Komatsu HD785-7 Dump Truck Drowsiness Detection System (DDS) Shop Manual SEN06857-04 - PDF DOWNLOAD

SEN06857-04

DUMP TRUCK

HD785 -7 Drowsiness Detection System (DDS) SERIAL NUMBERS

30001

and up

00 INDEX AND FOREWORD

HD785-7

00-1

INDEX

00 INDEX AND FOREWORD

INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 FOREWORD........................................................................................................................................... 00-4 BEFORE READING THIS MANUAL ................................................................................................ 00-4 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 DROWSINESS DETECTION SYSTEM................................................................................................... 10-3 LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM ..................................................... 10-3 SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM..................................................... 10-4 SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION)................. 10-5 FUNCTION OF DROWSINESS DETECTION SYSTEM .................................................................. 10-6 FUNCTION OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION) .............................. 10-7 OPERATION OF DROWSINESS DETECTION SYSTEM ................................................................ 10-8 COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM ................................................. 10-9 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 ELECTRICAL SYSTEM .......................................................................................................................... 30-3 SET OPTIONAL SELECTION OF MACHINE MONITOR ................................................................. 30-3 40 TROUBLESHOOTING .............................................................................................................................. 40-1 CONTENTS ............................................................................................................................................ 40-2 RELATED INFORMATION TO TROUBLESHOOT .................................................................................. 40-3 CONNECTOR LIST AND LAYOUT .................................................................................................. 40-3 FUSE LOCATION TABLE ................................................................................................................ 40-5 FAILURE CODE TABLE................................................................................................................... 40-7 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ........................................................ 40-8 FAILURE CODE [D5WNKB]............................................................................................................. 40-8 FAILURE CODE [DR81KR].............................................................................................................. 40-9 FAILURE CODE [DR81MA] ........................................................................................................... 40-14 FAILURE CODE [DV03KB] ............................................................................................................ 40-15 FAILURE CODE [DV03KY] ............................................................................................................ 40-16 FAILURE CODE [F9D0MC]............................................................................................................ 40-17 FAILURE CODE [F9D2KK] ............................................................................................................ 40-18 FAILURE CODE [F9DSKR]............................................................................................................ 40-20 FAILURE CODE [ZA0010] ............................................................................................................. 40-25 FAILURE CODE [ZA0011].............................................................................................................. 40-26 FAILURE CODE [ZA0012] ............................................................................................................. 40-27 FAILURE CODE [ZA0013] ............................................................................................................. 40-28 FAILURE CODE [ZA0014] ............................................................................................................. 40-29 FAILURE CODE [ZA0015] ............................................................................................................. 40-30 FAILURE CODE [ZA0016] ............................................................................................................. 40-31 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-3 HOW TO READ THIS MANUAL....................................................................................................... 50-3 SPECIAL TOOLS LIST .................................................................................................................... 50-5 ELECTRICAL SYSTEM .......................................................................................................................... 50-6 REMOVE AND INSTALL DRIVER STATUS MONITOR ................................................................... 50-6 REMOVE AND INSTALL TRANSLATOR CONTROLLER ................................................................ 50-9 REMOVE AND INSTALL DROWSINESS DETECTION CAMERA ................................................. 50-12 REMOVE AND INSTALL DROWSINESS ALARM BUZZER .......................................................... 50-15 REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS ................................. 50-30 90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1 CONTENTS ............................................................................................................................................ 90-2 HOW TO READ THE CODES FOR ELECTRIC CABLE ......................................................................... 90-3 ELECTRICAL CIRCUIT DIAGRAM ......................................................................................................... 90-7 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM ..................................................................... 90-7 ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS)) ......................90-11 00-2

HD785-7

00 INDEX AND FOREWORD

INDEX

INDEX..................................................................................................................................................................1

HD785-7

00-3

BEFORE READING THIS MANUAL

00 INDEX AND FOREWORD

FOREWORD BEFORE READING THIS MANUAL This shop manual contains only descriptions which are different from that of the standard machine (HD785-7: Applicable machines 30001 and after) For items which are not described in this shop manual, see the shop manual for the standard machine (HD785-7: Applicable machines 30001 and after)

00-4

HD785-7

10 STRUCTURE AND FUNCTION

HD785-7

10-1

CONTENTS

10 STRUCTURE AND FUNCTION

CONTENTS DROWSINESS DETECTION SYSTEM.......................................................................................................... 10-3 LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM ............................................................ 10-3 SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM............................................................ 10-4 SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION)........................ 10-5 FUNCTION OF DROWSINESS DETECTION SYSTEM ......................................................................... 10-6 FUNCTION OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION) ..................................... 10-7 OPERATION OF DROWSINESS DETECTION SYSTEM ....................................................................... 10-8 COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM ........................................................ 10-9 TRANSLATOR CONTROLLER ........................................................................................................ 10-9 DROWSINESS DETECTION CAMERA ......................................................................................... 10-13 DRIVER STATUS MONITOR ......................................................................................................... 10-14

10-2

HD785-7

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM

DROWSINESS DETECTION SYSTEM LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM

1: Translator controller

4. Drowsiness detection camera

2: Driver status monitor

5: Drowsiness detection system ready lamp

3: Drowsiness alarm buzzer

6: Driver status monitor unit LED

HD785-7

10-3

SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM

10 STRUCTURE AND FUNCTION

SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM

1: KOMTRAX Plus controller

5. Drowsiness detection camera

2: Retarder controller

6: Drowsiness alarm buzzer

3: Translator controller

7: Drowsiness detection system ready lamp

4: Driver status monitor

10-4

HD785-7

10 STRUCTURE AND FUNCTION

SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION)

SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION)

1: Retarder controller

4. Drowsiness detection camera

2: Translator controller

5: Drowsiness alarm buzzer

3: Driver status monitor

6: Drowsiness detection system ready lamp

HD785-7

10-5

FUNCTION OF DROWSINESS DETECTION SYSTEM

10 STRUCTURE AND FUNCTION

FUNCTION OF DROWSINESS DETECTION SYSTEM •

This system recognizes the operator's face with the drowsiness detection camera. If the Driver Status Monitor judges from the movement of eyelid or direction of face that the operator has a drowsiness, sleeps for a short time, looks aside, or loses the balance, the drowsiness alarm buzzer and notification sound occur to give a warning to the operator, to support the safe operation.

•

This system starts at the same time as you turn the starting switch to the ON position. Also, it stops at the same time as you turn the starting switch to the OFF position.

•

You can check the operation status of this system by the lighting status (light up/flash/go off) of the drowsiness detection system ready lamp.

•

If the driver status monitor senses that the operator sleeps for a short time, looks aside, loses the balance, or has a drowsiness, the information is stored to the translator controller as a failure code.

•

The stored information as a failure code is transmitted from the KOMTRAX Plus controller via the retarder controller to the server.

REMARK For the notification by LED and sound, see "Operation and Maintenance Manual".

10-6

HD785-7

10 STRUCTURE AND FUNCTION

FUNCTION OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION)

FUNCTION OF DROWSINESS DETECTION SYSTEM (EU SPECIFICATION) •

This system recognizes the operator's face with the drowsiness detection camera. If the Driver Status Monitor judges from the movement of eyelid or direction of face that the operator has a drowsiness, sleeps for a short time, looks aside, or loses the balance, the drowsiness alarm buzzer and notification sound occur to give a warning to the operator, to support the safe operation.

•

This system starts at the same time as you turn the starting switch to the ON position. Also, it stops at the same time as you turn the starting switch to the OFF position.

•

You can check the operation status of this system by the lighting status (light up/flash/go off) of the drowsiness detection system ready lamp.

REMARK For the notification by LED and sound, see "Operation and Maintenance Manual".

HD785-7

10-7

OPERATION OF DROWSINESS DETECTION SYSTEM

10 STRUCTURE AND FUNCTION

OPERATION OF DROWSINESS DETECTION SYSTEM Preparation state The system is started and starts the self-diagnosis when the starting switch is at the ON position. After the selfdiagnosis is completed and the system is started normally, the operation notification sound (Three short beeps) occurs, and the status goes to the normal operation state.

When a failure is sensed When the Driver Status Monitor sensed •

The failure notification sound occurs from the notification sound speaker.

•

Keep the preparation state.

When other than the Driver Status Monitor sensed •

The failure code is shown on the machine monitor.

•

Keep the preparation state.

Normal operation state The system senses no abnormality and operates normally. The state is as follows.

•

The drowsiness detection system ready lamp lights up.

•

The operation notification sound and drowsiness alarm buzzer do not occur.

•

If a failure is sensed during the normal operation state, the status changes to the preparation state.

Alarm state When short time sleep and drowsiness are sensed The system judges that the operator sleeps for a short time or the drowsiness of operator is above the specified level during the travel. The state is as follows.

•

The drowsiness detection system ready lamp flashes.

•

The alarm notification sound and drowsiness alarm buzzer occur.

•

If a failure is sensed during the alarm state, the status changes to the preparation state.

When inattentive driving and loss of balance are sensed The system judges that the operator looks aside or loses the balance during the travel. The state is as follows.

•

The drowsiness detection system ready lamp flashes.

•

The alarm notification sound occurs.

•

If a failure is sensed during the alarm state, the status changes to the preparation state.

You can release the alarm state with one of the conditions that follow.

•

When the system judges that the operator has no more short time sleep, inattentive driving, loss of balance, and drowsiness.

•

When the travel speed becomes below 1km/h.

REMARK For the notification by LED and sound, see "Operation and Maintenance Manual".

10-8

HD785-7

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM TRANSLATOR CONTROLLER STRUCTURE OF TRANSLATOR CONTROLLER General view

1: CN TLC1

3: CN TLC3

2: CN TLC2

INPUT AND OUTPUT SIGNALS OF TRANSLATOR CONTROLLER CN TLC1 Pin No.

Signal name

Input/output signal

1

(*1)

-

2

(*1)

-

3

(*1)

-

4

(*1)

-

5

(*1)

-

6

(*1)

-

7

(*1)

-

8

(*1)

-

9

(*1)

-

10

(*1)

-

HD785-7

10-9

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

Pin No.

Signal name

10 STRUCTURE AND FUNCTION

Input/output signal

11

(*1)

-

12

(*1)

-

13

(*1)

-

14

(*1)

-

15

(*1)

-

16

(*1)

-

17

(*1)

-

18

(*1)

-

19

(*1)

-

20

(*1)

-

21

(*1)

-

22

(*1)

-

23

(*1)

-

24

(*1)

-

*1: Do not connect these pins. The malfunctions or failures can occur.

CN TLC2 Pin No.

Signal name

Input/output signal

1

(*1)

-

2

(*1)

-

3

(*1)

-

4

(*1)

-

5

(*1)

-

6

(*1)

-

7

(*1)

-

8

(*1)

-

9

(*1)

-

10

(*1)

-

11

(*1)

-

12

(*1)

-

13

(*1)

-

14

(*1)

-

15

(*1)

-

16

(*1)

-

17

(*1)

-

18

Drowsiness alarm buzzer

19

(*1)

-

20

(*1)

-

21

Travel speed pulse

10-10

Output

Output

HD785-7

10 STRUCTURE AND FUNCTION

Pin No.

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

Signal name

Input/output signal

22

CAN_0_L

Input/output

23

CAN_1_L

Input/output

24

External start-up signal

25

(*1)

-

26

(*1)

-

27

(*1)

-

28

(*1)

-

29

(*1)

-

30

(*1)

-

31

(*1)

-

32

CAN_0_H

Input/output

33

CAN_1_H

Input/output

34

(*1)

-

35

(*1)

-

36

(*1)

-

37

(*1)

-

38

(*1)

-

39

(*1)

-

40

(*1)

-

Input

*1: Do not connect these pins. The malfunctions or failures can occur.

CN TLC3 Pin No.

Signal name

Input/output signal

1

Continuous power supply (24V)

Input

2

Solenoid power supply (24V)

Input

3

(*1)

-

4

(*1)

-

5

(*1)

-

6

(*1)

-

7

(*1)

-

8

(*1)

-

9

(*1)

-

10

Option selection 1

Input

11

Continuous power supply (24V)

Input

12

Solenoid power supply (24V)

Input

13

(*1)

14

Starting switch ACC signal

15

(*1)

-

16

(*1)

-

HD785-7

Input

10-11

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

Pin No.

Signal name

10 STRUCTURE AND FUNCTION

Input/output signal

17

(*1)

-

18

(*1)

-

19

(*1)

-

20

Option selection 2

21

GND (continuous power supply)

-

22

Solenoid power supply (24V)

Input

23

(*1)

24

Starting switch ACC signal

25

(*1)

-

26

(*1)

-

27

(*1)

-

28

(*1)

-

29

(*1)

-

30

(*1)

-

31

GND (continuous power supply)

-

32

GND (continuous power supply)

-

33

GND (continuous power supply)

-

34

System operating lamp

35

(*1)

-

36

(*1)

-

37

(*1)

-

38

(*1)

-

39

(*1)

-

40

(*1)

-

Input

Input

Output

*1: Do not connect these pins. The malfunctions or failures can occur.

10-12

HD785-7

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

DROWSINESS DETECTION CAMERA STRUCTURE OF DROWSINESS DETECTION CAMERA General view

1. Drowsiness detection camera main unit

4: Drowsiness detection system ready lamp

2: Drowsiness detection camera

5: Connector

3: Near-infrared LED

INPUT AND OUTPUT SIGNALS OF DROWSINESS DETECTION CAMERA Pin No.

Signal name

Input/output signal

1

GND

2

Camera signal (+)

Output

3

Camera signal (-)

Output

4

Camera power supply

Input

HD785-7

-

10-13

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

10 STRUCTURE AND FUNCTION

DRIVER STATUS MONITOR STRUCTURE OF DRIVER STATUS MONITOR General view

3

4

2

1

6

5

G0119144

1: Driver status monitor

4: SD memory card slot

2: Notification sound speaker

5: Camera cable connector

3: Driver status monitor unit LED

6: CN DDS1

INPUT AND OUTPUT SIGNALS OF DRIVER STATUS MONITOR CN DDS1 Pin No.

Signal name

Input/output signal

1

GND

Input

2

(*1)

-

3

Travel speed pulse

4

CAN_1_H

Input/output

5

CAN_1_L

Input/output

10-14

Input

HD785-7

10 STRUCTURE AND FUNCTION

Pin No.

COMPONENT PARTS OF DROWSINESS DETECTION SYSTEM

Signal name

Input/output signal

6

(*1)

-

7

Continuous power supply (24V)

8

(*1)

-

9

(*1)

-

10

(*1)

-

11

(*1)

-

12

(*1)

-

13

Starting switch ACC signal

14

(*1)

Input

Input -

*1: Do not connect these pins. The malfunctions or failures can occur.

Camera cable connector Pin No.

Signal name

Input/output signal

1

GND

Output

2

CAMERA SIG+

Input

3

CAMERA SIG-

Input

4

PWR

Output

HD785-7

10-15

30 TESTING AND ADJUSTING

HD785-7

30-1

CONTENTS

30 TESTING AND ADJUSTING

CONTENTS ELECTRICAL SYSTEM ................................................................................................................................. 30-3 SET OPTIONAL SELECTION OF MACHINE MONITOR ........................................................................ 30-3

30-2

HD785-7

30 TESTING AND ADJUSTING

SET OPTIONAL SELECTION OF MACHINE MONITOR

ELECTRICAL SYSTEM SET OPTIONAL SELECTION OF MACHINE MONITOR Set the function of drowsiness detection system with “OPTIONAL SELECTION”.

NOTICE • Make sure that the machine model selection is done before you set the optional selection.

• Check all the items.

1. Set to the service menu selection screen.

1) Make sure that either of the "service meter, odometer setting", "action code", or "failure code" is shown on the character display.

2)

Do the operations that follow with the machine monitor mode selector switch.

Switch operation: Press the switches (1) and (2) at the same time for 5 seconds or more. When the character display becomes blank, release the switches (1) and (2).

3)

When the ID input screen is shown, input the ID that follows with the machine monitor mode selector switch.

ID: 6491 Switch (1): Moves the selection to the left end. And goes back to the operator mode screen if you press the switch twice.

Switch (2): Decreases the selected number Switch (3): Validates the selected number Switch (4): Increases the selected number REMARK • If the ID input screen is left without switch operation for longer than 60 seconds, it automatically returns to the operator mode screen.

• The inputted and validated ID will be effective until you turn the starting switch to the OFF position.

HD785-7

30-3

SET OPTIONAL SELECTION OF MACHINE MONITOR

2.

30 TESTING AND ADJUSTING

When the service menu selection screen is shown, select “OPTIONAL SELECTION”, and hold the switch (3) for 5 seconds or more.

Switch (1): Returns to the operator mode screen Switch (2): Returns to the previous service menu screen Switch (3): Validates the selection Switch (4): Proceeds to the next service menu screen REMARK Press the switch (3) for 5 seconds or more to validate the selection and the display screen is switched.

3.

When the optional selection screen is shown, select “DROWSINESS”.

Switch (1): Returns to the service menu selection screen Switch (2): Returns to the previous option item Switch (3): Validates the selection Switch (4): Proceeds to the next option item REMARK • The setting status of the option item is displayed on the left side of the lower row.

“ADD”: Option is set “NO ADD”: Option is NOT set • Even if the current settings are correct, press the switch (3) twice to validate the settings to send information to the controller.

Table of option selection items and default values Item name Function of drowsiness detection system

4.

Screen display

Code

Default value

DROWSINESS

25

NO ADD

Remarks Select “ADD” if the drowsiness detection system is installed.

Make sure that the installation state and screen setting of the drowsiness detection system. Press the switch (3) to validate the setting.

Switch (1): Returns to the optional selection screen.

Switch (2): Returns to the previous option item

30-4

HD785-7

30 TESTING AND ADJUSTING

SET OPTIONAL SELECTION OF MACHINE MONITOR

Switch (3): Validates the setting Switch (4): Proceeds to the next option item REMARK • “ADD”: Sets the option.

• “NO ADD”: Does not set the option.

• If you press the switch (3) and validate the setting, the setting will be valid even if you close “DROWSINESS” screen.

5.

Set the starting switch to the OFF position and wait for 15 seconds to store the setting on the controller.

HD785-7

30-5

40 TROUBLESHOOTING

HD785-7

40-1

CONTENTS

40 TROUBLESHOOTING

CONTENTS RELATED INFORMATION TO TROUBLESHOOT ......................................................................................... 40-3 CONNECTOR LIST AND LAYOUT ......................................................................................................... 40-3 FUSE LOCATION TABLE ....................................................................................................................... 40-5 FAILURE CODE TABLE.......................................................................................................................... 40-7 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................... 40-8 FAILURE CODE [D5WNKB].................................................................................................................... 40-8 FAILURE CODE [DR81KR]..................................................................................................................... 40-9 FAILURE CODE [DR81MA] .................................................................................................................. 40-14 FAILURE CODE [DV03KB] ................................................................................................................... 40-15 FAILURE CODE [DV03KY] ................................................................................................................... 40-16 FAILURE CODE [F9D0MC]................................................................................................................... 40-17 FAILURE CODE [F9D2KK] ................................................................................................................... 40-18 FAILURE CODE [F9DSKR]................................................................................................................... 40-20 FAILURE CODE [ZA0010] .................................................................................................................... 40-25 FAILURE CODE [ZA0011]..................................................................................................................... 40-26 FAILURE CODE [ZA0012] .................................................................................................................... 40-27 FAILURE CODE [ZA0013] .................................................................................................................... 40-28 FAILURE CODE [ZA0014] .................................................................................................................... 40-29 FAILURE CODE [ZA0015] .................................................................................................................... 40-30 FAILURE CODE [ZA0016] .................................................................................................................... 40-31

40-2

HD785-7

40 TROUBLESHOOTING

CONNECTOR LIST AND LAYOUT

RELATED INFORMATION TO TROUBLESHOOT CONNECTOR LIST AND LAYOUT Three-dimensional drawing Address

Connector No.

Connector type

Number of pins

BZ

M

2

Drowsiness alarm buzzer

D-5

CAN01

DT2

3

Resistance

B-6

CAN11

DT2

3

Resistance

E-6

CAN13

DT2

3

Resistance

B-5

CAN14

DT2

3

Resistance

D-6

DDS1

J.S.T

14

Driver status monitor

D-6

DLL

DT2A

12

Service connector

C-5

DPC1_F

AMP070

20

Machine connector

C-5

DPC1_M

AMP070

20

Intermediate connector

C-5

DPC2A_F

AMP070

18

Machine connector

C-5

DPC2A_M

AMP070

18

Intermediate connector

C-5

TLC2

DRC

40

Translator controller

C-5

TLC3

DRC

40

Translator controller

C-5

HD785-7

Installation position

40-3

CONNECTOR LIST AND LAYOUT

40 TROUBLESHOOTING

TLC2 DLL DPC2A_F

CAN01

CAN13

X CAN11

DPC1_F

BZ

DPC2A_M TLC3

DPC1_M

DDS1

CAN14

X G0117569 $

40-4

%

&

'

(

)

HD785-7

40 TROUBLESHOOTING

FUSE LOCATION TABLE

FUSE LOCATION TABLE Fuse box (BT2) position and connection table REMARK Those for the other fuse boxes (BT1, BT3 and BT4) are the same as for the standard machine.

G0117570

Circled numbers correspond to terminal numbers shown in the circuit diagram of each failure code.

Fuse box BT2 Type of power supply

Breaker output

Key switch (ACC) Key switch (BR)

Fuse No.

Fuse capacity

(11)

10A

Machine monitor

(12)

10A

Rearview monitor (option), VHMS download

(13)

10A

Parking brake circuit

(14)

20A

Power window (L.H.)

(15)

20A

Power window (R.H.)

(16)

10A

-

Destination of circuit

Switched power supply

FUB1 (80A)

Continuous power supply

FUA2 (30A)

(17)

10A

Horn

Switched power supply

FUB1 (80A)

(18)

10A

Machine monitor, DC-DC converter, translator controller, driver status monitor

HD785-7

40-5

FUSE LOCATION TABLE

Type of power supply

Continuous power supply

40-6

Breaker output

FUA2 (30A)

40 TROUBLESHOOTING

Fuse No.

Fuse capacity

(19)

10A

Transmission controller

(20)

20A

B terminal

(21)

10A

Retarder controller, ABS controller

(22)

20A

Hazard lamp

(23)

10A

Secondary steering

(24)

10A

Room lamp, radio

(25)

10A

Machine monitor, VHMS controller, translator controller, driver status monitor

Destination of circuit

HD785-7

40 TROUBLESHOOTING

FAILURE CODE TABLE

FAILURE CODE TABLE Failure code

Failure

Applicable equipment

Action code

History category

D5WNKB

Travel Speed Line Signal Ground Fault

T/D

E01

Electrical system

DR81KR

CAN Disconnection (DDS)

T/D

E01

Electrical system

DR81MA

Option Setting Mismatch (Translator Controller)

BK

E03

Electrical system

DV03KB

Drowsiness Alarm Buzzer Output Ground Fault

T/D

E01

Electrical system

DV03KY

Drowsiness Alarm Buzzer Output Hot Short Circuit

T/D

E01

Electrical system

F9D0MC

Defective Translator Controller

T/D

E03

Electrical system

F9D2KK

Translator Controller Solenoid Power Source System Trouble

T/D

E03

Electrical system

F9DSKR

CAN Disconnection (Translator Controller)

BK

E03

Electrical system

ZA0010

Drowsiness alarm signal 2

T/D

E02

Electrical system

(*1)

ZA0011

Poor driving posture alarm signal

T/D

E01

Electrical system

(*1)

ZA0012

Eye closure alarm signal

T/D

E02

Electrical system

(*1)

ZA0013

Inattentive driving (looking up) alarm signal

T/D

E01

Electrical system

(*1)

ZA0014

Inattentive driving (looking down) alarm signal

T/D

E01

Electrical system

(*1)

ZA0015

Inattentive driving (looking left) alarm signal

T/D

E01

Electrical system

(*1)

ZA0016

Inattentive driving (looking right) alarm signal

T/D

E01

Electrical system

(*1)

Remarks

*1: This failure code is not set for the EU specification. Accordingly, it is not transmitted to KOMTRAX. •

In this table, failure codes are listed in the alphabetical sequence.

•

Applicable equipment is the controller which checks the system.

BK: Retarder controller T/D: Translator controller

HD785-7

40-7

FAILURE CODE [D5WNKB]

40 TROUBLESHOOTING

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) FAILURE CODE [D5WNKB] Action

Failure code

level E01 Detail of failure

Failure

D5WNKB

Travel Speed Line Signal Ground Fault (Translator controller system)

The travel speed sent to the driver status monitor is incorrect.

Action of conNone troller Phenomenon on machine

The various alarms on the driver status monitor are not shown.

Related information No.

Cause

1

Open circuit (wire breakage or defective contact of connector) in wiring harness

2

Ground fault in wiring harness (contact with GND circuit)

Procedure, measurement location, criteria and remarks 1.

Starting switch: OFF

2.

Disconnect the connectors TLC2 and DDS1. Connect a T-adapter to each female side.

Resistance

Between TLC2 (female) (21) and DDS1 (female) (3)

Max. 1Ω

1.

Starting switch: OFF

2.

Disconnect the connectors TLC2 and DDS1. Connect a T-adapter to one of them on the female side.

Resistance

Between ground and TLC2 (female) (21) or DDS1 (female) (3)

Min. 1MΩ

Circuit diagram of the travel speed line signal

40-8

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [DR81KR]

FAILURE CODE [DR81KR] Action level

Failure code DR81KR

E03 Detail of failure

Failure

CAN Disconnection (DDS) (Translator controller system)

The translator controller cannot obtain the information from driver status monitor in CAN communication circuit.

Action of conKeeps the information when the failure occurred. troller Phenomenon on machine

Related information

No.

System does not operate normally in some cases.

•

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

•

Start of CAN communication is recognized by each controller when ACC signal of starting switch is received.

•

Because each controller and machine monitor is directly connected to the battery, power is continuously provided even when the starting switch is in the OFF position.

•

Since signal of active line is pulse voltage, it cannot be measured by using multimeter.

•

The translator controller detects it and the retarder controller provides the failure information to the machine monitor.

•

Do the troubleshooting for the driver status monitor power supply system (Refer to the Causes 1 to 6). Then, do the troubleshooting for CAN wiring harness.

Cause

Procedure, measurement location, criteria and remarks

REMARK Inspect the battery voltage and the specific gravity of battery electrolyte.

1

Defective battery

2

Defective circuit breaker (FUA2)

3

Defective No.25 of fuse BT2

Voltage

Battery voltage

Min. 24V

Specific gravity

Specific gravity of battery electrolyte

Min. 1.26

If the circuit breaker is tripped, circuit probably has ground fault. (See cause 6.)

1.

Starting switch: OFF

2.

Remove No.25 of fuse BT2 (the fuse at the bottom)

If fuse is burnt out, circuit may have ground fault. (See cause 6.)

HD785-7

40-9

FAILURE CODE [DR81KR]

No.

40 TROUBLESHOOTING

Cause

Procedure, measurement location, criteria and remarks 1.

Starting switch: OFF

2.

Disconnect the connector DDS1. Connect a T-adapter to the female side of DDS1.

Between DDS1 (female) (1) and ground

Resistance

4

REMARK

Max. 1Ω

Check ER terminal for looseness and rust

Open circuit in wiring har1. ness

Starting switch: OFF

(wire breakage or defective contact)

2.

Disconnect the connector DDS1 from negative (-) terminal of battery. Connect a T-adapter to the female side of DDS1.

3.

Connect the negative (-) terminal of the battery.

Voltage

Between battery relay terminal B and ground

20 to 30V

Between DDS1 (7) and ground

20 to 30V

If voltage appears between battery relay terminal B and ground but not between DDS1 (7) and ground, an open circuit exists in wiring harness or fuse.

5

Ground fault in wiring harness (contact with GND circuit)

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

If the No.25 of fuse BT2 is blown out, replace it.

3.

Disconnect the connector DDS1. Connect a T-adapter to the female side.

Resistance

6

Min. 1MΩ

1.

Starting switch: OFF

Defective driver status monitor

2.

Disconnect the negative (-) terminal of the battery and insert the T-adapter to DDS1.

(power supply circuit)

3.

Connect the negative (-) terminal of the battery.

Voltage

7

Between DDS1 (female) (7) and ground

Defective CAN terminating resistor (internal open or short circuit)

Between DDS1 (7) and DDS1 (1)

20 to 30V

1.

Starting switch: OFF

2.

Disconnect the connectors CAN13 and CAN14. Connect the T-adapter to the male side.

Resistance

Between CAN13 (male) (A) and (B) (on the translator controller side)

120±12Ω

Between CAN14 (male) (A) and (B) (on the driver status monitor side)

120±12Ω

CAN communication line

REMARK CAN terminating resistors of 120Ω are connected in parallel. When the circuit resistance is measured from any connector, if the combined resistance is 60Ω, the wiring harness has no open circuit.

8

Open or short circuit in wiring harness

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect the connector TLC2 or DDS1. Connect a T-adapter to its female side.

REMARK If short circuit is found (the resistance between terminals is 1Ω and below), disconnect all CAN communication connectors of every controller, and check whether short circuit occurs between wiring harnesses or in the controller.

Resistance

40-10

Between TLC2 (female) (33) and (23)

Approx. 60Ω

Between DDS1 (female) (4) and (5)

Approx. 60Ω

HD785-7

40 TROUBLESHOOTING

No.

9

FAILURE CODE [DR81KR]

Cause

Procedure, measurement location, criteria and remarks 1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Insert a T-adapter to connectors TLC3, DDS1 and DPC1/DPC1_F.

3.

Connect the ground cable of the battery, and turn the starting switch to the ON position.

Defective starting switch ACC signal (start of CAN communication is not recognized)

Voltage

Between TLC3 (14) and (21)

20 to 30V

Between TLC3 (24) and (31)

20 to 30V

Between DDS1 (13) and (1)

20 to 30V

Between DPC1/DPC1_F (6) and (9)

20 to 30V

Between DPC1/DPC1_F (7) and (10)

20 to 30V

REMARK If no failure is found by check on cause 9, this check is not required.

10

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect the connectors TLC2, CAN13, CAN14, and DDS1, and connect T-adapter to female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

Resistance

Between TLC2 (female) (33) and CAN13 (female) (A)

Max. 1Ω

Between TLC2 (female) (23) and CAN13 (female) (B)

Max. 1Ω

Between TLC2 (female) (33) and CAN14 (female) (A)

Max. 1Ω

Between TLC2 (female) (23) and CAN14 (female) (B)

Max. 1Ω

Between TLC2 (female) (33) and DDS1 (female) (4)

Max. 1Ω

Between TLC2 (female) (23) and DDS1 (female) (5)

Max. 1Ω

REMARK If no failure is found by check on cause 10, this check is not required.

11

Open circuit in wiring harness

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect the connectors TLC3, DDS1, DPC1/DPC1_F, and connect Tadapter to each female side.

(wire breakage or defective contact of connector) Resistance

Between the starting switch (ACC) and TLC3 (female) (14) and (24)

Max. 1Ω

Between the starting switch (ACC) and DDS1 (female) (13)

Max. 1Ω

Between the starting switch (ACC) and DPC1/DPC1_F (female) (6) and (7)

Max. 1Ω

12

Defective driver status monitor

If no failure is found by the above checks, the driver status monitor is defective.

(Because this is an internal defect, troubleshooting cannot be done.)

13

Defective translator controller

If no failure is found by the checks above, the translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

14

Defective retarder controller

If no failure is found by the above checks, the retarder controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

HD785-7

40-11

FAILURE CODE [DR81KR]

40 TROUBLESHOOTING

Circuit diagram of the translator controller power supply

40-12

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [DR81KR]

Circuit diagram of CAN communication

HD785-7

40-13

FAILURE CODE [DR81MA]

40 TROUBLESHOOTING

FAILURE CODE [DR81MA] Action level

Failure code

E03 Detail of failure

Failure

DR81MA

Option Setting Mismatch (Translator Controller) (Retarder controller system)

When starting switch is turned to ON position, the option setting information sent from translator controller differs from that stored in the retarder controller.

Action of conNone troller Phenomenon on machine

•

The option system caution lamp lights up and the alarm buzzer sounds.

•

Even if cause of failure is eliminated, machine does not become normal until starting switch is turned to OFF position.

Related inforMethod of reproducing failure code: Turn the starting switch to the ON position. mation No.

Cause

Procedure, measurement location, criteria and remarks

1

Defective translator controller and retarder controller

The option setting of the translator controller or the retarder controller is probably incorrect. After replacing the translator controller or the retarder controller, set the options correctly. For details, see TESTING AND ADJUSTING.

2

3

Open circuit in wiring har- 1. ness 2.

Starting switch: OFF Disconnect the connector TLC3. Connect a T-adapter to the female side.

(wire breakage or defective contact)

Resistance

Defective translator controller

If no failure is found by the checks above, the translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

Between TLC3 (female) (20) and ground

Max. 1Ω

Circuit diagram of option setting

40-14

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [DV03KB]

FAILURE CODE [DV03KB] Action level

Failure code DV03KB

E01 Detail of failure Action of controller Phenomenon on machine

Failure

Drowsiness Alarm Buzzer Output Ground Fault (Translator controller system)

When the controller energizes the drowsiness alarm buzzer, an abnormal current flows through the circuit.

•

Stops to energize the drowsiness alarm buzzer circuit.

•

Even if the cause of the failure no longer exists, the machine does not become normal until the starting switch is turned to the OFF position.

Even when the driver status monitor detects drowsiness or drowsy operation, alarm buzzer does not sound.

Related infor- During the troubleshooting, when the starting switch is in the ON position, the drowsiness alarm mation buzzer sounds on and off for some period of time.

No.

1

Cause

Procedure, measurement location, criteria and remarks 1.

Starting switch: OFF

2.

Disconnect the connector BZ. Connect the T-adapter to the female side.

3.

Starting switch: ON

Defective drowsiness alarm buzzer

NOTICE

(Internal defect)

If the following voltages are normal and alarm buzzer does not operate, the drowsiness alarm buzzer is defective.

Voltage

2

Ground fault in wiring harness (contact with GND)

3

Defective translator controller

Between BZ (female) (1) and (2)

Starting switch: OFF

Max. 1V

Starting switch: ON

20 to 30V

1.

Starting switch: OFF

2.

Disconnect connectors TLC2 and BZ, and connect the T-adapter to female side of TLC2.

Resistance

Between TLC2 (female) (18) and ground

Min. 1MΩ

If no failure is found by the checks above, the translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

Circuit diagram of the drowsiness alarm buzzer

HD785-7

40-15

FAILURE CODE [DV03KY]

40 TROUBLESHOOTING

FAILURE CODE [DV03KY] Action

Failure code

level

DV03KY

E01 Detail of failure

Failure

Drowsiness Alarm Buzzer Output Hot Short Circuit (Translator controller system)

When the controller does not energize the drowsiness alarm buzzer solenoid, an abnormal current flows through the circuit.

Action of con- Even if the cause of the failure no longer exists, the machine does not become normal until the troller starting switch is turned to the OFF position.

Phenomenon on machine

The drowsiness alarm buzzer sound does not stop.

Related information No.

Cause

1

Hot short circuit in wiring harness (contact with 24V circuit)

Procedure, measurement location, criteria and remarks 1.

Starting switch: OFF

2.

Disconnect the connector TLC2. Connect a T-adapter to the female side.

3.

Starting switch: ON

Resistance 2

Defective translator controller

Between TLC2 (female) (18) and ground

Max. 1V

If no failure is found by the checks above, the translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

Circuit diagram of the drowsiness alarm buzzer

40-16

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [F9D0MC]

FAILURE CODE [F9D0MC] Action level E03 Detail of failure

Failure code

Failure

F9D0MC

Defective Translator Controller (Translator controller system)

Defective translator controller

Action of conNone troller Phenomenon on machine

The system does not operate normally.

Related inforMethod of reproducing failure code: Turn the starting switch to the ON position. mation No.

Cause

Procedure, measurement location, criteria and remarks

1

Defective translator controller

Translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

HD785-7

40-17

FAILURE CODE [F9D2KK]

40 TROUBLESHOOTING

FAILURE CODE [F9D2KK] Action level E03 Detail of failure

Failure code

Failure

F9D2KK

Translator Controller Solenoid Power Source System Trouble (Translator controller system)

Solenoid power supply voltage is 18V and below, while controller direct power supply voltage is normal.

Action of conNone troller Phenomenon on machine

Even when the driver status monitor detects drowsiness or drowsy operation, alarm buzzer does not sound.

Related infor- If fuse is blown out, check the circuits between fuse to TLC3 (female) (2), (12), and (22) for ground mation fault.

No.

Cause

Procedure, measurement location, criteria and remarks

1

Defective circuit breaker (FUB1)

If the circuit breaker is tripped, circuit probably has ground fault, etc. (See cause 4.)

2

Defective No.18 of fuse BT2

1.

Starting switch: OFF

2.

Remove No.18 of fuse BT2 (8th fuse from top)

If fuse is burnt out, circuit may have ground fault. (See cause 4.)

1.

Starting switch: OFF

2.

Disconnect the connector TLC3 from negative (-) terminal of battery. Connect a T-adapter to the female side of TLC3.

3.

Connect the negative (-) terminal of the battery.

4.

Starting switch: ON

Voltage

3

Between battery relay terminal M and ground

20 to 30V

Between ground and each of TLC3 (2), (12) and (22) 20 to 30V Open circuit in wiring harWhen the voltage of the No. 18 (15) of the fuse BT2 is correct and the voltage of ness (wire breakage or defec- the TLC3 (2), (12), and (22) are not correct, the wiring harness between No. 18 (15) of the fuse BT2 and the TLC3 (2), (12), and (22) has an open circuit. tive contact) 1.

Starting switch: OFF

2.

Disconnect the connector TLC3 from negative (-) terminal of battery. Connect a T-adapter to the female side of TLC3.

Resistance

Between ground and each of TLC3 (female) (21), (31), (32) and (33)

REMARK

Max. 1Ω

Check ER terminal for looseness and rust

4

Ground fault in wiring harness

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

If the No.18 of fuse BT2 is blown out, replace it.

3.

Disconnect the connector TLC3. Connect a T-adapter to the female side.

(contact with GND circuit) Resistance

40-18

Between ground and each of TLC3 (female) (2), (12) and (22)

Min. 1MΩ

HD785-7

40 TROUBLESHOOTING

No.

5

FAILURE CODE [F9D2KK]

Cause

Defective translator controller

Procedure, measurement location, criteria and remarks 1.

Starting switch: OFF

2.

Disconnect the negative (-) terminal of the battery and insert the T-adapter to TLC3.

3.

Connect the negative (-) terminal of the battery.

4.

Starting switch: ON

Voltage

Between ground and each of TLC3 (2), (12) and (12)

20 to 30V

Circuit diagram of power supply of the translator controller solenoid

HD785-7

40-19

FAILURE CODE [F9DSKR]

40 TROUBLESHOOTING

FAILURE CODE [F9DSKR] Action level

Failure code

E03 Detail of failure

Failure

F9DSKR

CAN Disconnection (Translator Controller) (Retarder controller system)

The retarder controller cannot obtain the information from the translator controller in CAN communication circuit.

Action of conKeeps the information when the failure occurred. troller Phenomenon on machine

Related information

No.

•

System does not operate normally in some cases.

•

The alarm information or failure information from translator controller cannot be updated

•

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

•

Start of CAN communication is recognized by each controller when ACC signal of starting switch is received.

•

Because each controller and machine monitor is directly connected to the battery, power is continuously provided even when the starting switch is in the OFF position.

•

Since signal of active line is pulse voltage, it cannot be measured by using multimeter.

•

Do the troubleshooting for the translator controller power supply system (Refer to the Causes 1 to 6). Then, do the troubleshooting for CAN wiring harness.

Cause

Procedure, measurement location, criteria and remarks

REMARK Inspect the battery voltage and the specific gravity of battery electrolyte.

1

Defective battery

2

Defective circuit breaker (FUA2)

3

Defective No.25 of fuse BT2

Voltage

Battery voltage

Min. 24V

Specific gravity

Specific gravity of battery electrolyte

Min. 1.26

If the circuit breaker is tripped, circuit probably has ground fault. (See cause 6.)

1.

Starting switch: OFF

2.

Remove No.25 of fuse BT2 (the fuse at the bottom)

If fuse is burnt out, circuit may have ground fault. (See cause 6.)

1.

Starting switch: OFF

2.

Disconnect the connector TLC3 from negative (-) terminal. Connect a Tadapter to the female side of TLC3.

Resistance

4

Open circuit in wiring harness (wire breakage or defective contact)

Between ground and each of TLC3 (female) (21), (31), (32) and (33)

REMARK

Max. 1Ω

Check ER terminal for looseness and rust 1.

Starting switch: OFF

2.

Disconnect the connector TLC3 from negative (-) terminal of battery. Connect a T-adapter to the female side of TLC3.

3.

Connect the negative (-) terminal of the battery.

Voltage

Between battery relay terminal B and ground

20 to 30V

Between ground and each of TLC3 (1) and (11)

20 to 30V

If voltage appears between battery relay terminal B and ground but not between ground and each of TLC3 (1) and (11), wiring harness or fuse has an open circuit.

40-20

HD785-7

40 TROUBLESHOOTING

No.

5

FAILURE CODE [F9DSKR]

Cause

Ground fault in wiring harness

Procedure, measurement location, criteria and remarks 1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

If the No.25 of fuse BT2 is blown out, replace it.

3.

Disconnect the connector TLC3. Connect a T-adapter to the female side.

(contact with GND circuit) Resistance

6

Defective translator controller (power supply circuit)

7

(internal open or short circuit)

Min. 1MΩ

1.

Starting switch: OFF

2.

Disconnect the negative (-) terminal of the battery and insert the T-adapter to TLC3.

3.

Connect the negative (-) terminal of the battery.

Voltage

Defective CAN terminating resistor

Between ground and each of TLC3 (female) (1), and (11)

Between each of TLC3 (1), (11) and each of TLC3 (21), (31), (32), and (33)

20 to 30V

1.

Starting switch: OFF

2.

Disconnect the connectors CAN01 and CAN11. Connect the T-adapter to the male side.

Resistance

Between CAN01 (male) (A) and (B) (on the translator controller side)

120±12Ω

Between CAN11 (male) (A) and (B) (on the retarder controller side)

120±12Ω

CAN communication line

REMARK CAN terminating resistors of 120Ω are connected in parallel. When the circuit resistance is measured from any connector, if the combined resistance is 60Ω, the wiring harness has no open circuit.

8

Open or short circuit in wiring harness

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect any connector of BRC2, TLC2, and RCA. Connect a T-adapter to its female side.

REMARK If short circuit is found (the resistance between terminals is 1Ω and below), disconnect all CAN communication connectors of every controller, and check whether short circuit occurs between wiring harnesses or in the controller.

Resistance

9

Approx. 60Ω

Between TLC2 (female) (32) and (22)

Approx. 60Ω

Between RCA (female) (1) and (2)

Approx. 60Ω

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Insert a T-adapter to connectors BRC3, TLC3 and DPC1/DPC1_F.

3.

Connect the ground cable of the battery, and turn the starting switch to the ON position.

Defective starting switch ACC signal (start of CAN communication is not recognized) Voltage

HD785-7

Between BRC2 (female) (33) and (23)

Between TLC3 (14) and (21)

20 to 30V

Between TLC3 (24) and (31)

20 to 30V

Between BRC3 (14) and (21)

20 to 30V

Between BRC3 (24) and (31)

20 to 30V

Between DPC1/DPC1_F (6) and (9)

20 to 30V

Between DPC1/DPC1_F (7) and (10)

20 to 30V

40-21

FAILURE CODE [F9DSKR]

No.

40 TROUBLESHOOTING

Cause

Procedure, measurement location, criteria and remarks

REMARK If no failure is found by check on cause 9, this check is not required.

10

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect the connectors BRC2, TLC2, CAN01, CAN11, and RCA. Connect T-adapter to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector) Resistance

Between TLC2 (female) (32) and CAN01 (female) (A)

Max. 1Ω

Between TLC2 (female) (22) and CAN01 (female) (B)

Max. 1Ω

Between TLC2 (female) (32) and CAN11 (female) (A)

Max. 1Ω

Between TLC2 (female) (22) and CAN11 (female) (B)

Max. 1Ω

Between BRC2 (female) (33) and TLC2 (female) (32)

Max. 1Ω

Between BRC2 (female) (23) and TLC2 (female) (22)

Max. 1Ω

Between BRC2 (female) (33) and CAN01 (female) (A)

Max. 1Ω

Between BRC2 (female) (23) and CAN01 (female) (B)

Max. 1Ω

Between BRC2 (female) (33) and CAN11 (female) (A)

Max. 1Ω

Between BRC2 (female) (23) and CAN11 (female) (B)

Max. 1Ω

Between BRC2 (female) (33) and RCA (female) (1)

Max. 1Ω

Between BRC2 (female) (23) and RCA (female) (2)

Max. 1Ω

REMARK If no failure is found by check on cause 10, this check is not required.

11

Open circuit in wiring harness

1.

Turn off the starting switch. Disconnect the ground cable of the battery.

2.

Disconnect the connectors BRC3, TLC3, DPC1/DPC1_F, and connect Tadapter to each female side.

(wire breakage or defective contact of connector) Resistance

Between the starting switch (ACC) and BRC3 (female) (14) and (24)

Max. 1Ω

Between the starting switch (ACC) and TLC3 (female) (14) and (24)

Max. 1Ω

Between the starting switch (ACC) and DPC1/DPC1_F (female) (6) and (7)

Max. 1Ω

12

Defective translator controller

If no failure is found by the checks above, the translator controller is defective. (Because this is an internal defect, troubleshooting cannot be done.)

13

Defective retarder controller

If no failure is found by the above checks, the retarder controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-22

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [F9DSKR]

Circuit diagram of the translator controller power supply

HD785-7

40-23

FAILURE CODE [F9DSKR]

40 TROUBLESHOOTING

Circuit diagram of the retarder controller

Circuit diagram of CAN communication

40-24

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [ZA0010]

FAILURE CODE [ZA0010] Action code E02 Detail of failure

Failure code

Failure

Drowsiness Alarm Signal 2 (Translator controller system)

ZA0010 Drowsiness of the operator is detected.

Action of conActivates a voice alarm and a drowsiness alarm buzzer. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No. 1

Cause

Procedure, measurement location, criteria and remarks

Drowsiness of the operaInstruct the operator to drive the machine with sufficient sleep and rest. tor is detected.

HD785-7

40-25

FAILURE CODE [ZA0011]

40 TROUBLESHOOTING

FAILURE CODE [ZA0011] Action code E01 Detail of failure

Failure code

Failure

Poor Driving Posture Alarm Signal (Translator controller system)

ZA0011 Poor driving posture of the operator is detected.

Action of conActivates a voice alarm. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No.

Cause

1

Poor driving posture of the operator is detected.

40-26

Procedure, measurement location, criteria and remarks Instruct the operator to focus on driving in the correct posture.

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [ZA0012]

FAILURE CODE [ZA0012] Action code E02 Detail of failure

Failure code

Failure

Eye Closure Alarm Signal (Translator controller system)

ZA0012 Eye closure of the operator is detected.

Action of conActivates a voice alarm and a drowsiness alarm buzzer. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No. 1

Cause

Procedure, measurement location, criteria and remarks

Eye closure of the operaInstruct the operator to drive the machine with sufficient sleep and rest. tor is detected.

HD785-7

40-27

FAILURE CODE [ZA0013]

40 TROUBLESHOOTING

FAILURE CODE [ZA0013] Action code E01 Detail of failure

Failure code

Failure

Inattentive Driving (Looking Up) Alarm Signal (Translator controller system)

ZA0013 Inattentive driving (looking up) of the operator is detected.

Action of conActivates a voice alarm. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No.

Cause

1

Inattentive driving (looking up) of the operator is detected.

40-28

Procedure, measurement location, criteria and remarks Instruct the operator to focus on driving in the correct posture.

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [ZA0014]

FAILURE CODE [ZA0014] Action code E01 Detail of failure

Failure code

Failure

Inattentive Driving (Looking Down) Alarm Signal (Translator controller system)

ZA0014 Inattentive driving (looking down) of the operator is detected.

Action of conActivates a voice alarm. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No. 1

Cause

Procedure, measurement location, criteria and remarks

Inattentive driving (looking down) of the operator Instruct the operator to focus on driving in the correct posture. is detected.

HD785-7

40-29

FAILURE CODE [ZA0015]

40 TROUBLESHOOTING

FAILURE CODE [ZA0015] Action code E01 Detail of failure

Failure code

Failure

Inattentive Driving (Looking Left) Alarm Signal (Translator controller system)

ZA0015 Inattentive driving (looking left) of the operator is detected.

Action of conActivates a voice alarm. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No. 1

40-30

Cause

Procedure, measurement location, criteria and remarks

Inattentive driving (looking left) of the operator is Instruct the operator to focus on driving in the correct posture. detected.

HD785-7

40 TROUBLESHOOTING

FAILURE CODE [ZA0016]

FAILURE CODE [ZA0016] Action code E01 Detail of failure

Failure code

Failure

Inattentive Driving (Looking Right) Alarm Signal (Translator controller system)

ZA0016 Inattentive driving (looking right) of the operator is detected.

Action of conActivates a voice alarm. troller Phenomenon on machine

None

Related inforThis failure code is not shown on the machine monitor. mation No.

Cause

1

Inattentive driving (looking right) of the operator is detected.

HD785-7

Procedure, measurement location, criteria and remarks Instruct the operator to focus on driving in the correct posture.

40-31

50 DISASSEMBLY AND ASSEMBLY

HD785-7

50-1

CONTENTS

50 DISASSEMBLY AND ASSEMBLY

CONTENTS RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-3 HOW TO READ THIS MANUAL.............................................................................................................. 50-3 SPECIAL TOOLS LIST ........................................................................................................................... 50-5 ELECTRICAL SYSTEM ................................................................................................................................. 50-6 REMOVE AND INSTALL DRIVER STATUS MONITOR .......................................................................... 50-6 REMOVE DRIVER STATUS MONITOR ........................................................................................... 50-6 INSTALL DRIVER STATUS MONITOR ............................................................................................ 50-8 REMOVE AND INSTALL TRANSLATOR CONTROLLER ....................................................................... 50-9 REMOVE TRANSLATOR CONTROLLER........................................................................................ 50-9 INSTALL TRANSLATOR CONTROLLER ....................................................................................... 50-10 REMOVE AND INSTALL DROWSINESS DETECTION CAMERA ........................................................ 50-12 REMOVE DROWSINESS DETECTION CAMERA......................................................................... 50-12 INSTALL DROWSINESS DETECTION CAMERA .......................................................................... 50-13 REMOVE AND INSTALL DROWSINESS ALARM BUZZER ................................................................. 50-15 REMOVE DROWSINESS ALARM BUZZER .................................................................................. 50-16 INSTALL DROWSINESS ALARM BUZZER ................................................................................... 50-23 REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS ........................................ 50-30 REMOVE DROWSINESS DETECTION WIRING HARNESS......................................................... 50-31 INSTALL DROWSINESS DETECTION WIRING HARNESS.......................................................... 50-47

50-2

HD785-7

50 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.

Reading the special tools list •

The special tools required for removal and installation work are described in the list as symbols such as A, ..., X. Part number, part name, necessity, and quantity are described.

•

Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.

•

The symbols used in the table of special tools indicate the following meanings.

■: Not substitutable, and work cannot be performed without the tool. ●: Very useful tools which can be substituted with commercially available tools.

Reading the work procedures All the necessary information for the work procedure, the precautions and prior knowledge relating to the work procedures is described step by step.

Reading the symbols Important safety and quality portions are marked with the following symbols so that Shop Manual is used effectively.

Symbol

Item

Summary

k

Danger

This symbol indicates extremely high possibility of serious harm which will result in death or serious injury if it is not avoided.

k

Warning

This symbol indicates serious harm a potentially hazardous situation which will result in death or serious injury if it is not avoided.

k

Caution

This symbol indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.

Weight

This symbol indicates the weight of parts and components. Be careful when selecting wires and working posture for slinging work.

Tightening torque

This symbol indicates the tightening torque for portions which requires special care in assembling work.

Coat

This symbol indicates a place to be coated with adhesive, grease, etc. in assembling work.

Oil and coolant

This symbol indicates a place to supply oil, coolant, etc. along with the quantity. (*1)

Draining

This symbol indicates a place to drain oil, coolant, etc. and the quantity.

Safety

This signal indicates the works which require special caution for the machine safety when assembling.

*1: For details of a place to supply oil, coolant, etc. and the quantity, see SPECIFICATIONS, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”

Reading the signal word Signal word for notice and remark describes the following.

HD785-7

50-3

HOW TO READ THIS MANUAL

50 DISASSEMBLY AND ASSEMBLY

Symbol

Item

Summary

NOTICE

Notice

If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.

REMARK

Remarks

Information contained in this signal word is useful to know.

Reading the unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.

50-4

HD785-7

50 DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLS LIST

SPECIAL TOOLS LIST How to read the tool list Special tools to be used when you remove and install the drowsiness detection wiring harness Symbol A

Part name Pin puller

HD785-7

Part No. Commercially available

Specifications DEUTSCH:0411-240-2005

Q'ty

Remarks

1

50-5

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DRIVER STATUS MONITOR

ELECTRICAL SYSTEM REMOVE AND INSTALL DRIVER STATUS MONITOR Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same.

No.

Part name

Part No.

Specifications

Q'ty

1

Hexagonal wrench

Commercially available

4mm

1

2

Torque wrench (hexagonal)

Commercially available

0 to 20Nm

1

Remarks

Precautions before and during work

k Stop the machine on a level ground, set the parking brake switch to the PARKING (P) position, and

stop the engine.

k Chock the tires to prevent unexpected movement of the machine.

k Set the battery disconnect switch to the OFF position. (For details, see the shop manual for the

standard machine, STRUCTURE AND FUNCTION, MAINTENANCE STANDARD, “BATTERY DISCONNECT SWITCH”.)

k When you disconnect the wirings and hoses, be careful not to deform or damage them with the clips

and clamps.

k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the work.

NOTICE Check the connector numbers and installation positions before you disconnect the wirings and hoses, and write them down.

REMOVE DRIVER STATUS MONITOR 1.

Remove the hexagonal socket head screws (1) (4 pieces), and remove the bracket (2).

REMARK • Be careful not to lose the washer.

• The driver status monitor (3) and wiring harness are attached to the bracket (2) at this time.

Tool: Hexagonal wrench Hexagonal socket head screw (1): Width across flats 4mm, M6

50-6

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DRIVER STATUS MONITOR

2.

Disconnect the drowsiness detection camera cable connector (4) and connector DDS1 (5).

3.

Remove the screws (6) (4 pieces), and remove the driver status monitor (3).

Tool: Phillips screwdriver Screw (6): M4

HD785-7

50-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DRIVER STATUS MONITOR

INSTALL DRIVER STATUS MONITOR 1.

Install the driver status monitor (3) to the bracket (2) with the screws (6) (4 pieces).

REMARK • Install the driver status monitor (3) in the correct direction.

• When you install it, be careful not to let the driver status monitor (3) stay outside the surface (a) of the bracket (2).

Tool: Phillips screwdriver Screw (6): M4

2.

Connect the drowsiness detection camera cable connector (4) and connector DDS1 (5).

3.

Install the bracket (2) with the hexagonal socket head screws (1) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (1): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

50-8

socket

head

screw

(1):

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL TRANSLATOR CONTROLLER

REMOVE AND INSTALL TRANSLATOR CONTROLLER Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same.

No.

Part name

Part No.

Specifications

Q'ty

1

Phillips screwdriver

Commercially available

2

Socket wrench

Commercially available

13mm

1

3

Hexagonal wrench

Commercially available

4mm

1

4

Torque wrench (phillips screwdriver)

Commercially available

0 to 10Nm

1

5

Torque wrench (socket)

Commercially available

0 to 50Nm

1

Remarks

1

Precautions before and during work

k Stop the machine on a level ground, set the parking brake switch to the PARKING (P) position, and

stop the engine.

k Chock the tires to prevent unexpected movement of the machine.

k Set the battery disconnect switch to the OFF position. (For details, see the shop manual for the

standard machine, STRUCTURE AND FUNCTION, MAINTENANCE STANDARD, “BATTERY DISCONNECT SWITCH”.)

k When you disconnect the wirings and hoses, be careful not to deform or damage them with the clips

and clamps.

k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the work.

NOTICE Check the connector numbers and installation positions before you disconnect the wirings and hoses, and write them down.

REMOVE TRANSLATOR CONTROLLER 1.

Pull up the seat surface of the trainer seat (1).

HD785-7

50-9

REMOVE AND INSTALL TRANSLATOR CONTROLLER

2.

50 DISASSEMBLY AND ASSEMBLY

Remove the screws (2) (4 pieces), and remove the cover (3).

Tool: Phillips screwdriver

3.

Loosen the hexagonal socket head bolt at the center of each connector, and disconnect the connectors TLC2 (4) and TLC3 (5) from the translator controller (6).

Tool: Hexagonal wrench Hexagonal socket head bolt: Width across flats 4mm, M5

4.

Remove the bolts (7) (4 pieces), and remove the translator controller (6).

REMARK Be careful not to lose the washer.

Tool: Ratchet handle Bolt (7): Width across flats 13mm, M8

INSTALL TRANSLATOR CONTROLLER 1.

Install the translator controller (6) with the bolts (7) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (socket) Bolt (7): Width across flats 13mm, M8 Bolt (7): 27 to 34Nm{2.8 to 3.5kgfm}

2.

Connect the connectors TLC2 (4) and TLC3 (5) to the translator controller (6) with the hexagonal socket head bolt at the center of each connector.

NOTICE Do not tighten them too much. They can be damaged.

Tool: Hexagonal wrench Hexagonal socket head bolt: Width across flats 4mm, M5

50-10

HD785-7

50 DISASSEMBLY AND ASSEMBLY

3.

REMOVE AND INSTALL TRANSLATOR CONTROLLER

Install the cover (3) with the screws (2) (4 pieces).

Tool: Torque wrench (phillips screwdriver) Screw (2): 3.44 to 4.41Nm{0.35 to 0.45kgfm}

4.

Set the seat surface of the trainer seat (1) to its initial position.

HD785-7

50-11

REMOVE AND INSTALL DROWSINESS DETECTION CAMERA

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION CAMERA Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same.

No.

Part name

Part No.

Specifications

Q'ty

1

Phillips screwdriver

Commercially available

2

Hexagonal wrench

Commercially available

4mm

1

3

Torque wrench (hexagonal)

Commercially available

0 to 20Nm

1

4

Torque wrench (phillips screwdriver)

Commercially available

0 to 5Nm

1

Remarks

1

Precautions before and during work

k Stop the machine on a level ground, set the parking brake switch to the PARKING (P) position, and

stop the engine.

k Chock the tires to prevent unexpected movement of the machine.

k Set the battery disconnect switch to the OFF position. (For details, see the shop manual for the

standard machine, STRUCTURE AND FUNCTION, MAINTENANCE STANDARD, “BATTERY DISCONNECT SWITCH”.)

k When you disconnect the wirings and hoses, be careful not to deform or damage them with the clips

and clamps.

k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the work.

NOTICE Check the connector numbers and installation positions before you disconnect the wirings and hoses, and write them down.

REMOVE DROWSINESS DETECTION CAMERA 1.

Remove the hexagonal socket head screws (1) (2 pieces), and remove the drowsiness detection camera (2).

REMARK • The wiring harness is fixed at this time.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (1): Width across flats 4mm, M6

50-12

HD785-7

50 DISASSEMBLY AND ASSEMBLY

2.

REMOVE AND INSTALL DROWSINESS DETECTION CAMERA

Remove the screws (6) (2 pieces), and remove the bracket (7).

Tool: Phillips screwdriver Screw (6): M3

3.

Remove the screws (3) (2 pieces), and remove the connector cover (4).

Tool: Phillips screwdriver Screw (3): M3

4.

Disconnect the connector (5).

INSTALL DROWSINESS DETECTION CAMERA 1.

Connect the connector (5) to the drowsiness detection camera (2).

2.

Install the connector cover (4) with the screws (3) (2 pieces).

NOTICE Do not tighten them too much. They can be damaged.

Tool: Torque wrench (phillips screwdriver) Screw (3): M3 Screw (3): 0.5Nm{0.05kgfm}

HD785-7

50-13

REMOVE AND INSTALL DROWSINESS DETECTION CAMERA

3.

50 DISASSEMBLY AND ASSEMBLY

Install the bracket (7) with the screws (6) (2 pieces).

NOTICE Do not tighten them too much. They can be damaged.

Tool: Torque wrench (phillips screwdriver) Screw (6): M3 Screw (6): 0.5Nm{0.05kgfm}

4.

Install the drowsiness detection camera (2) with the hexagonal socket head screws (1) (2 pieces).

NOTICE Do not tighten them too much. They can be damaged.

REMARK • Be sure to put the washer.

• Align the holes (a) of the bracket (6) and (7), and set the position of the drowsiness detection camera (2).

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (1): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

50-14

socket

head

screw

(1):

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

REMOVE AND INSTALL DROWSINESS ALARM BUZZER Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same.

No.

Part name

Part No.

Specifications

Q'ty

1

Phillips screwdriver

Commercially available

2

Socket wrench

Commercially available

10mm

1

3

Hexagonal wrench

Commercially available

4mm

1

4

Torque wrench (phillips screwdriver)

Commercially available

0 to 10Nm

1

5

Torque wrench (socket)

Commercially available

0 to 50Nm

1

6

Torque wrench (hexagonal)

Commercially available

0 to 50Nm

1

Remarks

1

Precautions before and during work

k Stop the machine on a level ground, set the parking brake switch to the PARKING (P) position, and

stop the engine.

k Chock the tires to prevent unexpected movement of the machine.

k Set the battery disconnect switch to the OFF position. (For details, see the shop manual for the

standard machine, STRUCTURE AND FUNCTION, MAINTENANCE STANDARD, “BATTERY DISCONNECT SWITCH”.)

k When you disconnect the wirings and hoses, be careful not to deform or damage them with the clips

and clamps.

k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the work.

NOTICE Check the connector numbers and installation positions before you disconnect the wirings and hoses, and write them down.

HD785-7

50-15

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

50 DISASSEMBLY AND ASSEMBLY

REMOVE DROWSINESS ALARM BUZZER 1.

Remove the hexagonal socket head screws (1) (2 pieces), and remove the drowsiness detection camera (2).

REMARK • The drowsiness detection camera cable is fixed at this time.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (1): Width across flats 4mm, M6

2.

Remove the clamp (3).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw for clamp (3): Width across flats 4mm, M6

3.

Remove the hexagonal socket head screws (4) (3 pieces), and remove the bracket (5).

REMARK • The drowsiness detection camera cable is attached to the bracket (5) at this time.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (4): Width across flats 4mm, M6

4.

Remove the grommet (6) and drowsiness detection camera cable together from the bracket (5).

REMARK Move the drowsiness detection camera (2) to a safe place not to interfere with the removal work of the buzzer.

50-16

HD785-7

50 DISASSEMBLY AND ASSEMBLY

5.

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

Remove the hexagonal socket head screws (8) (4 pieces), and remove the cover (9).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (8): Width across flats 4mm, M6

6.

Remove the hexagonal socket head screws (10) (4 pieces), and remove the cover (11).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (10): Width across flats 4mm, M6

7.

Remove the cover (13) as follows.

1) Move the GPS antenna (14) to the front side of the machine.

2)

Remove the hexagonal socket head screws (12) (5 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (12): Width across flats 4mm, M6

HD785-7

50-17

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

3)

50 DISASSEMBLY AND ASSEMBLY

Remove the cover (13).

REMARK Put the drowsiness detection camera (2) through the opening (b) of the cover (13).

8.

Remove the hexagonal socket head screws (15) (2 pieces), and remove the cover (16).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (15): Width across flats 4mm, M6

9.

Remove the bolts (17) (2 pieces), and disconnect the bracket (18).

REMARK Move the dashboard cover (19) to a safe place not to interfere with the removal work of the buzzer.

Tool: Socket wrench Bolt (17): Width across flats 10mm, M6

50-18

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

10. Remove the hexagonal socket head screws (20) (4 pieces), and remove the dashboard cover (19).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (20): Width across flats 4mm, M6

11. Remove the bolts (21) (6 pieces), and remove the air conditioner duct (22).

Tool: Socket wrench Bolt (21): Width across flats 10mm, M6

12. Disconnect the connectors RVB (23) and RVM (24).

13. Pull out the switch (25).

NOTICE The wiring harness can be disconnected or damaged if you pull out the switch (25) by force.

REMARK • The wiring harness is attached to the switch (25) at this time.

• Switch (25): Power mode selector switch

HD785-7

50-19

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

50 DISASSEMBLY AND ASSEMBLY

14. Disconnect the connector PWM2 (26), and remove the switch (25).

15. Disconnect the connectors AISS (27), EXH (28), ARSC (29), HAZ (30), and ABS (31).

16. Disconnect the connector CG1 (33) of the cigarette lighter (32).

17. Disconnect the connectors CK1 (34) and CHECK (35).

50-20

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

18. Disconnect the connectors SDE (36) and CH1 (37).

19. Disconnect the connectors AGS (36a) and DEFSW (37a).

20. Disconnect the connectors CH2 (38), FOG (39), and BLS (40).

21. Disconnect the connector HMSW (38a).

HD785-7

50-21

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

50 DISASSEMBLY AND ASSEMBLY

22. Remove the hexagonal socket head screws (41) (8 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (41): Width across flats 4mm, M6

23. Remove the cover (42).

NOTICE • Remove the cover (42) carefully.

• Make sure that the wiring harness of the switch is not tangled up, and remove it.

• Remove the cover (42) carefully not to interfere with the parts (c), (d), and (e).

24. Disconnect the connector BZ (43), and remove it from the connector stand.

25. Remove the screws (44) (2 pieces), and remove the drowsiness alarm buzzer (45).

Tool: Phillips screwdriver Screw (44): M4

50-22

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

INSTALL DROWSINESS ALARM BUZZER 1.

Install the drowsiness alarm buzzer (45) with the screws (44) (2 pieces).

Tool: Torque wrench (phillips screwdriver) Screw (44): M4 Screw (44): 0.98 to 1.27Nm{0.1 to 0.13kgfm}

2.

Install the connector BZ (43) to the connector stand, and connect it.

3.

Set the cover (42) to the installation position.

NOTICE • Make sure that the wiring harness of the switch is not tangled up.

• Be careful not to let the cover (42) interfere with the parts (c), (d), and (e).

4.

Install the cover (42) with the hexagonal socket head screws (41) (8 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (41): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

HD785-7

socket

head

screw

(41):

50-23

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

5.

Connect the connector HMSW (38a).

6.

Connect the connectors CH2 (38), FOG (39), and BLS (40).

7.

Connect the connectors AGS (36a) and DEFSW (37a).

8.

Connect the connectors SDE (36) and CH1 (37).

9.

Connect the connectors CK1 (34) and CHECK (35).

50-24

50 DISASSEMBLY AND ASSEMBLY

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

10. Connect the connector CG1 (33) of the cigarette lighter (32).

11. Connect the connectors AISS (27), EXH (28), ARSC (29), HAZ (30), and ABS (31).

12. Pull out the connector PWM2 (26), and connect the switch (25).

NOTICE The wiring harness can be disconnected or damaged if you pull out the connector PWM2 (26) by force.

REMARK Switch (25): Power mode selector switch

13. Install the switch (25).

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50-25

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

50 DISASSEMBLY AND ASSEMBLY

14. Connect the connectors RVB (23) and RVM (24).

15. Install the air conditioner duct (22) with the bolts (21) (6 pieces).

Tool: Torque wrench (socket) Bolt (21): Width across flats 10mm, M6 Bolt (21): 11.8 to 14.7Nm{1.2 to 1.5kgfm}

16. Install the dashboard cover (19) with the hexagonal socket head screws (20) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (20): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(20):

17. Connect the bracket (18) with the bolts (17) (2 pieces).

Tool: Torque wrench (socket) Bolt (17): Width across flats 10mm, M6 Bolt (17): 11.8 to 14.7Nm{1.2 to 1.5kgfm}

18. Install the cover (16) with the hexagonal socket head screws (15) (2 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (15): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

50-26

socket

head

screw

(15):

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

19. Install the cover (13) as follows.

1)

Set the cover (13) to the installation position.

2)

Pull out the drowsiness detection camera (2) through the opening (b) of the cover (13).

3)

Install the cover (13) with the hexagonal socket head screws (12) (5 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (12): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

4)

socket

head

screw

(12):

Move the GPS antenna (14) to the top of the plate (14a).

HD785-7

50-27

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

20. Install the cover (11) with the hexagonal socket head screws (10) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (10): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(10):

21. Install the cover (9) with the hexagonal socket head screws (8) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (8): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(8):

22. Install the grommet (6) and drowsiness detection camera cable together to the bracket (5).

23. Install the bracket (5) with the hexagonal socket head screws (4) (3 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (4): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(4):

24. Install the clamp (3).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw for clamp (3): Width across flats 4mm, M6 Hexagonal socket head screw for clamp (3): 9.8Nm{1.0kgfm}

50-28

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS ALARM BUZZER

25. Install the drowsiness detection camera (2) with the hexagonal socket head screws (1) (2 pieces).

REMARK • Be sure to put the washer.

• Align the holes (a) of the bracket (5) and (5a), and set the position of the drowsiness detection camera (2).

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (1): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

HD785-7

socket

head

screw

(1):

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same.

No.

Part name

Part No.

Specifications

Q'ty

1

Phillips screwdriver

Commercially available

2

Socket wrench

Commercially available

10mm

1

3

Socket wrench

Commercially available

13mm

1

4

Socket wrench

Commercially available

17mm

1

5

Hexagonal wrench

Commercially available

4mm

1

6

Ratchet handle

Commercially available

9.5sq

1

7

Torque wrench (phillips screwdriver)

Commercially available

0 to 10Nm

1

8

Torque wrench (socket)

Commercially available

0 to 100Nm

1

9

Torque wrench (hexagonal)

Commercially available

0 to 50Nm

1

10

Diagonal pliers

Commercially available

1

11

Band

Commercially available

21

12

Adhesive tape

Commercially available

1

Remarks

1

Special tools to be used when you remove and install the drowsiness detection wiring harness Symbol A

Part name Pin puller

Part No. Commercially available

Specifications DEUTSCH:0411-240-2005

Q'ty

Remarks

1

Precautions before and during work

k Stop the machine on a level ground, set the parking brake switch to the PARKING (P) position, and

stop the engine.

k Chock the tires to prevent unexpected movement of the machine.

k Set the battery disconnect switch to the OFF position. (For details, see the shop manual for the

standard machine, STRUCTURE AND FUNCTION, MAINTENANCE STANDARD, “BATTERY DISCONNECT SWITCH”.)

k When you disconnect the wirings and hoses, be careful not to deform or damage them with the clips

and clamps.

k If the wirings and hoses can be deformed or damaged, remove the clips and clamps before the work.

50-30

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

NOTICE Check the connector numbers and installation positions before you disconnect the wirings and hoses, and write them down.

REMOVE DROWSINESS DETECTION WIRING HARNESS 1.

Remove the hexagonal socket head screws (1) (2 pieces), and remove the drowsiness detection camera (2).

REMARK • The drowsiness detection camera cable is fixed at this time.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (1): Width across flats 4mm, M6

2.

Remove the clamp (3).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw for clamp (3): Width across flats 4mm, M6

3.

Remove the hexagonal socket head screws (4) (3 pieces), and remove the bracket (5).

REMARK • The drowsiness detection camera cable is attached to the bracket (5) at this time.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (4): Width across flats 4mm, M6

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

4.

50 DISASSEMBLY AND ASSEMBLY

Remove the grommet (6) and drowsiness detection camera cable together from the bracket (5).

REMARK Move the drowsiness detection camera (2) to a safe place not to interfere with the removal work of the buzzer.

5.

Remove the hexagonal socket head screws (8) (4 pieces), and remove the cover (9).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (8): Width across flats 4mm, M6

6.

Remove the hexagonal socket head screws (10) (4 pieces), and remove the cover (11).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (10): Width across flats 4mm, M6

7.

Remove the cover (13) as follows.

1) Move the GPS antenna (14) to the front side of the machine.

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50 DISASSEMBLY AND ASSEMBLY

2)

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

Remove the hexagonal socket head screws (12) (5 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (12): Width across flats 4mm, M6

3)

Remove the cover (13).

REMARK Put the drowsiness detection camera (2) through the opening (b) of the cover (13).

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

8.

50 DISASSEMBLY AND ASSEMBLY

Remove the hexagonal socket head screws (15) (2 pieces), and remove the cover (16).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (15): Width across flats 4mm, M6

9.

Remove the bolts (17) (2 pieces), and disconnect the bracket (18).

REMARK Move the dashboard cover (19) to a safe place not to interfere with the removal work of the buzzer.

Tool: Socket wrench Bolt (17): Width across flats 10mm, M6

10. Remove the hexagonal socket head screws (20) (4 pieces), and remove the dashboard cover (19).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (20): Width across flats 4mm, M6

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

11. Remove the bolts (21) (6 pieces), and remove the air conditioner duct (22).

Tool: Socket wrench Bolt (21): Width across flats 10mm, M6

12. Disconnect the connectors RVB (23) and RVM (24).

13. Pull out the switch (25).

NOTICE The wiring harness can be disconnected or damaged if you pull out the switch (25) by force.

REMARK • The wiring harness is attached to the switch (25) at this time.

• Switch (25): Power mode selector switch 14. Disconnect the connector PWM2 (26), and remove the switch (25).

HD785-7

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50 DISASSEMBLY AND ASSEMBLY

15. Disconnect the connectors AISS (27), EXH (28), ARSC (29), HAZ (30), and ABS (31).

16. Disconnect the connector CG1 (33) of the cigarette lighter (32).

17. Disconnect the connectors CK1 (34) and CHECK (35).

18. Disconnect the connectors SDE (36) and CH1 (37).

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

19. Disconnect the connectors AGS (36a) and DEFSW (37a).

20. Disconnect the connectors CH2 (38), FOG (39), and BLS (40).

21. Disconnect the connector HMSW (38a).

22. Remove the hexagonal socket head screws (41) (8 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (41): Width across flats 4mm, M6

HD785-7

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50 DISASSEMBLY AND ASSEMBLY

23. Remove the cover (42).

NOTICE • Remove the cover (42) carefully.

• Make sure that the wiring harness of the switch is not tangled up, and remove it.

• Remove the cover (42) carefully not to interfere with the parts (c), (d), and (e).

24. Disconnect the connector BZ (43).

25. Cut the adhesive tape that is put on the part (m) of the connectors DPC2A_M (47) and DPC1_M (48).

Tool: Diagonal pliers

26. Cut the band (44).

Tool: Diagonal pliers 27. Disconnect the connectors DPC1_F (45), DPC2A_F (46), DPC2A_M (47), and DPC1_M (48).

28. Cut the band (49).

Tool: Diagonal pliers

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

29. Cut the bands (50) (3 pieces).

Tool: Diagonal pliers

30. Remove the bolts (61) (4 pieces), and remove the trainer seat (62).

Tool: Ratchet handle Bolt (61): Width across flats 17mm, M10

31. Remove the hexagonal socket head screws (54) (2 pieces), and remove the cover (55).

REMARK • Remove it only for the machine with power window specification.

• Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (54): Width across flats 4mm, M6 32. Remove the wiring harness (57) from the clamp (56) as follows.

REMARK Remove it only for the machine with power window specification.

1)

Pull the band (h) in the direction of the arrow (j) until it is removed while you pull the protrusion (f) of the clamp (56) in the direction of the arrow (g).

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

2)

50 DISASSEMBLY AND ASSEMBLY

Remove the wiring harness (57) from the clamp (56).

33. Remove the bolt (58), and remove the connector stand (59).

REMARK • Remove it only for the machine with power window specification.

• The wiring harness is attached to the connector stand (59) at this time.

• Move the wiring harness to a safe place not to interfere with the removal work of the trainer seat bracket (60).

34. Remove the driver status monitor. For details, see “REMOVE DRIVER STATUS MONITOR”.

50-40

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

35. Remove the floor mats (63), (64), and (65).

36. Remove the screws (66) (3 pieces), and remove the cover (67).

REMARK Be careful not to lose the washer.

Tool: Phillips screwdriver Screw (66): M6

37. Remove the hexagonal socket head screws (68) (3 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (68): Width across flats 4mm, M6

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

38. Remove the bolts (69) (2 pieces), and remove the cover (70).

Tool: Socket wrench Bolt (69): Width across flats 17mm, M10

39. Remove the hexagonal socket head screws (71) (4 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (71): Width across flats 4mm, M6

40. Remove the bolts (72) (2 pieces), and remove the cover (73).

Tool: Socket wrench Bolt (72): Width across flats 17mm, M10

41. Remove the bolts (74) (4 pieces), and remove the cover (75).

Tool: Socket wrench Bolt (74): Width across flats 17mm, M10 42. Remove the screws (76) (4 pieces), and remove the cover (77).

Tool: Phillips screwdriver Screw (76): M6 43. Remove the bolts (78) (2 pieces), and remove the bracket (79).

REMARK • Move the bracket (79) to a safe place not to interfere with the removal work of the trainer seat bracket (61).

• The wiring harness is attached to the bracket (79) at this time.

Tool: Socket wrench Bolt (78): Width across flats 13mm, M8

50-42

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

44. Remove the bolts (51) (4 pieces), and remove the pre-lubrication controller (52).

REMARK • Remove it only for the machine with pre-lubrication specification.

• The wiring harness is attached to the pre-lubrication controller (52) at this time.

• Move the pre-lubrication controller (52) to a safe place not to interfere with the removal work of the trainer seat bracket (61).

Tool: Socket wrench Bolt (51): Width across flats 13mm, M8 45. Remove the clamps (80) and (81).

REMARK • The clamps (80) and (81) are tightened together.

• The size of the clamps (80) and (81) are different from each other. Handle them carefully.

Tool: Socket wrench Bolt for clamp (80), (81): Width across flats 17mm, M10 46. Remove the connector CAN14 (82) from the connector stand.

47. Disconnect the connector AGC (53), and remove it from the connector stand.

REMARK Disconnect it only for the machine with auto-greasing specification.

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

48. Remove the bolts (83) (6 pieces), and remove the trainer seat bracket (61).

Tool: Socket wrench Bolt (83): Width across flats 17mm, M10

49. Remove the hexagonal socket head screws (91) (2 pieces).

REMARK Be careful not to lose the washer.

Tool: Hexagonal wrench Hexagonal socket head screw (91): Width across flats 4mm, M6

50. Remove the bolts (92) (2 pieces), and remove the cover (93).

Tool: Socket wrench Bolt (92): Width across flats 17mm, M10

51. Cut the bands (94) (3 pieces).

Tool: Diagonal pliers

50-44

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

52. Cut the bands (95) (8 pieces).

Tool: Diagonal pliers

53. Remove the connectors CAN01 (96) and CAN13 (97) from the connector stand.

54. Disconnect the connectors TLC2 (98) and TLC3 (99).

55. Remove the connector DLL (100) from the connector stand.

56. Remove the clamps (101) and (102) (2 pieces).

REMARK The size of the clamps (101) and (102) are different from each other. Handle them carefully.

Tool: Socket wrench Bolt for clamp (101), (102): Width across flats 17mm, M10

57. Cut the bands (103) (5 pieces).

Tool: Diagonal pliers

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

58. Disconnect the connector RCA (108).

REMARK You do not need to disconnect it if the connectors RCA (108), BRC2_23 (105), and BRC2_33 (106) are normal.

59. Remove the clamp (104).

Tool: Socket wrench Bolt for clamp (104): Width across flats 17mm, M10

50-46

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

60. Disconnect the connectors BRC2_23 (105) and BRC2_33 (106), and remove the wiring harness (109).

BRC2_23 (105): Blue BRC2_33 (106): Yellow REMARK You do not need to disconnect the connector or remove the wiring harness (109) if the connectors RCA (108), BRC2_23 (105), and BRC2_33 (106) are normal.

Tool: Pin puller (A)

61. Remove the drowsiness detection wiring harness (107).

NOTICE Do not remove the drowsiness detection wiring harness (107) by force. It can cause the disconnection or damage.

INSTALL DROWSINESS DETECTION WIRING HARNESS 1.

Set the drowsiness detection wiring harness (107) to the installation position.

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

2.

50 DISASSEMBLY AND ASSEMBLY

Connect the connectors BRC2_23 (105) and BRC2_33 (106), and install the wiring harness (109).

BRC2_23 (105): Blue BRC2_33 (106): Yellow REMARK • Insert the connectors BRC2_23 (105) and BRC2_33 (106) securely.

• This procedure is not required if the connectors RCA (108), BRC2_23 (105), and BRC2_33 (106) are normal.

3.

Install the clamp (104).

Tool: Torque wrench (socket) Bolt for clamp (104): Width across flats 17mm, M10 Bolt for clamp (104): 59 to 74Nm{6 to 7.5kgfm}

50-48

HD785-7

50 DISASSEMBLY AND ASSEMBLY

4.

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

Connect the connector RCA (108) of the wiring harness (109) to the drowsiness detection wiring harness (107).

REMARK This procedure is not required if the connectors RCA (108), BRC2_23 (105), and BRC2_33 (106) are normal.

5.

Install the bands (103) (5 pieces).

REMARK Use the new band (103).

6.

Install the clamps (101) and (102) (2 pieces).

REMARK The size of the clamps (101) and (102) are different from each other. Handle them carefully.

Tool: Torque wrench (socket) Bolt for clamp (101), (102): Width across flats 17mm, M10 Bolt for clamp (101), (102): 59 to 74Nm{6 to 7.5kgfm}

7.

Install the connector DLL (100) to the connector stand.

8.

Connect the connectors TLC2 (98) and TLC3 (99).

9.

Install the connectors CAN01 (96) and CAN13 (97) to the connector stand.

HD785-7

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

10. Install the bands (95) (8 pieces).

REMARK Use the new band (95).

11. Install the bands (94) (3 pieces).

REMARK Use the new band (94).

12. Install the cover (93) with the bolts (92) (2 pieces).

Tool: Torque wrench (socket) Bolt (92): Width across flats 17mm, M10 Bolt (92): 59 to 74Nm{6 to 7.5kgfm}

13. Install the hexagonal socket head screws (91) (2 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (91): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

50-50

socket

head

screw

(91):

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

14. Install the trainer seat bracket (61) with the bolts (83) (6 pieces).

Tool: Torque wrench (socket) Bolt (83): Width across flats 17mm, M10 Bolt (83): 59 to 74Nm{6 to 7.5kgfm}

15. Install the connector AGC (53) to the connector stand, and connect it.

REMARK Connect it only for the machine with auto-greasing specification.

16. Install the connector CAN14 (82) to the connector stand.

17. Install the clamps (80) and (81).

REMARK • The clamps (80) and (81) are tightened together.

• The size of the clamps (80) and (81) are different from each other. Handle them carefully.

Tool: Torque wrench (socket) Bolt for clamp (80), (81): Width across flats 17mm, M10 Bolt for clamp (80), (81): 59 to 74Nm{6 to 7.5kgfm}

HD785-7

50-51

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

18. Install the pre-lubrication controller (52) with the bolts (51) (4 pieces).

REMARK • Install it only for the machine with pre-lubrication specification.

• The wiring harness is attached to the pre-lubrication controller (52) at this time.

Tool: Torque wrench (socket) Bolt (51): Width across flats 13mm, M8 Bolt (51): 27 to 34Nm{2.8 to 3.5kgfm} 19. Install the bracket (79) with the bolts (78) (2 pieces).

REMARK The wiring harness is attached to the bracket (79) at this time.

Tool: Torque wrench (socket) Bolt (78): Width across flats 13mm, M8 Bolt (78): 27 to 34Nm{2.8 to 3.5kgfm}

20. Install the cover (77) with the screws (76) (4 pieces).

Tool: Torque wrench (phillips screwdriver) Screw (76): M6 Screw (76): 3.44 to 4.41Nm{0.35 to 0.45kgfm} 21. Install the cover (75) with the bolts (74) (4 pieces).

Tool: Torque wrench (socket) Bolt (74): Width across flats 17mm, M10 Bolt (74): 59 to 74Nm{6 to 7.5kgfm} 22. Install the cover (73) with the bolts (72) (2 pieces).

Tool: Torque wrench (socket) Bolt (72): Width across flats 17mm, M10 Bolt (72): 59 to 74Nm{6 to 7.5kgfm}

23. Install the hexagonal socket head screws (71) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (71): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

50-52

socket

head

screw

(71):

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

24. Install the cover (70) with the bolts (69) (2 pieces).

Tool: Torque wrench (socket) Bolt (69): Width across flats 17mm, M10 Bolt (69): 59 to 74Nm{6 to 7.5kgfm}

25. Install the hexagonal socket head screws (68) (3 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (68): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(68):

26. Install the cover (67) with the screws (66) (3 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (phillips screwdriver) Screw (66): M6 Screw (66): 3.44 to 4.41Nm{0.35 to 0.45kgfm}

HD785-7

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50 DISASSEMBLY AND ASSEMBLY

27. Install the floor mats (63), (64), and (65).

28. Install the driver status monitor. For details, see “INSTALL DRIVER STATUS MONITOR”.

29. Install the connector stand (59) with the bolt (58).

REMARK • Install it only for the machine with power window specification.

• The wiring harness is attached to the connector stand (59) at this time.

50-54

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REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

30. Install the wiring harness (57) with the clamp (56) as follows.

REMARK Install it only for the machine with power window specification.

1)

Set the wiring harness (57) to the installation position of the clamp (56).

2)

Put the wiring harness (57) through the clamp (56).

3)

Put the band (h) through the clamp (56), and pull it in the direction of the arrow (g).

REMARK Make sure that the wiring harness (57) is fixed with the clamp (56).

31. Install the cover (55) with the hexagonal socket head screws (54) (2 pieces).

REMARK • Install it only for the machine with power window specification.

• Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (54): Width across flats 4mm, M6 Hexagonal socket head screw (54): 9.8Nm{1.0kgfm} 32. Install the trainer seat (62) with the bolts (61) (4 pieces).

Tool: Torque wrench (socket) Bolt (61): Width across flats 17mm, M10 Bolt (61): 59 to 74Nm{6 to 7.5kgfm}

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50 DISASSEMBLY AND ASSEMBLY

33. Install the bands (50) (3 pieces).

REMARK Use the new band (50).

34. Install the band (49).

REMARK Use the new band (49).

35. Connect the connectors DPC1_F (45), DPC2A_F (46), DPC2A_M (47), and DPC1_M (48).

36. Install the band (44).

REMARK Use the new band (44).

37. Put the adhesive tape on the part (m) of the connectors DPC2A_M (47) and DPC1_M (48) to fix.

REMARK Fix the connectors DPC2A_M (47) and DPC1_M (48) to the drowsiness detection wiring harness.

Tool: Adhesive tape

38. Connect the connector BZ (43).

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39. Connect the connector HMSW (38a).

40. Set the cover (42) to the installation position.

NOTICE • Make sure that the wiring harness of the switch is not tangled up.

• Be careful not to let the cover (42) interfere with the parts (c), (d), and (e).

41. Install the cover (42) with the hexagonal socket head screws (41) (8 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (41): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(41):

42. Connect the connectors CH2 (38), FOG (39), and BLS (40).

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50 DISASSEMBLY AND ASSEMBLY

43. Connect the connectors AGS (36a) and DEFSW (37a).

44. Connect the connectors SDE (36) and CH1 (37).

45. Connect the connectors CK1 (34) and CHECK (35).

46. Connect the connector CG1 (33) of the cigarette lighter (32).

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47. Connect the connectors AISS (27), EXH (28), ARSC (29), HAZ (30), and ABS (31).

48. Pull out the connector PWM2 (26), and connect the switch (25).

NOTICE The wiring harness can be disconnected or damaged if you pull out the connector PWM2 (26) by force.

REMARK Switch (25): Power mode selector switch

49. Install the switch (25).

50. Connect the connectors RVB (23) and RVM (24).

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50 DISASSEMBLY AND ASSEMBLY

51. Install the air conditioner duct (22) with the bolts (21) (6 pieces).

Tool: Torque wrench (socket) Bolt (21): Width across flats 10mm, M6 Bolt (21): 11.8 to 14.7Nm{1.2 to 1.5kgfm}

52. Install the dashboard cover (19) with the hexagonal socket head screws (20) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (20): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(20):

53. Connect the bracket (18) with the bolts (17) (2 pieces).

Tool: Torque wrench (socket) Bolt (17): Width across flats 10mm, M6 Bolt (17): 11.8 to 14.7Nm{1.2 to 1.5kgfm}

54. Install the cover (16) with the hexagonal socket head screws (15) (2 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (15): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(15):

55. Install the cover (13) as follows.

1)

50-60

Set the cover (13) to the installation position.

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50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

2)

Pull out the drowsiness detection camera (2) through the opening (b) of the cover (13).

3)

Install the cover (13) with the hexagonal socket head screws (12) (5 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (12): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

4)

socket

head

screw

(12):

Move the GPS antenna (14) to the top of the plate (14a).

56. Install the cover (11) with the hexagonal socket head screws (10) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (10): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

HD785-7

socket

head

screw

(10):

50-61

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

50 DISASSEMBLY AND ASSEMBLY

57. Install the cover (9) with the hexagonal socket head screws (8) (4 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (8): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(8):

58. Install the grommet (6) and drowsiness detection camera cable together to the bracket (5).

59. Install the bracket (5) with the hexagonal socket head screws (4) (3 pieces).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (4): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

socket

head

screw

(4):

60. Install the clamp (3).

REMARK Be sure to put the washer.

Tool: Torque wrench (hexagonal) Hexagonal socket head screw for clamp (3): Width across flats 4mm, M6 Hexagonal socket head screw for clamp (3): 9.8Nm{1.0kgfm}

50-62

HD785-7

50 DISASSEMBLY AND ASSEMBLY

REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS

61. Install the drowsiness detection camera (2) with the hexagonal socket head screws (1) (2 pieces).

REMARK • Be sure to put the washer.

• Align the holes (a) of the bracket (5) and (5a), and set the position of the drowsiness detection camera (2).

Tool: Torque wrench (hexagonal) Hexagonal socket head screw (1): Width across flats 4mm, M6 Hexagonal 9.8Nm{1.0kgfm}

HD785-7

socket

head

screw

(1):

50-63

90 CIRCUIT DIAGRAMS

HD785-7

90-1

CONTENTS

90 CIRCUIT DIAGRAMS

CONTENTS HOW TO READ THE CODES FOR ELECTRIC CABLE ................................................................................ 90-3 ELECTRICAL CIRCUIT DIAGRAM ................................................................................................................ 90-7 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM ............................................................................ 90-7 ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS)) .............................90-11

90-2

HD785-7

90 CIRCUIT DIAGRAMS

HOW TO READ THE CODES FOR ELECTRIC CABLE

HOW TO READ THE CODES FOR ELECTRIC CABLE In the electric circuit diagram, the type, size and color of electric wires are shown by symbols. This symbol is called a electric wire cord and it is useful for understanding the electric circuit diagram.

Example) AEX 0.85 L: It shows the blue cable with the electrical wire number 0.85 for heat resistant low voltage electric wire for automobiles.

The type of electric wire is shown by a symbol.

AEX

0.85 L

The types, symbols and materials of the wires are as shown in (Table 1).

(For AV and AVS, it can be distinguished by size (electrical wire number), so they are not shown on the electric circuit diagram) The wire size are shown by the electrical wire number.

The wire size and electrical wire number are as shown in (Table 2).

The color of electric wire is shown by color code.

Color codes are as shown in (Table 3).

Type, symbol and material (Table 1) Type

Low voltage electric wire for automobiles Thin low voltage electric wire for automobiles

symbol

Conductor materials

Insulator materials

Operating temperature range (℃)

For high current wiring AV

(electrical wire number 5 or more) For general wiring

AVS

Soft vinyl chloride

-30 to +60

(Type 1) Thin low voltage electric wire for automobiles

CAVS

Annealed copper wires for electrical purposes

AEX

(electrical wire number 3 or less) For medium and small excavators (electrical wire number 1.25 or less)

(Type 2)

Heat resistant low voltage electric wire

Application example

Heat resistant crosslinked polyethylene

-50 to +110

For general wiring of extreme cold weather specification For wiring for high ambient temperature

•

The difference between AV and AVS is only the coating thickness and the coating outside diameter.

•

CAVS uses a circular compression conductor for the conductor.

•

CAVS is different from AV and AVS in conductor outside diameter and coating thickness.

•

AEX is different from AV and AVS in coating material.

HD785-7

90-3

HOW TO READ THE CODES FOR ELECTRIC CABLE

90 CIRCUIT DIAGRAMS

Φd

ΦD

Dimension

G0041640

(Table 2) Electrical wire number

Conductor

Coating D

90-4

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

2f

2

3f

3

5

Number of element wires

20

7

30

11

50

16

37

26

58

41

65

Element wire diameter (mm)

0.18

0.32

0.18

0.32

0.18

0.32

0.26

0.32

0.26

0.32

0.32

Crosssectional area (mm2)

0.51

0.56

0.76

0.88

1.27

1.29

1.96

2.09

3.08

3.30

5.23

d (approximately) (mm)

1.0

1.2

1.5

1.9

1.9

2.3

2.4

3.0

AVS

Criteria (mm)

2.0

2.2

2.5

2.9

2.9

3.5

3.6

—

AV

Criteria (mm)

—

—

—

—

—

—

—

4.6

AEX

Criteria (mm)

2.0

2.2

2.7

3.0

3.1

—

3.8

4.6

HD785-7

90 CIRCUIT DIAGRAMS

HOW TO READ THE CODES FOR ELECTRIC CABLE

Electrical wire number

8

15

20

30

40

50

60

85

100

Number of element wires

50

84

41

70

85

108

127

169

217

Element wire diameter (mm)

0.45

0.45

0.80

0.80

0.80

0.80

0.80

0.80

0.80

Crosssectional area (mm2)

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

d (approximately) (mm)

3.7

4.8

6.0

8.0

8.6

9.8

10.4

12.0

13.6

AVS

Criteria (mm)

—

—

—

—

—

—

—

—

—

AV

Criteria (mm)

5.5

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

AEX

Criteria (mm)

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

Conductor

Coating D

Electrical wire number

Conductor

0.5f

0.5

0.75f

0.85

1.25f

1.25

Number of element wires

—

7

—

11

—

16

Element wire diameter

—

- (circular compressed)

—

- (circular compressed)

—

- (circular compressed)

—

0.56

—

0.88

—

1.29

d (approximately) (mm)

—

0.9

—

1.1

—

1.4

Criteria (mm)

—

1.6

—

1.8

—

2.1

Cross-sectional area (mm2)

Coating D

CAVS

REMARK "F" for the electrical wire number shows flexible.

Color code table (Table 3) Color code

Electric wire color

Color code

Electric wire color

B

Black

LgW

Lightgreen and white

Br

Brown

LgY

Lightgreen and yellow

BrB

Brown and black

LR

Blue and red

BrR

Brown and red

LW

Blue and white

HD785-7

90-5

HOW TO READ THE CODES FOR ELECTRIC CABLE

90 CIRCUIT DIAGRAMS

Color code

Electric wire color

Color code

Electric wire color

BrW

Brown and white

LY

Blue and yellow

BrY

Brown and yellow

O

Orange

Ch

Charcoal

P

Pink

Dg

Darkgreen

R

Red

G

Green

RB

Red and black

GB

Green and black

RG

Red and green

GL

Green and blue

RL

Red and blue

Gr

Gray

RW

Red and white

GR

Green and red

RY

Red and yellow

GW

Green and white

Sb

Sky blue

GY

Green and yellow

Y

Yellow

L

Blue

YB

Yellow and black

LB

Blue and black

YG

Yellow and green

Lg

Lightgreen

YL

Yellow and blue

LgB

Lightgreen and black

YR

Yellow and red

LgR

Lightgreen and red

YW

Yellow and white

REMARK In the two color configuration, the first color shows the ground color of the wire and the second color shows the marking color. Example) GW shows that there is white which is marking color in green which is ground color.

Circuit type and color code Type of electric wire

AEX

Charge

R

WG

—

—

—

—

R

—

Ground contact

B

—

—

—

—

—

B

—

Activation

R

—

—

—

—

—

R

—

Lighting

RW

RB

RY

RG

RL

—

O

—

Meter, gauge

Y

YR

YB

YG

YL

YW

Y

Gr

Signal

G

GW

GR

GY

GB

GL

G

Br

L

LW

LR

LY

LB

—

L

—

Br

BrW

BrR

BrY

BrB

—

—

—

Lg

LgR

LgY

LgB

LgW

—

—

—

O

—

—

—

—

—

—

—

Gr

—

—

—

—

—

—

—

P

—

—

—

—

—

—

—

Sb

—

—

—

—

—

—

—

Dg

—

—

—

—

—

—

—

Ch

—

—

—

—

—

—

—

Type of circuit

Others

90-6

AVS, AV, CAVS

HD785-7

90 CIRCUIT DIAGRAMS

SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM Symbol

Content

Conductive wire

Conductive wire (crossings not connected)

Conductive wire (crossings connected)

Binding wire

Terminal

Chassis ground

Terminal ground

Contact, switch

Push button switch (NO type) NO: Normally Open

Push button switch (NC type) NC: Normally Close

Pull button switch (NO type) NO: Normally Open

Pull button switch (NC type) NC: Normally Close

HD785-7

90-7

SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

Symbol

90 CIRCUIT DIAGRAMS

Content

Variable

Resistor

Variable resistor

Diode

Light-emitting diode (LED)

Photo diode

Low voltage diode (zener diode)

PNP transistor

NPN transistor

Magnet coil

Battery

Fuse

90-8

HD785-7

90 CIRCUIT DIAGRAMS

SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

Symbol

Content Connector •

Concave side (left on the figure): female

•

Convex side (right on the figure): male

REMARK The figure shows the disconnected state.

QQ type connector (left: male, right: female)

REMARK The figure shows the connected state.

Solenoid

Motor

Lamp

Pressure switch (NO type) NO: Normally Open

Pressure switch (NC type) NC: Normally Close

Potentiometer, fuel control dial

Temperature sensor

Starting switch

Backup alarm

Horn

HD785-7

90-9

SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM

Symbol

90 CIRCUIT DIAGRAMS

Content

Buzzer

Antenna

90-10

HD785-7

ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS)) HD785-7 REMARK This figure includes the equipment and device that are not available as optional items in some areas.

CN-DPC1_M

CN-DPC1_F

CN-DPC2A_M

CN-DPC2A_F

CN-DLL

CN-CAN11

CN-CAN01

RCA_M

RCA_F

CN-BRC2_33 CN+BRC2_23

CN-DDS1

CN-CAN14

CN-CAN13

CN-TLC3

CN-TLC2

CN-TLC1

CN-BZ

G0140634

HD785-7

90-11

INDEX

INDEX B Before reading this manual................................... 00-4

C Connector list and layout...................................... 40-3

D Driver status monitor...........................................10-14 Driver status monitor - Input and output signals. 10-14 Driver status monitor - Install................................ 50-8 Driver status monitor - Remove............................ 50-6 Driver status monitor - Remove/Install..................50-6 Driver status monitor - Structure......................... 10-14 Drowsiness alarm buzzer - Install....................... 50-23 Drowsiness alarm buzzer - Remove................... 50-16 Drowsiness alarm buzzer - Remove/Install.........50-15 Drowsiness detection camera.............................10-13 Drowsiness detection camera - Input and output signals.............................................................. 10-13 Drowsiness detection camera - Install................ 50-13 Drowsiness detection camera - Remove............ 50-12 Drowsiness detection camera - Remove/Install..50-12 Drowsiness detection camera - Structure........... 10-13 Drowsiness detection system............................... 10-3 Drowsiness detection system - Component parts.10-9 Drowsiness detection system - Function.............. 10-6 Drowsiness detection system - Layout drawing....10-3 Drowsiness detection system - Operation............ 10-8 Drowsiness detection system - System diagram.. 10-4 Drowsiness detection system (EU SPECIFICATION) Function......................................................... 10-7 Drowsiness detection system (EU SPECIFICATION) System diagram.............................................10-5 Drowsiness detection wiring harness - Install..... 50-47 Drowsiness detection wiring harness - Remove. 50-31 Drowsiness detection wiring harness - Remove/Install .....................................................................50-30

Failure code [F9D0MC].......................................40-17 Failure code [F9D2KK]........................................40-18 Failure code [F9DSKR]....................................... 40-20 Failure code [ZA0010].........................................40-25 Failure code [ZA0011].........................................40-26 Failure code [ZA0012].........................................40-27 Failure code [ZA0013].........................................40-28 Failure code [ZA0014].........................................40-29 Failure code [ZA0015].........................................40-30 Failure code [ZA0016].........................................40-31 Failure code table................................................. 40-7 Fuse - Location table............................................ 40-5

H How to read the codes for electric cable...............90-3 How to read this manual....................................... 50-3

O Optional selection of machine monitor - Set......... 30-3

R Related information on disassembly and assembly..... .......................................................................50-3 Related information to troubleshoot...................... 40-3

S Special tools list.................................................... 50-5

T Translator controller.............................................. 10-9 Translator controller - Input and output signals.....10-9 Translator controller - Install................................50-10 Translator controller - Remove..............................50-9 Translator controller - Remove/Install................... 50-9 Translator controller - Structure............................ 10-9 Troubleshooting by failure code (display of code).40-8

E Electrical circuit - Symbols.................................... 90-7 Electrical circuit diagram....................................... 90-7 Electrical circuit diagram (Drowsiness Detection System (DDS))................................................... 90-11 Electrical system...........................................30-3,50-6

F Failure code [D5WNKB]........................................40-8 Failure code [DR81KR]......................................... 40-9 Failure code [DR81MA].......................................40-14 Failure code [DV03KB]....................................... 40-15 Failure code [DV03KY]....................................... 40-16 1

HD785-7 DUMP TRUCK Form No. SEN06857-04

©2021 KOMATSU All Rights Reserved Printed in Japan 09-2021