PRODUCT MANUAL

POWER MODE BYPASS CONTROLLER TO SUIT

KOMATSU HD785-5 AND HD785-7 VEHICLES

Part No. 11337

 DISCLAIMER

Copyright © Remote Control Technologies Pty Ltd (RCT) All rights reserved.

 No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written
permission of Remote Control Technologies Pty Ltd. (RCT).

 Information provided in this manual is intended to be accurate and reliable. However, Remote Control Technologies Pty Ltd (RCT)
assumes no responsibility for its use or infringements upon the rights of third parties that may result from its use.

 All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation.
Remote Control Technologies Pty Ltd (RCT) will accept no responsibility for actual use of the product based on these illustrative
examples.

 Please contact your nearest Remote Control Technologies Pty Ltd (RCT) branch for more information concerning applications in life
critical situations or high reliability.

 Remote Control Technologies Pty Ltd (RCT) reserves the right to make changes to any product herein to improve reliability, function
or design. All specifications are subject to change without notice.

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 Contents

GENERAL SAFETY WARNINGS 4

PRODUCT OVERVIEW 5

FEATURES AND FUNCTIONS 5

OPERATION AND USE 5

CONTROLLER STATUS INDICATOR OPERATION 6

INSTALLATION GUIDE 7
INSTALLATION FOR KOMATSU HD785-5 7
Wiring Connections 7
INSTALLATION FOR KOMATSU HD785-7 7
Wiring Connections 7
DIAGRAMS 8
Wiring Diagram to Suit Komatsu HD785-5 (519c)) 8
Wiring Diagram to Suit Komatsu HD785-7 (519d) 9

CALIBRATION 10

SERVICE INFORMATION 10
SERVICE SCHEDULE 10
SERVICE PROCEDURE 10

PARTS LIST 10

TECHNICAL SPECIFICATIONS 11

COMPLIANCE AND STANDARDS 12

TROUBLESHOOTING 12

GLOSSARY 13

WARRANTY 13

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 GENERAL SAFETY WARNINGS
PERSONAL SAFETY
■ Everyone is responsible for safety.
■ The installer/service personnel should be trained and authorized to complete the required work.
■ Ensure that the machine is safely isolated during installation and testing to protect all personnel.
■ Complete all required risk assessments and job safety analysis (JSA) before commencing work.
■ Observe all site specific and machine OEM procedures regarding the following:
– working at heights
– working in heat
– working in confined spaces
– all other site specific occupational health and safety (OH&S) procedures

MACHINE
■ Carry out all prestart operations as per site and machine OEM procedures.
■ Ensure the machine is safely isolated during installation and testing to protect the machine and other
equipment in the area.
■ Do not operate any machine with a known fault and report all findings to the supervisor in writing.
■ Test and operate machine as per machine OEM and site procedures.
■ Read and understand machine and site specific operational and testing instructions.

PRODUCT
Before applying power to the equipment, the user/repairer/ installer must read all product instructions. If in
doubt, seek assistance.

■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting
power to any component.
■ The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs.
■ Retain product and installation instructions for future use.
■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine.
■ Observe all machine, site and RCT product warnings.
■ Follow all machine, site and RCT product operating procedures at all time.

The application of safety should not be limited to the above recommendations.

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 PRODUCT OVERVIEW

®
The Muirhead Power Mode Bypass Controller, part number 11337, is designed to automatically select
either standard mode or power mode based on whether or not the tray is loaded.

FEATURES AND FUNCTIONS

■ Multi-voltage 12-24 V
■ Environmentally sealed – IP65
■ Simple to install
■ No ongoing maintenance
■ Power boost switch available as an option

OPERATION AND USE

®
When no load is detected, the Muirhead Power Mode Bypass Controller will automatically select standard
mode. When a load is detected, the controller will automatically select power mode. The controller
automatically filters the payload input to eliminate the controller falsely changing states.

The power indicator will illuminate when the controller has put the vehicle into power mode.

An optional momentary switch or key-switch can be fitted to manually place the vehicle into power mode.
This may be used for servicing of the vehicle or where a boost of power from the vehicle is required.

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 CONTROLLER STATUS INDICATOR OPERATION

STATE INDICATOR SEQUENCE

Battery Power-up ■ All indicators will turn on.

■ All indicators will turn off.
■ After power-up, the controller will revert to normal operation.

Status Indicator in Operation RED – Fault.

■ If outputs have problems, this will turn on.
■ Outputs 1 & 2 – high current outputs: checked for over current.
■ Output 3 – not checked as it is a low side driver.
■ Output 4 – checked for correct output voltage.
Alarm Indication
■ Temperature – checked for board temperature exceeding 80 °C.
System Status
YELLOW – Pulses during normal operation, indicates system OK.
Power Indication ■ Flashes on and off at one-second intervals (on for one second, off for one
second).

GREEN – On for normal operation.

■ Flashes when valid input goes active (number of flashes = input number).
■ Allows checking that inputs are correctly wired and that the hardware is
seeing the input toggle.

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 INSTALLATION GUIDE
1. Install the controller in a suitable location preferably in the cabin.

2. Refer to the wiring table below and the wiring diagram in this manual to connect the controller.
It is recommended that the wiring is installed alongside the OEM wiring ensuring that it is secured at
regular intervals; this will provide protection from heat and abrasion, and any other excess damage that
may occur with extended vehicle operation. When securing the wiring to the OEM wiring, ensure that the
loom is away from moving vehicle parts which could lead to loom damage.

INSTALLATION FOR KOMATSU HD785-5

Connect wiring as per drawing 519c and as follows:

Wiring Connections

NO. FUNCTION DESCRIPTION

1 Battery +VE Connect to a protected 12–24 V battery
2 Ground Connect to ground/battery negative
3 NC Not connected (spare)
4 Output 2 Connect to pin 10 of CNS connector
5 Switch 1 (Optional) connected to bypass switch/pushbutton
6 N/C Not connected
7 N/C Not connected
8 Input 1 Connect to the payload strut sensor
9 Output 1 Connect to pin 3 of the power mode switch (remove link between pins 2 & 3)
10 N/C Not connected
11 Bypass GND (Optional) connected to bypass switch/pushbutton
12 Battery + VE Connected to LED + VE

Ensure that pins 1, 4 and 5 of the vehicles OEM power mode switch have been isolated and made safe.

INSTALLATION FOR KOMATSU HD785-7

Connect wiring as per 519d and as follows:

Wiring Connections

PIN. DESCRIPTION CONNECTION

1 Battery +ve Connect to a protected 12–24 V battery
2 GND Connect to ground/battery negative
3 Output 1 Connect to pin 3 of the power mode switch
4 N/C Not connected
5 Bypass (Optional) connected to bypass switch/pushbutton
6 N/C Not connected
7 N/C Not connected
8 Input 1 Connect to the payload strut sensor
9 N/C Not connected
10 N/C Not connected
11 Bypass GND (Optional) connected to bypass switch/pushbutton
12 N/C Not connected

Ensure that pins 3 and 6 of the vehicles OEM power mode switch (PWM2_M) have been isolated and made
safe.

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 M0698.docx | Rev 1.9 | Modified on 04/09/2015 | Copyright © RCT
1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
A A
OEM CIRCUIT
SHIFT LIMIT SWITCH POWER MODE SWITCH
OPERATION
WHEN THE VEHICLE IS NOT LOADED, THE RCT CONTROL
ACTIVATES THE CIRCUIT TO ENABLE ECONOMY MODE.
WHEN THE TRUCK IS LOADED, A SIGNAL FROM THE STRUT
SENSOR TRIGGERS THE RCT CONTROL WHICH ACTIVATES
B THE CIRCUIT TO CONTROL POWER MODE. B
NOTE 1 : THE POWER MODE SWITCH WILL NO LONGER
FUNCTION, HOWEVER THE LIGHT WILL ILLUMINATE WHEN
IN POWER MODE.
C C
1

1
4

4
2

2
6

6
7

3
CUT THIS WIRE,
JOIN EXISTING
WIRE TO PIN 2
D D
CUT THIS WIRE AND ISOLATE TO MAKE SAFE
OPTIONAL
SWITCH TO
BYPASS ALL DIMENSIONS IN MILLIMETERS
UNCONTROLLED DOCUMENT
Wiring Diagram to Suit Komatsu HD785-5 (519c))

SCALE
RCT POWER / ECONOMY NTS A4
BYPASS CONTROL
3rd ANGLE
E PROJECTION E
JOIN EXISTING WIRE TO
WIRE GOING TO PIN 4
www.rct.net.au
11
10

12

CNS
1

4
2

6
3

8
9
5

COPYRIGHT - ALL RIGHTS RESERVED

This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
to RCT, on demand.
IGNITION
1 !
GROUND
F 2  F
3
GROUND OUT POWER MODE
4 N12596 www.rct.net.au
OPTIONAL BYPASS
BYPASS TO SUIT
5 KOMATSU HD785-5
6
CONNECTS TO PAYLOAD STRUT 7 EXTERNAL WIRING
SENSOR WIRE AT PAYLOAD PAYLOAD STRUT SENSOR
8
SYSTEM. USE PM6 WIRE 6 (REAR
G GROUND OUT G
LEFT) OR WIRE 7 (REAR RIGHT). 9

(11110)

(11981)
10

1.2 K
GROUND
11 PART
11337
DIAGRAMS

IMPORTANT: ALL CUT WIRES MUST BE INSULATED 12 NO

STOCK
CODE MH-PMB-01
AND SECURED TO MAKE SAFE. CONNECTOR
BY AD
ON PCB
DRN CW DATE 21/08/14
APPD AD DATE 21/08/14
H SHEET
1 of 1 H
STATUS
Released

8 | 16
DWG No REV
519c 0
1 2 3 4 5 6 7 8 9 10 11 12
 9 | 16
1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
park brake wires added to
1 F3-7 BT 24/10/14
pin 6&7, notes added
A A
OEM CIRCUIT
OPERATION
WHEN THE VEHICLE IS NOT LOADED, THE RCT CONTROL
POWER MODE SWITCH POWER MODE SWITCH
ACTIVATES THE CIRCUIT TO ENABLE ECONOMY MODE.
(HD465) (HD785)
WHEN THE TRUCK IS LOADED, A SIGNAL FROM THE STRUT
B B
SENSOR TRIGGERS THE RCT CONTROL WHICH ACTIVATES
THE CIRCUIT TO CONTROL POWER MODE.
PWM2_M
PWM_M

NOTE 1 : THE POWER MODE SWITCH WILL NO LONGER

FUNCTION, THE DASH LIGHT WILL STILL ILLUMINATE WHEN
IN POWER MODE.
C C
3

5
6

6
2

4
1

CUT THIS WIRE AND JOIN PIN 3 OF SWITCH TO PIN 1

CUT THIS WIRE AND JOIN PIN 6 OF SWITCH TO PIN 3
CUT THIS WIRE AND JOIN PIN 5 OF SWITCH TO PIN 2
D D
OPTIONAL BYPASS
SWITCH/PUSHBUTTON
ALL DIMENSIONS IN MILLIMETERS
UNCONTROLLED DOCUMENT
SCALE
Wiring Diagram to Suit Komatsu HD785-7 (519d)

NTS A4
3rd ANGLE
E RCT POWER / ECONOMY PROJECTION E
BYPASS CONTROL
www.rct.net.au

M0698.docx | Rev 1.9 | Modified on 04/09/2015 | Copyright © RCT

COPYRIGHT - ALL RIGHTS RESERVED
This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
IGNITION part for any purpose without the express
1 ! authority of RCT. The drawing is to be returned
GROUND to RCT, on demand.
2 
OPTIONAL PARK BRAKE INPUTS. EITHER CAN BE OUTPUT
3
USED DEPENDING ON MACHINE CONFIGURATION.
F 4 N12596 www.rct.net.au
F
SPECIAL NOTE: IF THE PARK BRAKE INPUT IS ACTIVE AND THE STRUT
OPTIONAL BYPASS
SENSOR INPUT IS ACTIVE, THE UNIT WILL NOT SELECT POWER MODE. 5
PARK BRAKE INPUT -VE POWER MODE
CONNECTS TO PAYLOAD 6 BYPASS TO SUIT
STRUT SENSOR WIRE. PARK BRAKE INPUT +VE KOMATSU HD785-7
USE PW1_MIC PIN 12 7
PAYLOAD STRUT SENSOR
(WIRE 1706 RIGHT REAR) 8
ALTERNATIVELY USE EXTERNAL WIRING
9
BRC1_DRC_KEYA PIN 7
(ALSO WIRE 1706 RIGHT REAR) 10
G G
GND
11
IMPORTANT: ALL CUT WIRES MUST BE INSULATED AND SECURED TO MAKE SAFE. 12
CONNECTOR PART
NO 11337
ON PCB STOCK
CODE MH-PMB-01
BY AD
DRN RH DATE 21/08/14
APPD AD DATE 21/08/14
H SHEET
1 of 1 H
STATUS
Released
DWG No REV
519d 1
1 2 3 4 5 6 7 8 9 10 11 12
 CALIBRATION
Not applicable

SERVICE INFORMATION
SERVICE SCHEDULE
The manufacturer recommends that the following service procedure should be performed at each machine’s
scheduled service interval.

SERVICE PROCEDURE
1. Perform a visual inspection; include the following:

a) Control unit.
b) Wiring connections and looms.
c) Check that all switches and solenoids are in good working condition.

2. Perform a system test as per the Operation and Use section of this manual for the operation of the
controller.

PARTS LIST
PART NO. DESCRIPTION
11337 Power mode bypass controller
1520 Momentary toggle switch (supplied separately)
2022 Deutsch connector 12-socket
2076 Contact socket for above Deutsch connector
1959 Lock wedge for above Deutsch connector
2118 Blocking contact for above Deutsch connector

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 TECHNICAL SPECIFICATIONS
Dimensions, controller only Length: 119 mm | Width: 80 mm | Height/Depth: 65 mm

Dimensions, boxed for freight Length: 140 mm | Width: 140 mm | Height/Depth: 70 mm

Weight, controller only 255 g

Weight, including loom / packaging
600 g
for freight
Input nominal voltage 12 to 24 V
Ignition output continuous current
10 A
maximum
Auxiliary output continuous current
0.7 A
maximum
Operating temperate range −40 °C to +85 °C

Connection types 12-pin receptacle

Inputs Ignition supply, battery supply, chassis ground

Min & max input voltage 9 to 35 V DC

Enclosure type ABS

Environmental protection IP rating IP65

Programming/adjustment N/A

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 COMPLIANCE AND STANDARDS
Remote Control Technologies Pty Ltd has an obligation as a manufacturer to comply with the regulations as
required by the relevant regulatory bodies, depending on the market and location.

This product currently complies with the following:

ACMA
■ IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for
Residential, Commercial and Light Industrial Environments.
■ IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.

EU
■ IEC 61000-6-1:2005 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for
Residential, Commercial and Light Industrial Environments.
■ IEC 61000-6-3:2006, A1:2010 Electromagnetic Compatibility (EMC) – Part 6-3: Generic Standards –
Emissions for Residential, Commercial and Light Industrial Environments.
■ RoHS 2 Directive 2011/65/EU

FCC
This device is exempt from FCC regulations under 47 CFR 15.103 Exempted devices.

IC
This device is exempt from IC regulations under ICES-003 — Information Technology Equipment (ITE) —
Limits and Methods of Measurement.

TROUBLESHOOTING
FAULT POSSIBLE CAUSE
Device not working. Check wiring and connections.
Intermittent fault. Check wiring and connections.

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 GLOSSARY

A Amp (Ampere) mW Milli Watts

AC Alternating Current N/A Not Applicable
AMS Advanced Management System N/C Normally Closed
Aux Auxiliary Output N/O Normally Open
CAN Controller Area Network OEM Original Equipment Manufacturer
CMIO Control Master Input Output PCB O/P Outputs
CMR Control Master Receiver Out Output
CMT Control Master Transmitter PB Push Button
CM2200 Control Master 2200 Remote Set PC Personal Computer
COMMS Communications PCB Printed Circuit Board
CPU Central Processor Unit PIN Personal Identification Number
DC Direct Current PLC Programmable Logic Controller
E.G. For example POT Potentiometer
ETR Energised To Run PPM Pulses Per Metre
ETS Energised To Stop PWM Pulse Width Modulation
ESD Engine Shutdown PWR Power
FET Field Effect Transistor RCT Remote Control Technologies Pty Ltd
GND Ground Rev Revision
H Hours RF Radio Frequency
HEX Hexidecimal Numbering System RH Relative Humidity
ID Identity RPM Revolutions per minute
i.e That is RX Receiver
Recommended Standard (number 232) for
In Input RS232 serial data transfer
IP Ingress Protection Source The output can supply/drive current out
kg Kilogram SYS System
Km/h Kilometres Per Hour TOV Text On Video
LCD Liquid Crystal Display TX Transmitter
LED Light Emitting Diode V Volts
LK Link °C Degrees Centigrade
M Minutes # Number
mA Milli Amps < Less Than
MAX Maximum > Greater Than
MCU Multi Control Unit % Percentage
MFU Multi Function Unit
Mega Hertz (million(s) cycles per
MHz second)
MIN Minimum
mm millimetres

WARRANTY
Please see the RCT standard warranty, available on our website - www.rct.net.au

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 NOTES

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 NOTES

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PERTH
Unit 2-5/511 Abernethy Road
Kewdale WA 6105
Ph: +61 (0) 8 9353 6577
Fax: +61 (0) 8 9353 6578

BRISBANE
Unit 6/26 Flinders Parade
North Lakes QLD 4509
Ph: +61 (0) 7 3385 0172
Fax: +61 (0) 7 3385 0173

KALGOORLIE
24 Percy Road
Kalgoorlie WA 6430
Ph: +61 (0) 8 9021 1600
Fax: +61 (0) 8 9091 4927

MT ISA
1A Ryan Road
Mt Isa QLD 4825
Ph: +61 (0) 7 4749 0233
Fax: +61 (0) 7 4749 0232

MELBOURNE
Unit 4 Hallmarc Office Park
15 Ricketts Road
Mt Waverley VIC 3149
Ph: +61 (0) 3 9545 5859
Fax: +61 (0) 3 9545 6193

AFRICA: +27 (0) 83 292 4246

NORTH AMERICA: +1 801 712 6077
RUSSIA/CIS: +7 (910) 411 11-74
SOUTH AMERICA: +56 9 7387 2385