potentiometer 1: Out of input signal range
Trouble (Out of input signal range of lever potentiometer 1 or 2)
Contents of • The signal voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 0.3 V or above 4.7
trouble V.
Action of
• Operates body by using normal one of 2 potentiometers.
controller
Problem that
appears on • Machine is not affected in particular.
machine
Related
information

2) Disconnect connectors BRC1, BRC3, and HSL.
3) Connect T-adapter to them (female).
Between BRC3 (female) (34) and HSL Resis-
(female) (4) tance
harness
1 Between BRC1 (female) (20) and HSL Resis-
(female) (2) tance
contact)
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (1) tance
and standard 2) Disconnect connectors BRC1, BRC3, and HSL.
value in normal 3) Connect T-adapter.
state Grounding fault in wiring Between ground and BRC3 (female) (34) Resis-
Min. 1 Mz
2 harness or HSL (female) (4) tance
(Contact with ground circuit) Between ground and BRC1 (female) (20) Resis-
Min. 1 Mz
or HSL (female) (2) tance
Between ground and BRC1 (female) (19) Resis-
Min. 1 Mz
or HSL (female) (3) tance
Hot short in wiring harness 4) Turn the starting switch ON.
3
(Contact with 24V circuit) Between ground and HSL (female) (4) Voltage Approx. 5 V
Between ground and HSL (female) (2) Voltage Max. 1 V
Between ground and HSL (female) (3) Voltage Max. 1 V
78 HD785-7

2) Disconnect connector HSL.
4 Defective hoist lever
Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Possible causes If no abnormality is found in the above troubleshooting, the retarder
and standard controller may be defective. (Since this is an internal defect, trou-
value in normal bleshooting cannot be performed.)
state
a Reference
5 Defective retarder controller 3) Insert T-adapter.
4)Turn the starting switch ON.
Between BRC3 (34) – BRC1
(21)
Between BRC1 (20) – (21) Voltage 0.3 – 4.7 V
HD785-7 79
Failure code [DK53L8] Failure in hoist lever potentiometer 2:

Disagreement of analog signal 1
Action code Failure code Failure in hoist lever potentiometer 2: Disagreement of analog
Trouble signal
E03 DK53L8 (Retarder controller system)
Contents of
• The total voltage of the signal circuit of hoist lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
trouble
Action of
• The controller recognizes the hoist lever position as "NEUTRAL".
controller
Problem that
appears on • Body does not operate.
machine
Related • This failure can be checked in the monitoring function (Code: 34305 (V)).
information • If the failure code "DK52KX" is displayed, perform troubleshooting for it.

Short circuit in wiring har- 3) Connect the T-adapter to the female side of HSL.
1
ness
Resis-
Between HSL (female) (2) and (3) Max. 1 z
tance
2) Disconnect connector HSL and connect the T-adapter to male
side.
Possible causes
Resis-
and standard Between HSL (male) (2) and (3) Max. 1 z
tance
value in normal
state 1) Turn the starting switch OFF.
2 Defective hoist leverx 2) Insert T-adapter into connector HSL.
Sum of voltages 2 and 3 Voltage 4.5 – 5.5 V
• If the failure is not repaired by performing the troubleshooting in
1 above, the retarder controller is defective.
80 HD785-7
HD785-7 81
Failure code [DK54KX] Body positioner sensor: Out of input signal

range 1
Action code Failure code Body positioner sensor: Out of input signal range
Trouble
Contents of
• The signal circuit voltage of the body positioner is below 0.3 V or above 4.7 V.
trouble
Action of • The controller controls dumping according to the hoist lever signal.
controller • The controller controls, assuming that the body is not seated.
• Body seating shocks become large.
Problem that
• The hoist lever positioner does not function.
appears on
machine • The maximum gear speed is limited.
• The machine cannot travel in reverse if the hoist lever is not at "FLOAT".
Related
information

2) Disconnect connector B07.
1 Defective body positioner
Resis-
Between B07 (male) (C) and (A) 4 – 6 kz
tance
Resis-
Between B07 (male) (B) and (A) 0 – 6 kz
tance
2) Disconnect connectors BRC1, BRC3, and B07.
Disconnection in wiring Between BRC1 (female) (8) and B07 Resis-
harness Max. 1 z
2 (female) (B) tance
contact) Between BRC3 (female) (34) and B07 Resis-
Max. 1 z
Possible causes (female) (C) tance
and standard Between BRC1 (female) (21) and B07 Resis-
(female) (A) tance
state
2) Disconnect connectors BRC1, BRC3, and B07.
Grounding fault in wiring 3) Connect T-adapters to them (female).
3 harness Between BRC1 (female) (8) or B07 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (B) and ground tance
Between BRC3 (female) (34) or B07 Resis-
Min. 1 Mz
2) Disconnect connector B07.
3) Connect T-adapter B07 (female) or insert T-adapter into conec-
Hot short in wiring tor BRC1, BRC3.
(Contact with 24V circuit) Between ground and BRC1 (8) or B07
Voltage Max. 1 V
(female) (B)
Between ground and BRC3 (34) or B07
Voltage Max. 1 V
(female) (C)
82 HD785-7

If no abnormality is found in the above troubleshooting, the
retarder controller may be defective. (Since this is an internal
Possible causes a Reference
and standard 1) Turn the starting switch OFF.
value in normal 5 Defective retarder controller 2) Disconnect connectors BRC1, BRC3, and B07.
state 3) Insert T-adapter.
Between BRC3 (34) – BRC1
(21)
HD785-7 83
Failure code [DKD0L6] Failure in steering speed sensor 1

Action code Failure code Failure in steering speed sensor
Trouble
E01 DKD0L6 (Retarder controller system)
Contents of • Disconnection, grounding fault, or short circuit occurs in the signal circuit of the steering speed sen-
trouble sor and no signals are input.
Action of
controller • Fix the auto-suspension in the M mode.
Problem that
machine
Related
information • This failure can be checked in the monitoring function (Code: 35403 (rad/s)).

2) Disconnect connector SR3.
1
ply
Power
Between SR3 (female) (1) and (3) supply 10 – 13 V
Voltage
2) Disconnect connectors BRC1, BRC2, and SR3.
3) Connect T-adapter.
Between BRC2 (female) (29) and SR3 tance
harness (female) (3)
2
contact) Between BRC2 (female) (37) and SR3 Resis-
Max. 1 z
(female) (2) tance
Possible causes a If the power supply voltage is normal,
and standard this check is not required. Resis-
Between BRC1 (female) (16) and SR3 tance
state (female) (1)
2) Disconnect connectors BRC1, BRC2, and SR3.
Grounding fault in wiring Between ground and BRC2 (female) (37) Resis-
Min. 1 Mz
3 harness or SR3 (female) (2) tance
(Contact with ground circuit) a If the power supply voltage is normal,
Min. 1 Mz
Between ground and BRC1 (female) (16) tance
or SR3 (female) (1)
a The measurement is impoosible with the multimeter because of
pulse voltage.
Steering speed sensor 2) Disconnect connector SR3.
4 3) Insert T-adapter.
defective
5) Turn the steering wheel slowly.
Between SR3 (2) and (3) Voltage See Fig-1.
84 HD785-7

If no abnormality is found in the above troubleshooting, the
retarder controller may be defective. (Since this is an internal
a Reference
2) Disconnect connectors BRC1, BRC2.
Possible causes 3) Insert T-adapter.
and standard 4) Turn the starting switch ON.
value in normal
state 5 Retarder controller defective Between BRC1 (16) and Voltage 10 – 13 V
BRC2 (29)
a The measurement is impoosible with the multimeter because of
pulse voltage.
2) Disconnect connector BRC2.
5) Turn the steering wheel slowly.
Between BRC2 (37) and (29) Voltage See Fig-1.
HD785-7 85
Failure code [DKH0KX] Clinometer sensor signal out of range 1

Action code Failure code Clinometer sensor signal out of range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of Inclination sensor has become below 0.5 V or above 4.5 V.
Action of
Problem that
appears on • Machine roll angle abnormality [989D00] cannot be detected.
machine
• Signal from Inclination sensor can be checked with monitoring function (Code: 32900 (°) and 32903
Related
(V)).
information
• Cannot detect tipping over.

2) Disconnect connector AS3.
3) Connect T-adapter to connector AS3 (female).
Defective sensor power
supply
Power
Between AS3 (female) (C) and (A) supply 20 – 30 V
Voltage
2) Disconnect connectors ATC1 and AS3.
3) Connect T-adapter to connectors ATC1 (female) and AS3
(female).
Between ATC1 (female) (19) and AS3 Resis-
Max. 1 z
Disconnection in wiring (female) (B) tance
harness a If the power supply voltage is normal, this
2
(Disconnection or defective check is not required. Resis-
contact) Max. 1 z
Between ATC1 (female) (16) and AS3 tance
Possible causes (female) (C)
and standard a If the power supply voltage is normal, this
value in normal check is not required. Resis-
Max. 1 z
state Between ATC1 (female) (21) and AS3 tance
(female) (A)
2) Disconnect connectors ATC1 and AS3.
3) Connect T-adapter to ATC1 or AS3 (female).
Ground fault in wring har- Between ground and ATC1 (female) (19) or Resis-
Min. 1 Mz
3 ness AS3 (female) (B) tance
(Contact with ground circuit) a If the power supply voltage is normal, this
Min. 1 Mz
Between ground and ATC1 (female) (16) or tance
AS3 (female) (C)
2) Disconnect connector AS3.
Defective hot short in wiring 3) Connect T-adapter to AS3 (female) or insert T-adapter into
4 harness ATC1.
Between ground and ATC1 (female) (19) or
Voltage Max. 1 V
AS3 (female) (B)
86 HD785-7

2) Insert T-adapter into AS3.
5 Defective pitch angle sensor 3) Turn starting switch ON.
Between AS3 (B) and (A)
a Approximately 2.6 V in horizontal
Possible causes mission controller may be defective. (Since this is an internal defect,
and standard troubleshooting cannot be performed.)
value in normal
state a Reference
Defective transmission 1) Turn starting switch OFF.
6 2) Insert T-adapter into connector ATC1.
controller
Between ATC1 (16) – (21) Voltage 20 – 30 V
Between ATC1 (19) – (21)
HD785-7 87
Failure code [DKH1KX] (or VHMS_LED display: "n4"o"33") Abnormality

in clinometer sensor 1
Action code Failure code Pitch angle sensor: Abnormality (Disconnection or short circuit)
Trouble
E01 DKH1KX (VHMS & PLM controller system)
Contents of
• Abnormality (Disconnection or short circuit) was detected in signal from pitch angle sensor.
trouble
controller • Cannot detect tipping over.
Problem that
appears on • Load weight is not displayed or recorded correctly.
machine
Related
information • Input signal from pitch angle sensor can be checked with monitoring function (Code: 32901 (°),
32902 (V)).

2) Disconnect connector PM3.
3) Connect T-adapter to PM3 (female).
1
ply
Power
Between PM3 (female) (C) and (A) supply 20 - 30 V
Voltage
2) Disconnect connectors HM-CN1, HM-CN2B and PM3.
3) Connect T-adapter to HM-CN1 (female) or HM-CN2B (female)
and PM3 (female).
Between HM-CN2B (female) (3) and PM3 Resis-
Max. 1 z
ness a If the power supply voltage is normal, this
2
(Disconnection or defective check is not required. Resis-
contact) Max. 1 z
Between HM-CN1 (female) (2) and PM3 tance
Possible causes (female) (C)
and standard a If the power supply voltage is normal, this
value in normal check is not required. Resis-
state Max. 1 z
Between HM-CN2B (female) (9) and PM3 tance
(female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B and PM3.
3) Connect T-adapter to HM-CN1 (female) or HM-CN2B (female).
Between ground and HM-CN2B (female) Resis-
Ground fault in wring har- Min. 1 z
3 (3) or PM3(female) (B) tance
ness
(Contact with ground circuit) a If the power supply voltage is normal, this
Min. 1 z
Between ground and HM-CN1 (female) (2) tance
or PM3(female) (C)
2) Disconnect connector PM3.
Defective hot short in wiring 3) Connect T-adapter to PM3 (female) or insert T-adapter into
4 harness HM-CN2B.
Between ground and HM-CN2B (female)
Voltage Max. 1 V
(3) or PM3 (female) (B)
88 HD785-7

2) Insert T-adapter into connector PM3.
5 Defective clinometer sensor 3) Turn starting switch ON.
Between PM3 (B) and (A)
Voltage 0.5 - 4.5 V
Possible causes & PLM controller may be defective. (Since this is an internal defect,
and standard troubleshooting cannot be performed.)
value in normal
state a Reference
Defective VHMS & PLM con- 1) Turn starting switch OFF.
6 2) Insert T-adapter into HM-CN1, HM-CN2B.
troller
Between HM-CN1 (2) and HM-CN2B (9) Voltage 20 - 30 V
Between HM-CN2B (3) and HM-CN2B (9)
Voltage 0.5 - 4.5 V
HD785-7 89
Failure code [DLF1KA] Transmission input shaft speed sensor:

Disconnection 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
Trouble
E03 DLF1KA (Transmission controller system)
Contents of • The signal circuit of the transmission input shaft speed sensor is disconnected and signals are not
trouble input.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
• The lockup system is reset and the gear cannot be shifted.
appears on
Related
• This failure can be checked in the monitoring function (Code: 31200 (rpm)).
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission input shaft
a For details, see Testing and adjusting, "Adjustment of transmis-
speed sensor
sion speed sensor".
2) Disconnect connector N1 (CN3).
Defective transmission input
2 Resis-
shaft speed sensor Between N1 (CN3) (male) (1) and (2) 500 – 1,000 z
tance
Between N1 (CN3) (male) (1), (2) and Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Disconnection or short circuit 3) Connect T-adapter (female).
value in normal 3
in wiring harness
state Resis-
Between ATC2 (female) (40) and (29) 500 – 1,000 z
tance
a If no abnormality is found in checks on cause 3, this check is not
required.
Disconnection in wiring 2) Disconnect connectors ATC2 and N1 (CN3).
4
Between ATC2 (female) (40) and N1 Resis-
contact) Max. 1 z
Between ATC2 (female) (29) and N1 Resis-
Max. 1 z
5 defective. ( Since this is an internal failure, troubleshooting can not
troller
be performed. )
90 HD785-7
HD785-7 91
Failure code [DLF1LC] Transmission input shaft speed sensor:

Disagreement of revolution speed signal 1
Action code Failure code Transmission input shaft speed sensor: Disagreement of revolution
Trouble speed signal
E03 DLF1LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission intermediate shaft speed
Contents of
sensor signal, and transmission output shaft speed sensor signal is different from the signal speed
trouble
of the transmission input shaft speed sensor.
Action of • The controller keeps the current gear speed and turns the lockup operation OFF.
Problem that
appears on
Related
information

Defective transmission input
1 Resis-
shaft speed sensor Between N1 (CN3) (male) (1) and (2) 500 – 1,000 z
tance
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect connectors ATC2 and N1 (CN3).
2 harness 3) Connect T-adapter (female).
(Contact with ground circuit) Between ground and ATC2 (female) Resis-
Min. 1 Mz
Possible causes (40) or N1 (CN3) (female) (1) tance
and standard 1) Turn the starting switch OFF.
value in normal 2) Disconnect connectors N1 (CN3).
state 3) Connect T-adapter to N1 (CN3) (female) or insert T-adapter into
Defective hot short in wiring
3 harness ATC2.
(Contact with 24V circuit) 4) Turn the starting switch ON.
Between ground and ATC2 (40) or N1
Voltage Max. 1 V
(CN3) (female) (1)
2) Disconnect connector ATC2 and N1 (CN3).
Short circuit in wiring har- 3) Connect T-adapter to ATC2 (female).
4
ness
Between ATC2 (female) (40) and each Resis-
Min. 1 Mz
pin other than (40) tance
troller
be performed. )
92 HD785-7
HD785-7 93
Failure code [DLF2KA] Transmission intermediate shaft speed sensor:

Disconnection 1
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Trouble
E03 DLF2KA (Transmission controller system)
Contents of • The signal circuit of the transmission intermediate shaft speed sensor is disconnected and signals
trouble are not input.
Problem that
appears on
Related
information

Press the sensor lightly against the revolution pickup gear, and
Wrong adjustment of
then return it by 1/2 – 1 turn.
1 transmission intermediate
a For details, see Testing and adjusting, "Adjustment of transmis-
shaft speed sensor
sion speed sensor".
Defective transmission inter-
2 Resis- 500 –
mediate shaft speed sensor Between N2 (CN4) (male) (1) and (2)
tance 1,000 z
Min. 1 Mz
ground tance
Possible causes
and standard Disconnection or short circuit 3) Connect T-adapter (female).
value in normal 3
in wiring harness
state Resis- 500 –
tance 1,000 z
a If no abnormality is found in checks on cause 3, this check is not
required.
Disconnection in wiring 2) Disconnect connectors ATC2, N2 (CN4).
4
Between ATC2 (female) (20) and N2 (CN4) Resis-
contact) Max. 1 z
(female) (1) tance
Between ATC2 (female) (39) and N2 (CN4) Resis-
Max. 1 z
(female) (2) tance
troller
be performed. )
94 HD785-7
HD785-7 95
Failure code [DLF2LC] Transmission intermediate shaft speed sensor:

Disagreement of revolution speed signal 1
Action code Failure code Transmission intermediate shaft speed sensor: Disagreement of
Trouble revolution speed signal
E03 DLF2LC (Transmission controller system)
• The speed calculated from the engine speed sensor signal, transmission input shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from the signal speed of the
trouble
transmission intermediate shaft speed sensor.
Problem that
appears on
Related
information

Transmission intermediate
1 Resis-
shaft speed sensor defective Between N2 (CN4) (male) (1) and (2) 500 – 1,000 z
tance
Min. 1 Mz
ground tance
Grounding fault in wiring 2) Disconnect connectors ATC2 and N2 (CN4).
2 harness 3) Connect T-adapter (female).
(Contact with ground circuit) Between ground and ATC2 (female) Resis-
Possible causes Min. 1 Mz
(20) or N2 (CN4) (female) (1) tance
and standard
state 2) Disconnect connector N2 (CN4).
Defective hot short in wiring 3) Connect T-adapter to N2 (CN4) or insert T-adapter into ATC2.
Between ground and ATC2 (20) or N2
Voltage Max. 1 V
(CN4) (female) (1)
2) Disconnect connector ATC2 and N2 (CN4).
Short circuit in wiring har- 3) Connect T-adapter to ATC2 (female).
4
ness
Between ATC2 (female) (20) and each Resis-
Min. 1 Mz
pin other than (20) tance
troller
be performed. )
96 HD785-7

HD785-7 SEN01274-15 Shop Manual-1005-1205

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HD785-7 SEN01274-15 Shop Manual-1005-1205

Uploaded by

Copyright:

Available Formats

SEN01943-03 40 Troubleshooting

Circuit diagram related

Failure code [DB19KQ] Disagreement of model selection (Retarder

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DB1RKR] CAN communication (retarder controller):

• AISS is locked in LOW. (until starting switch is turned OFF.)

• Method of reproducing failure code: Turn the starting switch to ON position.

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DB1RMA] Disagreement of option setting (Retarder

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DB2RKR] CAN communication (engine controller):

• Method of reproducing failure code: Turn the starting switch to ON position.

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [dB2RKR] CAN communication (engine controller):

• Method of reproducing failure code: Turn the starting switch to ON position.

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBB0KK] or VHMS_LED display: "n9" o "01" 1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBB0KQ] (or VHMS_LED display: "nF" o "11")

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DBB3KK] (or VHMS_LED display: "n9" o "05")

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBB5KP] (or VHMS_LED display: "n9" o "04")

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBB6KP] (or VHMS_LED display: "n9" o "02")

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBB7KP] (or VHMS_LED display: "n9" o "03")

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBBQKR] (or VHMS_LED display: "n8" o "02")

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DBBRKR] Abnormality in CAN communication (VHMS) 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DBC2KK] ABS controller solenoid power supply: Power

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBC3KK] ABS controller battery direct power supply:

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related

Failure code [DBC9KQ] Disagreement of model selection (ABS

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [DBCRKR] Abnormality in CAN communication (ABS) 1

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting