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SEBM027612

MACHINE MODEL HD465-7 HD605-7

SERIAL NUMBER 7001 and up 7001 and up

• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • HD465-7, HD605-7 mount the SAA6D170E-3 engine. For details of the engine, see the 170-3 Series Engine Shop Manual.

© 2006 All Rights Reserved Printed in Japan 02-06(02)

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CONTENTS
No. of page ........................................................................................................................... 01-1

01 10

GENERAL

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ................................................................. 10-1 TESTING AND ADJUSTING ............................................................................... 20-1 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1 OTHERS

20 30 90

............................................................................................................................... 90-1

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HD465-7, HD605-7

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20-760 20-761 20-762 20-762-1 20-763 20-764 20-765 20-766 20-767 20-768 20-769 20-770 20-771 20-772 20-773 20-774 20-801 20-802 20-803 20-804 20-805 20-806 20-807 20-808 20-809 20-810 20-811 20-812 20-813 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-821 20-822 20-823 20-824 20-825 20-826 20-827 20-828 20-829 20-830 20-831 20-832 20-833 20-834 20-835

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20-944 20-945 20-946 20-947 20-948 20-949 20-950 20-951 20-952 20-953 20-954 20-955 20-956 20-957 20-958 20-959 20-960 20-961 20-962 20-963 20-964 20-965 20-966 20-967 20-1001 20-1002 20-1003 20-1003-1 20-1004 20-1005 20-1006 20-1006-1 20-1006-2 20-1006-3 20-1006-4 20-1006-5 20-1006-6 20-1006-7 20-1006-8 20-1007 20-1008 20-1009 20-1010 20-1011 20-1012 20-1013 20-1014 20-1015 20-1016 20-1017 20-1018

(1) (10) (10) (10) (10) (10) (10) (10) (10) (2) (10) (10) (2) (10) (10) (10) (10) (10) (10) (10) (5) (10) (10) (10) (10) (5) (5) (5) (10) (10) (10) (10) (5) (10) (5) (10) (5) (10) (5) (10) (2) (10) (2) (10) (10) (10) (10) (10) (10) (2) (10)

20-1019 20-1020 20-1021 20-1022 20-1023 20-1023-1 20-1023-2 20-1023-3 20-1023-4 20-1023-5 20-1023-6 20-1023-7 20-1023-8 20-1023-9 20-1023-10 20-1024 20-1025 20-1026 20-1027 20-1028 20-1029 20-1030 20-1031 20-1032 20-1033 20-1034 20-1035 20-1036 20-1051 20-1052 20-1053 20-1054 20-1055 20-1056 20-1057 20-1058 20-1059 20-1060 20-1061 20-1062 20-1063 20-1064 20-1065 20-1066 20-1067 20-1068 20-1069 20-1070 20-1071 20-1072 20-1073

(10) (10) (2) (10) (10) (10) (5) (10) (5) (10) (5) (10) (5) (10) (6) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (5) (10) (10) (5) (10) (10) (10) (10) (10) (5) (10) (10) (10) (10) (10) (5) (10) (5) (10) (10) (10) (10) (10) (5) (10)

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20-1074 20-1075 20-1076 20-1077 20-1078 20-1079 20-1080 20-1081 20-1082 20-1101 20-1102 20-1103 20-1104 20-1105 20-1106 20-1107 20-1108 20-1109 20-1110 20-1111 20-1112 20-1113 20-1114 20-1115 20-1116 20-1117 20-1118 20-1119 20-1120 20-1151 20-1152 20-1153 20-1154 20-1155 20-1156 20-1157 20-1159 20-1160 20-1161 20-1162 20-1163 20-1164 20-1165 20-1166 20-1167 20-1168 20-1169 20-1170 20-1171 20-1172 20-1173

(10) (10) (10) (10) (5) (10) (10) (10) (10) (2) (10) (2) (10) (10) (10) (10) (7) (7) (2) (7) (10) (2) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10)

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20-1175 20-1176 20-1177 20-1178 20-1179 20-1180 20-1181 20-1182 20-1183 20-1201 20-1202 20-1203 20-1204 20-1205 20-1206 20-1207 20-1251 20-1252 20-1253 20-1254 20-1255 20-1256 20-1257 20-1258 20-1259 20-1260 20-1261 20-1262 20-1263 20-1264 20-1265 20-1266 20-1268 20-1269 20-1270 20-1271 20-1272 20-1273 20-1274 20-1275 20-1276 20-1277 20-1278 20-1279 20-1280 20-1281 20-1282 20-1283 20-1284 20-1285 20-1286

(10) (10) (10) (10) (10) (10) (10) (10) (10) (11) (11) (11) (11) (11) (11) (11) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12)

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20-1287 20-1288 20-1290 20-1291 20-1292 20-1293 20-1294 20-1295 20-1296 20-1297 20-1298 20-1299 20-1300 20-1301 20-1302 20-1303 20-1304 20-1305 20-1306 20-1307 20-1308 20-1309 20-1310 30-1 30-2 30-3 30-4 30-5 30-5-1 30-5-2 30-5-3 30-5-4 30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23

(12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (12) (10) (10) (3) (3) (3) (10) (10) (11) (10) (3) (10) (10) (10) (10) (3) (10) (10) (3) (10) (3) (10) (3) (3) (3) (10) (10) (10)

30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74

(10) (3) (10) (10) (3) (3) (3) (3) (10) (10) (10) (3) (3) (3) (10) (3) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (3) (3) (3) (3) (10) (10) (3) (3) (3) (10) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3)

30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-113-1 30-113-2 30-113-3 30-114 30-115 30-116 30-117 30-117-1 30-117-2 30-117-3 30-118 30-119 30-120

(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (4) (10) (10) (3) (10) (3) (3) (10) (3) (3) (10) (10) (10) (3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (10) (10) (3) (10) (10) (8) (10) (3) (10) (3) (10) (10) (8) (10) (10) (10) (10)

HD465-7, HD605-7

00-2-5
(12)

Mark

Page

Revision Mark number

Page

Revision Mark number

Page

Revision Mark number

Page

Revision Mark number

Page

Revision number

30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152

(3) (3) (3) (3) (3) (3) (3) (3) (3) (10) (3) (3) (3) (3) (4) (3) (3) (3) (3) (3) (10) (3) (3) (7) (4) (4) (10) (4) (10) (4) (4) (10) (12) (12) (12)

q 90-1 q q
90-2 90-3 90-5 90-7 90-9 90-11 90-13 90-15 90-17 90-19 90-21 90-23 90-25 90-26-1 90-26-3 90-27 90-29

Q Q q Q

(7) (7) (10) (10) (12) (12) (12) (12) HD465-7, HD605-7

00-2-6
(12)

SAFETY

SAFETY NOTICE

SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • • Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

00-3

SAFETY

SAFETY NOTICE

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

00-4

FOREWORD

GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.

k

Safety

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

a

Caution

4

Weight

3 2 5 6

Tightening torque

Coat

Oil, water

Drain

00-6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 • If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41%
SAD00479

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

! The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ! The adapter can be pushed in about 3.5 mm. ! Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ! Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ! Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ! When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
Type 1

00-8

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

Type 3 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
Disassembly

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code LT-1A Part No. 790-129-9030 Q’ty 150 g Container Tube Main applications, features

LT-1B

790-129-9050

LT-2

09940-00030

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50 LG-1

79A-129-9110 790-129-9010

LG-5

790-129-9080

LG-6 Gasket sealant LG-7

790-129-9020

790-129-9070

Three bond 1211 Three bond 1207B

790-129-9090

419-15-18131

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. • Features: Resistance to heat and chemicals Polyethylene 50 g • Used for anti-loosening and sealant container purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case

00-10

FOREWORD

COATING MATERIALS

Category

Komatsu code LM-G

Part No. 09940-00051

Q’ty 60 g

Container Can

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

Molybdenum disulphide lubricant

LM-P

09940-00040 SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

200 g

Tube

G2-LI

Various

Various

G2-CA

Various

Various

• Used for normal temperature, light load bearing at places in contact with water or steam.

Grease

Primer

Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

• Used for heavy load portion

400 g 16 kg

• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) • Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

400 g 16 kg

20 ml 417-926-3910 20 ml

Glass container Glass container Glass container

22M-54-27230

20 ml

22M-54-27240

150 ml

Can Adhesive for cab glass

22M-54-27250

20 ml

Glass container Ecocart (Special container) Polyethylene container Polyethylene container Polyethylene container Polyethylene container Cartridge

22M-54-27210

320 ml

Adhesive

417-926-3910

320 ml

20Y-54-39850 417-926-3920

310 ml 320 ml

Caulking material

20Y-54-55130

333 ml

22M-54-27220

333 ml

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Tightening torque Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190 235 – 285 320 – 400 455 – 565 610 – 765 785 – 980 1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2 kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2 kgm 1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5 23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100 118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ! In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49 Tightening torque

SAD00483

kgm 2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter mm 10 12 16

Width across flat mm 14 17 22 Nm 59 – 74 98 – 123 235 – 285

Tightening torque kgm 6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42

Width across flat mm

Tightening torque (Nm {kgm}) Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010 {3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Varies depending on type of connector.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52

Width across flat mm 14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm}) Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5 {0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5} Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 Nm 10 0 2 24 0 4 43 0 6 77 0 12 Tightening torque kgm 1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 14 Nm 802 10 0 2 12 0 2 24 0 4 36 0 5 Tightening torque kgm 0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 Nm 301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9 Tightening torque kgm 0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.20 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ! Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range 34 – 54 {3.5 – 5.5} 34 – 63 {3.5 – 6.5} 03 22 24 04 05 06 (10) (12) (14) 27 32 36 41 46 55 54 – 93 {5.5 – 9.5} 59 – 98 {6.0 – 10.0} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type

Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series – 14 – 18 22 24 30 33 36 42 9 — – 18UN 16 – 11 — – 16UN 16 – 13 — – 16UN 16 1 – 14UNS 3 1 — – 12UN 16 – – – 14.3 – 17.5 – 20.6 25.4 30.2 – – –

02

19

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS
Copper wire Norminal number Number of strands Dia. of strands (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm2) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) Current rating (A) Applicable circuit

0.85 2 5 15 40 60 100

11 26 65 84 85 127 217

2.4 3.1 4.6 7.0 11.4 13.6 17.6

12 20 37 59 135 178 230

Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting

CLASSIFICATION BY COLOR AND CODE
Circuits Priority Classification Primary Code Color Code 2 Color White & Red Code 3 Color White & Black Code 4 Auxiliary WL — — — — — — — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR RY YG Yellow & Green YL GY Green & Yellow GB LY Blue & Yellow LB WB — — White & Black Red & White Rellow & Red Green & White Blue & White BY RB YB GR LR

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

W White WR

B Black —

B Black BW

R Red RW

Y Yellow YR

G Green GW

L Blue LW

1

Color White & Blue Code WG

Black & Red Red & Yellow — — — — RG

5 Color White & Green Code 6 Color — Red & Blue Yellow & White Green & Blue — Red & Green Yellow & Blue Green & Black Blue & Black RL YW GL

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches
1 mm = 0.03937 in

0 0 10 20 30 40 (A) 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

00-16

FOREWORD

CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62

2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83

3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03

4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24

5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44

6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64

7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85

8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05

9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon
1l = 0.2642 U.S. Gal

0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775

1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040

2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304

3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568

4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832

5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096

6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361

7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625

8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889

9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153

Liter to U.K. Gallon
1l = 0.21997 U.K. Gal

0 0 10 20 30 40 50 60 70 80 90 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797

1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017

2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237

3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457

4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677

5 1.100 3.300 5.499 7.969 9.899 12.098 14.298 16.498 18.697 20.897

6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117

7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337

8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557

9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3

1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5

2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7

3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0

4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2

5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4

6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7

7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9

8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1

9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4

00-19

7 953.7 440.0 654.2 725.8 512.1 597.6 881.5 810.1 469.3 924.6 497.0 398.3 227.5 682.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428 2 28.5 426.6 241.9 839.4 867.0 526.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485 6 85.8 384.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442 3 42.2 853.4 995.7 184.3 796.7 568.5 298.1 782.2 284.4 739.4 611.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542 00-20 .6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414 1 14.6 625.7 825.4 355.1 213.2 156.6 369.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499 7 99.9 583.9 327.8 640.3 540.4 170.1 910.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527 9 128.8 768.2233 lb/in2 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 0 142.FOREWORD CONVERSION TABLE kg/cm2 to lb/in2 1kg/cm2 = 14.7 696.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470 5 71.2 981.0 967.6 753.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513 8 113.9 455.9 711.1 341.3 668.8 256.8 896.7 312.9 199.4 483.2 412.0 270.5 938.5 554.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456 4 56.

0 15.8 53.2 104.2 –26.2 167.9 9.2 22.0 123.8°F °C –40. consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.3 23.0 338.2 12.6 100.3 13.6 109.0 6.2 –1.4 5.7 79.0 266.8 26.2 86.7 –16.4 1.6 46.0 –4.8 17.8 170.2 –21.6 55.6 91.4 210.4 75.6 26.2 158.6 16.2 185.6 181.2 203.4 –8.0 °C –11.6 199.9 19.6 68.9 4.4 201.6 21.4 –37.0 221.1 1. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.8 107.7 –11.9 29.6 118.4 30.0 150. and read the corresponding Fahrenheit temperature on the right.8 –17.8 62.0 35.2 95.0 42.2 176.0 –19.0 311.0 284.0 10.3 8.1 26.2 113.4 3.6 145.8 125.8 188.0 239.2 122.8 33.0 132.2 140.0 69.9 34.6 0 0.2 131.8 –2.1 –25.1 –0.6 154.8 161.4 111.2 –40 –35 –30 –25 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 °F –40.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 0 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 °F 114.4 192.8 28.8 98.9 –23.0 °C 27.8 23.6 43.9 24.0 105.2 14.0 –14.4 57.7 2.0 320.7 54.0 °C 7.4 35.0 293.2 32.2 17.1 73.0 248.1 21.7 65.6 31.8 134.7 –6.6 –10.0 –13.0 –24.3 28.8 71.3 –22.0 –4.3 18.6 73.0 –9.0 60.3 –7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 °F 51.4 165.0 204.3 3.8 –7.0 186.6 28.4 –31.1 48.7 12.1 16.6 6.7 –28.8 197.2 27.8 8.7 37.4 57.0 168.8 116.8 –27.6 –5.9 –13.4 147.4 12.8 179.1 –20.8 3.6 163.6 37. If it is desired to convert from Centigrade to Fahrenheit degrees.9 76.2 68.0 62.2 23.4 –18.0 141.2 32.4 21.8 18.4 39.4 10.1 –15.6 1.6 –15.2 –16.7 –21.6 11.2 212.4 93.7 –26.8 89.0 24.0 –31.0 5.3 71.2 77.2 194.2 –6. a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.6 82.6 –20.9 –18.1 31.0 33.3 33.4 15.8 206.0 257.0 78.4 48.6 64.2 2.2 59.8 44.4 –13.6 127.8 35.2 –34.6 190.9 –8.4 102.4 174.7 17.1 –10. consider the center column as a table of Centigrade values.9 –28.0 –2.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 °F 117.8 13.0 347.7 7.9 51.4 183.6 208.6 19.FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion .3 –27.8 8.2 41.0 25.3 –2. 1°C = 33.3 –17.2 149.9 14.6 36.2 –0.8 143.7 22.7 32.1 36.0 230.3 –12.2 60.2 50.0 275. If it is desired to convert from Fahrenheit to Centigrade degrees.4 –23.8 40.4 156.1 11.4 –3.0 96.3 46.7 –1.0 195.4 66.4 30.2 37.6 –25.0 00-21 .8 152.0 87.0 302.8 –22.4 84.0 30.8 –12.0 20.9 –3.2 5.4 129.4 25.4 20.6 10.1 –5.1 6.4 120.0 159.0 –22.0 329.6 136.8 80.0 15.6 172.4 138.

As for reference.FOREWORD UNITS UNITS In this manual. the measuring units are indicated with Internatinal System of units (SI). conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh} }. 00-22 04-05 .

................................01 GENERAL Specification drawings............... 01-10 HD465-7...........2 Specifications ............9 Fuel.... 01......... coolant and lubricants ........ 01............................ 01...........................................3 Weight table .......... HD605-7 01-1 .........

GENERAL SPECIFICATION DRAWINGS SPECIFICATION DRAWINGS HD465-7 HD605-7 01-2 HD465-7. HD605-7 .

595 4.000} 3.080 645 KOMATSU SAA6D170E-3 4-cycle. torque Fuel consumption (Min.5 kW x 2 units 24V.875 20.000 {715/2.256/1.150} 533/2. turning radius Dumping angle Overall length Overall width Dimensions Overall height Wheel base Front wheel Tread Rear wheel Ground clearance Model Type No.000 97. 7. HD605-7 01-3 (10) . water-cooled. travel speed Gradeability (sin ) Min.15 {23. direct injection.120 (47%) HD465-7. Empty Max.) Stating motor Alternator Battery mm {cc} kW/rpm{HP/rpm} Nm/rpm{kgm/rpm} g/kWh {g/HPh} mm mm 3.680 (53%) 31.555 (68%) 25 kg kg 22. 200Ah x 2 units m3 km/h % m ° mm mm mm mm mm 34.400} 207 {154} 24V.400 {332/1. of cylinders – Bore x stroke Piston displacement Engine Rated output Max.355 4.800 55. with turbocharger and after-cooler 6 – 170 x 170 23. load Gross Weight (front) Weight distribution Empty (rear) (front) Gross (rear) Struck Dump body capacity Heaped (2 :1) Performance Max.2 70 37 8.515 kg m3 66. 50A 12V.300 3.400 4.320 (32%) kg kg kg kg HD465-7 7001 and up 42. in-line 6-cylinder.GENERAL SPECIFICATIONS SPECIFICATIONS Machine model Serial No.5 48 9.

splash lubrication 3. Rear tire Tire pressure Front and rear tire kPa {kg/cm2} 24. Hydraulically controlled Parking brake Multiple disc wet type disc brake.up clutch 3-element. electrically-hydraulically actuated.538 Straight bevel gear. 2-phase Hydraulically actuated. HD605-7 . 1-stage.737 Type Fully hydraulic steering system Front axle Suspension Axle type Rear axle Front axle Suspension method Rear axle Independent suspension (Mac Pherson type) Full floating Hydropneumatic (Automatic damping force selection type) Hydropneumatic Front tire Tires Size and No. wet-type.00 – 35 – 36PR x 4 470 {4. 7001 and up Structure Torque converter Lock.75} Front wheel Service brake Breke system Rear axle Single dry disc type. force-feed type pump F7.00 – 35 – 36PR x 2 24. Hydraulically released spring type Retarder Oil cooled multiple disc type. Hydraulically controlled Oil cooled multiple disc brake. splash lubrication 4. splash lubrication Type Final drive Reduction ratio Steering system Planetary gear. multiple-disk clutch Type Transmission Power train No. of speeds TORQFLOW planetary gear Fully automatic.GENERAL SPECIFICATIONS Machine model HD465-7 Serial No. R1 Type Reduction gear Reduction ratio Differential type Spiral bevel gear. Hydraulically controlled 01-4 (10) HD465-7.

HD465-7 7001 and up For both steering and work equipment Type Delivery (at engine rated speed 2.000 rpm) /min Gear pump 456 /min Gear pump 228 /min Gear pump 348 Hydraulic system Hoist cylinder Type Cylinder No. – bore x stroke Piston type.774 mm HD465-7. HD605-7 01-5 .GENERAL SPECIFICATIONS Machine model Serial No. – bore (1st – 2nd) x stroke Steering cylinder Type No. double acting 2 – 85 mm x 410 mm 2-stage piston type (only 2nd stage: double-acting) 2 – (170 mm – 150 mm) x 1.000 rpm) Hydraulic pump For charging torque converter Type Delivery (at engine rated speed 2.000 rpm) For brake cooling Type Delivery (at engine rated speed 2.

900 63. water-cooled. load Gross Weight (front) Weight distribution Empty (rear) (front) Gross (rear) Struck Dump body capacity Heaped (2 :1) Performance Max. travel speed Gradeability (sin ) Min. 7. 200Ah x 2 units 01-6 (10) HD465-7.150} 533/2. Empty Max.5 kW x 2 units 24V.400 4.400 {332/1.595 4.325 (53%) 34.870 (32%) 74.575 (47%) 24. 50A 12V. HD605-7 .400} 207 {154} 24V.515 3.000 108.105 (68%) 29 40 70 37 8.256/1.300 3. in-line 6-cylinder. with turbocharger and after-cooler 6 – 170 x 170 23. direct injection. turning radius Dumping angle Overall length Overall width Dimensions Overall height Wheel base Front wheel Tread Rear wheel Ground clearance Model Type No.) Stating motor Alternator Battery mm {cc} kW/rpm{HP/rpm} Nm/rpm{kgm/rpm} g/kWh {g/HPh} mm mm m3 km/h % m ° mm mm mm mm mm kg m3 kg kg kg kg kg kg HD605-7 7001 and up 45.15 {23.5 48 9.355 4.080 645 KOMATSU SAA6D170E-3 4-cycle. of cylinders – Bore x stroke Piston displacement Engine Rated output Max.975 21.000 {715/2. torque Fuel consumption (Min.GENERAL SPECIFICATIONS Machine model Serial No.000} 3.

00 R35 aa x 2 24. of speeds TORQFLOW planetary gear Fully automatic.538 Straight bevel gear. 1-stage. wet-type. R1 Type Reduction gear Reduction ratio Differential type Spiral bevel gear. HD605-7 01-7 (10) . Hydraulically controlled HD465-7. Hydraulically controlled Parking brake Multiple disc wet type disc brake. Hydraulically released spring type Retarder Oil cooled multiple disc type. electrically-hydraulically actuated. force-feed type pump F7. splash lubrication 4. 2-phase Hydraulically actuated. Hydraulically controlled Oil cooled multiple disc brake.up clutch 3-element. splash lubrication Type Final drive Reduction ratio Steering system Planetary gear. Rear tire Tire pressure Front and rear tire Front wheel Service brake Breke system Rear axle Single dry disc type.0} Front tire Tires Size and No. multiple-disk clutch Type Transmission Power train No.737 Type Fully hydraulic steering system Front axle Suspension Axle type Rear axle Front axle Suspension method Rear axle Independent suspension (Mac Pherson type) Full floating Hydropneumatic (Automatic damping force selection type) Hydropneumatic 24. splash lubrication 3.GENERAL SPECIFICATIONS Machine model HD605-7 Serial No.00 R35 aa x 4 kPa {kg/cm2} 686 {7. 7001 and up Structure Torque converter Lock.

– bore (1st – 2nd) x stroke Steering cylinder Type No.000 rpm) Hydraulic pump For charging torque converter Type Delivery (at engine rated speed 2. double acting 2 – 85 mm x 410 mm 2-stage piston type (only 2nd stage: double-acting) 2 – (170 mm – 150 mm) x 1.774 mm 01-8 HD465-7. HD605-7 . – bore x stroke Piston type. HD605-7 7001 and up For both steering and work equipment Type Delivery (at engine rated speed 2.000 rpm) /min Gear pump 456 /min Gear pump 228 /min Gear pump 348 Hydraulic system Hoist cylinder Type Cylinder No.GENERAL SPECIFICATIONS Machine model Serial No.000 rpm) For brake cooling Type Delivery (at engine rated speed 2.

GENERAL WEIGHT TABLE WEIGHT TABLE This weight table is a guide for use when transporting or handling component.740 123 304 276 403 1.355 822 1.730 HD605-7 7001 and up 2.740 123 304 276 403 1.184 28 62 6.698 920 63 44 206 26 20 34 28 33 23 13.698 920 63 44 206 26 20 34 28 33 23 10. Unit: kg Machine model Serial Number Engine assembly Output shaft assembly Radiator assembly Fuel tank Torque converter assembly Transmission assembly Drive shaft assembly (front) Drive shaft assembly (rear) Rear axle assembly HD465-7 7001 and up 2.355 822 1. HD605-7 01-9 (10) .502 646 330 142 460 172 4.502 646 330 142 460 172 4.184 28 62 6.418 • Differential • Final drive (one-side) • Rear brake (one-side) Front axle (one-side) Front brake (one-side) Front suspension cylinder Rear suspension cylinder Frame Cab (Platform) Operator's seat Steering cylinder Hoist cylinder Demand valve Steering valve Hoist valve Hydraulic pump (SAR(3)–100+100) Hydraulic pump (SAR(3)–80+80) Hydraulic pump (SAR(3)100+(1)25) Dump body HD465-7.

GENERAL FUEL. HD605-7 . COOLANT AND LUBRICANTS FUEL. COOLANT AND LUBRICANTS 01-10 (10) HD465-7.

HD465-7. be sure to use e n g i n e o i l o f S A E 1 0 W. adjust the concentration of AF-ACL according to the operation and meintenance manual. a When starting the engine in an atmospheric temperature of lower than 0°C.3 each for right and left — Differential Case 95 95 Final drive case Specified oil level ( ) Refill capacity ( ) 32 each for right and left 21 each for right and left Fuel tank 780 — Cooling system 154 — Fuel and oil Select fuel and oil according to the above table. S A E 1 0 W . The refill capacity means the amount of oil needed to refill the system during normal inspection and maintenance. even through the atmospheric temperature goes up to 10°C or above during the day. HD605-7 01-11 (10) . the latter does not need to be replaced while the atmospheric temperature is above – 10°C.GENERAL FUEL. Hoist Oil Tank 180 122 Front Suspension 17 each for right and left — Rear Suspension 11. a The specified capacity means the total amount of oil including oil for components and oil in piping. COOLANT AND LUBRICANTS Engine Oil Pan Specified capacity ( ) Refill capacity ( ) 67 57 Transmission Case 285 190 Steering. If the atmospheric temperature drops below – 10°C.3 0 o r SAE15W-40. Coolant Since Komatsu genuine Supercoolant (AF-ACL) is added to the cooling water.

................................... 10-212 [Related to VHMS controller] VHMS controller ...................... 10............ 10-110 Air conditioner...... FUNCTION AND MAINTENANCE STANDARD Radiator......................... 10-7-1 Torque converter and transmission hydraulic piping....................... 10-67 Relay valve..................... 10-62 Brake valve................. 10................................................... 10-220 For details of VHMS............... 10-217 Exhaust temperature sensor/amp ........ 10-102 EPC valve......................................... 10-68 Front brake off valve........... see TESTING AND ADJUSTING...... 10-109 Hydraulic pump......................................................................................... 10-119 Engine control system .......5 Output shaft.................... 10-98 Hoist valve ............................ 10-134 Automatic shift control system ...................... 10-48 Suspension cylinder .... 10-78 Proportional reducing valve....................... 10-28 Axle .......... 10-86 Steering and hoist hydraulic system diagram.....................................................8 Torque converter .... 10-88 Dump body control .................................................................. 10.. HD465-7...... switches................................................ 10-27 ECMV .............................................................................................................................. 10-96 Steering cylinder .......................... 10-184 Automatic suspension system ............ fuel cooler ............................................. 10-91 Steering control valve ....... 10-218 Ambient temperature sensor......... 10-56 Steering column..... 10-10 Transmission .............................................................................................................................................4 Power train skeleton............................. 10-44 Wheels ................ HD605-7 10-1 (10) ............................................................................................................................................................................................................ work equipment oil cooler.................................. 10-97 Demand valve. 10-90 HYdraulic tank ........................................................... 10-84 Steering and hoist hydraulic piping.....................10 STRUCTURE............... 10-58 Steering linkage......................................................................... 10-76 Brake ........................................ 10-108 Hoist cylinder ........... 10-136 Payload meter (card type)........................................ 10-50 Rear axle support ................................................................ 10-59 Brake piping .............................................. 10-64 Emergency brake valve............. 10-204 Dump lever ..... 10-18 Transmission valve..... 10-38 Differential ........................................................................ 10.................3 Brake oil cooler....................................... 10-114 Machine monitor system................................6 Drive shaft ............ 10-71 Accumulator ................. 10-188 Retarder control system .............................. 10-42 Final drive.................... 10-46 Suspension..................................... 10-192 Sensors........... 10-219 Payload meter (Having VHMS) .............................. 10-83 Parking brake solenoid valve .. 10............... 10-69 Accumulator charge valve ....................... 10-216 BLOW-BY pressure sensor .......................... torque converter oil cooler............................ 10-92 Crossover relief valve ...... 10-218 Communications (orb•••orbcomm) controller/antenna.......................................................................... 10-75 Slack adjuster...... 10-151 Automatic emergency steering system........... 10-216 Engine oil temperature sensor........... after cooler....................

Work equipment oil cooler 6. HD605-7 10-3 (10) . TORQUE CONVERTER OIL COOLER. FUEL COOLER 1. AFTER COOLER. Upper tank 3. FUEL COOLER RADIATOR. Fuel cooler A : Coolant inlet port B : Coolant outlet port Specifications Radiator Core type: CF4-5 Total radiation surface: 130. TORQUE CONVERTER OIL COOLER.6 m2 Work equipment oil cooler Core type: CF40-1 Radiation surface: 2. Lower tank 4.STRUCTURE. AFTER COOLER. After cooler 7. Core 5.90 m2 Fuel cooler Core type: FC1-3 Heat radiation area: 6. FUNCTION AND MAINTENANCE STANDARD RADIATOR. WORK EQUIPMENT OIL COOLER.75 m2 HD465-7. WORK EQUIPMENT OIL COOLER. Pick-up for radiator coolant level sensor 2.

13 m2 Pressure resistance (oil side): 2. FUNCTION AND MAINTENANCE STANDARD BRAKE OIL COOLER BRAKE OIL COOLER 1.9 MPa {30 kg/cm2} 10-4 (10) HD465-7.STRUCTURE. Cooler element A : Oil inlet B : Oil outlet C : Coolant inlet D : Coolant outlet Oil cooler specifications Element type : Multiple plate Radiation surface: 8. HD605-7 .

2. HD605-7 10-5 . Engine Output shaft Front drive shaft Brake cooling pump (SAR(3)100+100) Torque converter transmission charge pump and brake cooling brake control pump (SAR(3)100+25) PTO Torque converter Transmission Rear drive shaft Differential gear Drive shaft Brake Tire Final drive Parking brake Steering. 5. 11. 12. 16. 4. HD465-7. 14. 10. 8. hoist and hoist control pump (SAR(3)80+80+(1)6) 6. 9. 15. 13. FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON POWER TRAIN SKELETON 1.STRUCTURE. 7. 3.

FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT OUTPUT SHAFT 1. Cover Function The output shaft is installed to the engine flywheel.STRUCTURE. Shaft 5. Coupling 6. Inner body 7. Flange 4. and absorbs the twisting vibration caused by changes in the engine torque. Outer body 3. Rubber cushion 2. 10-6 HD465-7. HD605-7 .

033 +0.005 –0.015 –0.050 – 0.10 0.005 –0.02 0.015 –0.1 Backlash limit 0.080 – 0.025 +0.003 Standard size Hole –0.013 Replace 2 3 4 Clearance between shaft and bearing Clearance between bearing and cover Clearance between bearing and shaft Wear of oil seal contact surface of coupling 55 150 85 5 110 Standard backlash Repair or replace 6 Backlash at spline 0.06 0.025 0.016 –0. FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT Unit: mm No.002 Repair limit 0 –0.045 0 –0.010 –0.045 – 0.040 +0.039 – 0.008 –0.005 – 0.231 Original dimension: Lo Defomation of rubber cushion Replace 7 90 75 External HD465-7. Check item Standard size Criteria Tolerance Standard clearance –0.024 +0.010 –0.006 –0.4 Standard backlash (Dimension at smallest width: L) 81 67 No cracks Clearance limit Remedy 1 Clearance between flywheel and bearing 100 Shaft 0 –0.040 –0. HD605-7 10-7 (10) .STRUCTURE.

the front drive shaft (1) and the transmission. Front drive shaft 2. 10-7-1 (6) HD465-7. HD605-7 .STRUCTURE. Rear drive shaft Outline • The power from the engine is transmitted through the output shaft. to the rear drive shaft (2). FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT DRIVE SHAFT 1.

FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 10-8 HD465-7.STRUCTURE. HD605-7 .

FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 1. Transmission 3. Torque converter valve 6. Hydraulic pump (SAR(3)100+(1)25) 5.STRUCTURE. Torque converter 2. Transmission oil filter HD465-7. Oil filler tube 4. HD605-7 10-9 .

PTO Gear (Number of teeth : 91) A : Main oil pressure detection port B : Torque converter oil inlet C : Torque converter oil inlet pressure detection port D : Torque converter oil outlet E : To transmission control valve F : To lock-up clutch G: Torque converter oil outlet pressure detection port H : To transmission lubrication Specification Type : 3-element. HD605-7 . 1-stage.32 10-10 (10) HD465-7. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER TORQUE CONVERTER 1.STRUCTURE. 2-phase With modulation With lock-up clutch Lock-up clutch : Wet type double plate clutch Hydraulic control (with modulation mechanism) Stall torque ratio: 2.

16. 15. HD605-7 10-11 . 12.STRUCTURE. 13. 5. 4. 8. 9. 14. 6. 2. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER 1. 3. Stator shaft One-way clutch Stator Disc Piston Clutch housing Retainer HD465-7. Coupling Input shaft (Number of teeth : 108) Front housing Drive case Turbine Race Torque converter valve Pump Rear housing 10. 7. 11.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER 10-12 HD465-7. HD605-7 .

8 Clearance limit 8 9 10 Replace Standard size 11 Clearance between clutch housing and piston (outside) φ 420 12 Clearance between clutch housing and piston (inside) φ 295 Shaft –0. HD605-7 10-13 .1 ±0.30 HD465-7.018 0 –0.013 +0.874 Remedy 2 3 4 Correction by chrome plating or replacement 5 6 Outer race one-way clutch transmission face inside diameter Inner race one-way clutch transmission face outside diameter Bushing sliding portion inside diameter Bushing sliding portion thickness Clutch disc thickness 7 φ 108.883 φ 108.191 Hole +0.96 5 5.1 ±0.59 φ 127.5 –0.1 φ 135.1 3.88 0.030 0 0 –0.272 φ 108. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER Unit: mm No.853 φ 109.5 – 0.4 ±0.STRUCTURE.1 ±0.844 Criteria Tolerance 0 –0.040 +0.1 φ 127.11 – 0.5 4.087 +0.8 φ 35.95 5.55 4.7 –0.025 0 +0.797 0.110 –0. 1 Check item Standard size Coupling oil seal sliding portion outside diameter Input shaft seal ring sliding portion inside diameter Pump housing seal ring sliding portion inside diameter Input shaft seal ring sliding portion inside diameter Stator shaft seal ring wear Width Thickness φ 110 φ 35 φ 135 φ 75 3.040 0 +0.097 0 +0.1 Tolerance Standard clearance 0.013 Repair limit φ 109.5 φ 75.081 0 0.04 4.

and the stator (8) rotates with the pump (6) and the turbine (2). the drive case (1) is separated from the turbine (2) and the torque converter functions as a normal torque converter. The power generated with the engine is transmitted to the coupling (3). Power of the pump (6) rotates the turbine (2) using oil as the medium and is transmitted from the turbine (2) to the transmission input shaft (7). Since the drive case (1) and the turbine (2) were connected. The power generated with the engine is transmitted to the coupling (3). the drive case (1) and the turbine (2) are connected and integrated.STRUCTURE. 10-14 (9) HD465-7. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER POWER TRAIN When the lock-up clutch is [RELEASED] When the lock-up clutch is [IN] • • • When the lock-up clutch is [RELEASED]. HD605-7 . the input shaft (4) and the clutch housing (5) through the drive shaft and the damper and rotates the drive case (1) and the pump (6) as one part. the power is transmitted directly to the transmission input shaft (7) from the turbine (2) not using oil as the medium. • • • When the lock-up clutch is [IN]. the input shaft (4) and the clutch housing (5) through the propeller shaft from the damper and rotates the drive case (5) and the pump (6) as one part.

FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER OIL FLOW • After the oil passed through the main relief valve. The oil from the turbine is forced to flow to the stator (3) and enters the pump again. The oil enters the turbine (4) after getting centrifugal force from the pump (2) and transmits its energy to the turbine (4). HD605-7 10-15 (9) . the torque converter relief valve adjusts the oil pressure below the set pressure. Then. HD465-7. passes through the oil route of the stator shaft (1) and flows to the pump (2) from between the pump (2) and the stator (3). flows to the oil cooler for cooling from the outlet port B and is used for lubricating the transmission. But part of the oil passes through between the turbine (4) and the stator (3). the oil enters the input port A.STRUCTURE.

main relief) 137 26 10-16 (10) HD465-7.2 Installed load 1153.081 0.061 0.5 93.081 Replace 2 Clearance between main relief spoon and body 32 3 Main relief valve spring Free length 118 Installed length 94.0 N {3. HD605-7 .6 kg} 315. Check item Standard size Criteria Tolerance Standard clearance 0.5 132.9 25. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER TORQUE CONVERTER VALVE Unit: mm No.3 kg} Free length 114.061 Repair limit Installed load 1213.1 kg} 30.0 N {32.035 – 0.8 kg} 32.5 17 4 5 Torque converter relief valve spring Poppet spring (touque converter relief.035 – 0.8 kg} 331.045 –0.2 N {33.035 –0.STRUCTURE.045 Standard size Hole +0.8 N {117.8 N {3.016 0 0.035 –0.2 N {123.016 0 +0.1 kg} Clearance limit Remedy 1 Clearance between torque converter spool and body 32 Shaft –0.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION TRANSMISSION 10-18 HD465-7. HD605-7 .

Input shaft 2. Coupling 4. Strainer 5. Drain valve A : Speed sensor (for input shaft) B : Speed sensor (for intermediate shaft) C : Speed sensor (for output shaft) D : Lubricating oil pressure detection port E : To pump (suction) F : To lock up G: From torque converter (main circuit) J : From oil cooler H : From torque converter (lubrication circuit) K : From torque converter (drain circuit) L : Brake cooling relief valve M: Lubrication relief valve N : To breather HD465-7. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION 1. Transmission valve 3.STRUCTURE. HD605-7 10-19 .

FUNCTION AND MAINTENANCE STANDARD TRANSMISSION 10-20 HD465-7. HD605-7 .STRUCTURE.

10. 35. 4 planetary pinion (Number of teeth : 21) No. 1 ring gear (Number of teeth : 98) No. 3 clutch hub No. 4 clutch (3rd) No. 6. 4 ring gear (Number of teeth : 93) No. 8. 1 clutch hub No. 1 clutch piston No. Input shaft No. 3 clutch housing No. 6. 20. 6 ring gear (Number of teeth : 105) No. 28. 34. 2. 7 clutch piston No. 5 planetary carrier No. 27. 7 planetary carrier No. 5 clutch piston No. 12. 6 sun gear (Number of teeth : 45) No. 3 clutch drum No.STRUCTURE. 5 sun gear (Number of teeth : 41) No. 3. HD605-7 10-21 . 17. 5 ring gear (Number of teeth : 93) No. 4. 2 clutch housing No. 37. 11. 26. 4 clutch piston HD465-7. 9. 5 planetary pinion (Number of teeth : 21) No. 18. 32. 14. 16. 7 planetary pinion (Number of teeth : 38) No. 30. 7. 15. 6 planetary pinion (Number of teeth : 30) No. 25. 31. 24. 38. 33. 22. 4 sun gear (Number of teeth : 51) No. 36. 7 ring gear (Number of teeth : 104) Output shaft No. 21. 19. 2 clutch piston No. 1 clutch (High) No. 4. 1 planetary pinion (Number of teeth : 32) No. 29. 39. 5 clutch (R) No. 41. 5 planetary pinion (Number of teeth : 21) No. 13. 7 clutch (1st) No. 6 clutch piston Intermediate shaft (No. 40. 23. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION 1. 1 sun gear (Number of teeth : 34) No. 3 clutch piston No. 6 clutch (2nd) No. 5. 3 clutch (4th) No. 2 clutch hub No. 2 clutch (Low) No. 7 sun gear : Number of teeth 28) No. 1 planetary carrier No.

FUNCTION AND MAINTENANCE STANDARD TRANSMISSION 10-22 HD465-7.STRUCTURE. HD605-7 .

0 Installed length 32.8 42 32.3.3 No.0 57.1 36.8 2. HD605-7 10-23 .6 kg} 49. 4 clutch Total thickness of 5 discs and 4 plates for No.28 ±0.03 ±0.0 2.1 N {5.10 –0.6 kg} Repair limit 25.8 N {11.5 N {7. 5 clutch Total thickness of 4 discs and 4 plates for No.45 13 Thickness of 1 disc 15 Wear of transmission input shaft seal ring (small) 16 Wear of transmission input shaft seal ring (large) 17 Wear of No.6 N {12.5 Width Thickness Width Thickness 27.5 kg} 42.03 ±0.70 2. 3 clutch Total thickness of 4 discs and 3 plates for No.3 33.6 kg} 179.10 ±0. 7 clutch No.12 Free length 39.8 4.7 Remedy 1 No.0 2 3 4 5 No.9 63.22 ±0.10 –0.30 1.1 N {9.95 3. No. 2.2 N {14. 4 clutch spring No.9 kg} 153.0 68.26 ±0. 1.0 35.6 47 44. Check item Standard size Criteria Repair limit Installed load 74.0 3. 1 clutch spring Free length 42. 3 clutch hub and No.0 N {15.2 N {4.10 ±0.8 5. 1 clutch Total thickness of 5 discs and 4 plates for No.3 kg} Tolerance ±0.26 ±0.0 4. 4 sun Thickness gear seal rings HD465-7.7 No.4 5.4.01 –0.0 36.03 ±0.30 ±0.10 –0. 1.5 48. 2. 6 clutch Total thickness of 4 discs and 3 plates for No. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Unit: mm No.6.56 1.2 kg} 97.5 N {18. 5 clutch spring No.0 Standard size 6 Total thickness of 3 discs and 2 plates for No.0 49.01 –0.5 63.26 ±0.5.6.01 –0.7 3. 7 clutch spring 52.8 39.10 ±0.STRUCTURE.9 43.0 68.0 5.0 kg} 141. 6 clutch spring No.3 kg} 119.1 4.85 52.4 5.4.8 45.6 4.6 7 8 9 10 11 12 Replace 42.7 N {6.3 4.55 2.Width rier.7 14 Thickness of 1 plate No.9 Installed load 63.9 85.4 kg} 113.0 91. 2 clutch Total thickness of 4 discs and 3 plates for No.1 75.6 4.0 5. 1 car.30 ±0.

4 sun gear and planetary gear Backlash between No.01 –0.1 –0.15 0 –0. 1 sun gear and planetary gear Backlash between No. 1.13 – 0.85 Remedy 18 Wear of No.17 – 0. 5 planetary gear and planetary gear Backlash between No.6 4. 6 planetary gear and ring gear Backlash between No.01 –0.6 3.6 6.6 2.0 4.0 4.16 – 0.15 – 0.14 – 0. 2 and 3 clutch collar seal rings 19 Wear of No. 1 planetary gear and ring gear Backlash between No.34 0.0 Criteria Tolerance –0.15 0.95 5.1 ±0.15 –0.41 Repair limit 3.13 – 0.04 ±0.36 0. 7 planetary gear and ring gear Disc inner teeth deformation Standard size Replace 0. 4 and 5 planetary gears) Thrust washer thickness (No. 4 planetary gear and ring gear Backlash between No.41 0. 6 and 7 carrier seal rings 22 Wear of No.01 –0.16 – 0.85 3. HD605-7 .15 3.0 Thickness Width Thickness Width Thickness Width Thickness Width Thickness 5.0 3.04 ±0.1 4.03 ±0.41 0.3 4.73 3. 6 and 7 carrier seal rings 23 24 25 26 27 28 29 30 31 32 33 34 Backlash between No.01 –0. 5 sun gear and planetary gear Backlash between No.14 – 0.STRUCTURE. Check item Standard size Width 4.6 3. 5 planetary gear and ring gear Backlash between No.3 Tolerance ±0.44 Repair limit : 0. 6 sun gear and planetary gear Backlash between No.36 0.4 35 Thrust washer thickness (No.12 –0. 7 sun gear and planetary gear Backlash between No.15 – 0.36 0.1 ±0.39 0.56 4.39 0. 4 and 5 carrier seal rings 20 Wear of No.13 – 0. 6 and 7 planetary gears) 2 3 36 10-24 HD465-7.16 – 0. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Unit: mm No.25 4. 6 and 7 carrier seal rings 21 Wear of No.0 6.85 3.1 Repair limit 1.36 0.04 ±0.

80 Wear 0.125 – 0.5 – 0.303 Clearance limit 0. 4 Inside No.86 0.5 – 0.5 – 0.110 – 0.089 0 +0.232 –0.30 0.5 1.30 – 0.05 max. Check item Location No.33 0.7 Outside No. if corrected and the allowable clearance is maintained.081 0 +0. HD605-7 10-25 .125 –0.097 0 +0.110 –0.781 0. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Unit: mm No. 7 gear train Standard size Replace the thrust washer or the carrier 38 Stepped-type wear of seal ring counter face — Standard size Replace Repair limit 119.6.7 Inside No.5 –0. 5 gear train No.30 – 0.80 0.125 – 0. 1 gear train No.33 When any damage like seized streak is found on any surface.5 –0.8 Tolerance Shaft –0.125 –0. 6 Inside 40 HD465-7.80 0.303 0.3 Outside Clearance between cylinder and piston Middle Inside No.303 0.84 0.80 0.7 –0.7 –0.097 0 +0.80 0.089 0 +0. 6 gear train No. Clearance limit 1.135 – 0.329 0.135 –0.214 –0.88 0. 4.30 – 0.30 – 0.5 1.763 0.272 0.5 – 0.5. 1 Outside Inside No.125 –0.5 1.5 –0.5 1. No.36 0.089 0 +0.081 0 +0. it can be used.5 Remedy 37 Planetary gear side clearance No. 5.7 –0.STRUCTURE.214 Hole +0.789 0.214 –0.191 –0.797 0.30 – 0.089 0 Standard clearance 0.5 –0.125 – 0. 2.87 0. Replace it if damaged remarkably 39 Output shaft oil seal contact surface 120 Standard size 430 405 275 255 175 430 395 380 375 Clutch No.063 0 +0. 4 gear train Criteria Standard clearance 0.7 –0.33 0.

714 3. 2 – No. These are divided into the front group and rear group. 4 planetary gear No. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Outline • The transmission consists of an F7 R1 planetary gear type transmission with a control valve. • One clutch pack in the front group and one clutch pack in the rear group are actuated simultaneously by oil pressure sent from the transmission valve to give the speed range and reduction ratio.000 0. 4 (High – 3rd) No. 1 – No. 2 – No. 1 – No. 3 (Low – 4th) No. 2 – No.475 1. 3 clutch (4th) No. 4 clutch (3rd) Planetary gear No. 5 planetary gear No. • The transmission and torque converter are connected at the transmission input shaft. 2 – No. 2 – No. 6 (Low – 2nd) No. Group Front group Clutch pack No. 1 – No. 6 clutch (2nd) No. HD605-7 .355 1.969 10-26 (10) HD465-7.742 3.333 2. 6 (High – 2nd) No. Gear Shifting Function • The inside of the transmission consists of 7 clutch packs and 5 sets of planetary gears. 7 (Low – 1st) No. 5 (Low – R) Reduction ration 4. 6 planetary gear No. 7 clutch (1st) Speed range F1 F2 F3 F4 F5 F6 F7 R Clutches engaged No.825 1. 4 (Low – 3rd) No.STRUCTURE. 1 planetary gear No. 1 clutch (High) No. 2 clutch (Low) No. 7 planetary gear Rear group No. 3 (High – 4th) No. • Gear shifting is carried out automatically by the automatic transmission according to changes in engine speed. 5 clutch (R) No.

3. 7.STRUCTURE. 6. 5. 9. 8. 10. 2. ECMV (for high clutch) ECMV (for lockup clutch) ECMV (for low clutch) ECMV (for 4th clutch) ECMV (for 3rd clutch) ECMV (for R clutch) ECMV (for 2nd clutch) ECMV (for 1st clutch) Valve oil filter Seat A : High clutch pressure detection port B : Lockup clutch pressure detection port C : Low clutch pressure detection port D : 4th clutch pressure detection port E : 3rd clutch pressure detection port F : R clutch pressure detection port G: 2nd clutch pressure detection port H : 1st clutch pressure detection port ECMV Clutch Operation Table ECMV Gear range F1 F2 F3 F4 F5 F6 F7 N R1 ¡ ¡ R 1st 2nd 3rd 4th Low High ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ HD465-7. HD605-7 10-27 (9) . 4. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION VALVE TRANSMISSION VALVE 1.

FUNCTION AND MAINTENANCE STANDARD ECMV ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve (FOR HIGH. Applicable clutch High. REV AND 1ST CLUTCHES) 1. Fill switch 5. HD605-7 . and the clutch for lockup. 1st Lockup Character on nameplate A******* E******* 10-28 (9) HD465-7. Proportional solenoid connector 3. Rev. Nameplate (*2) A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port *1: The spool of pressure control valve is difference between the clutch for High. *2: The character on nameplate is different between nameplates for high. Rev and 1st clutches. Pressure control valve (*1) 7. Pressure detection valve 4. Proportional solenoid 6. Fill switch connector 2.STRUCTURE. LOCKUP. Rev and 1st clutches and that for lockup clutch.

STRUCTURE. HD605-7 10-29 (10) . The pressure control valve (3) drains oil from the clutch port A through the drain port T. Since the modulation actuates as shown below. Since oil pressure force does not work to the pressure detection valve (4). the fill switch (5) is turned "OFF". FUNCTION AND MAINTENANCE STANDARD ECMV ECMV FOR LOCKUP CLUTCH Outline • This valve is used for setting oil pressure of the lockup clutch to the set pressure. the valve prevents the power train from causing peak torque. and the lockup clutch is [RELEASED]. no current is flowing to the proportional solenoid (1). Also. This improves operator comfort and makes the power train more durable. WHEN SWITCHING LOCKUP CLUTCH (Lockup clutch OFF to ON) Operation When the torque converter is operating without lockup. and for switching lockup clutch. WHEN SHIFTING GEAR (At direct driving) • When the torque converter is operating without lockup. HD465-7. the valve enables to engage the lockup clutch smoothly and to reduce shocks at the time of gearshift.

and bounce force of the pressure control valve spring (2). and when the clutch is filled with oil. • When the current is supplied to the proportional solenoid (1). Then the pump port P and the clutch port A open. FUNCTION AND MAINTENANCE STANDARD ECMV WHEN THE TORQUE CONVERTER IS OPERATING WITH LOCKUP (Torque converter operation with lockup : Lockup operation) At filling time At pressure adjusting time • Electric signal commands to flow the current to the proportional solenoid (1) in case of lockup operation. At the time. the solenoid generates thrusting force in proportion to the current. The solenoid thrust force balances with the sum of the clutch port thrust force by oil pressure. To reduce gear shift shock. the oil pressure of the lockup clutch is lowered once at the time of gear shift. Then the pressure is adjusted. 10-30 (9) HD465-7. the oil pressure becomes to such pressure as that the lockup piston push force balances with the torque converter internal pressure. HD605-7 . the fill switch (5) is turned "ON". Then oil pressure force balancing with solenoid force works in Chamber B and pushes the pressure control valve (3) to the left. the valve starts filling the clutch with oil.STRUCTURE.

the fill switch is turned "ON" by the pressure of the clutch. It has the functions below. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve. While oil pressure is being applied to the clutch. By making the proportional solenoid-produced thrust act on the pressure control valve spool. 2. controlling the oil flow and oil pressure. ECMV and fill switch • One fill switch is installed for one ECMV. By controlling the amount of command current. HD465-7. If the clutch finishes filling. a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. FUNCTION AND MAINTENANCE STANDARD ECMV ECMV FOR SPEED RANGE CLUTCH Outline of ECMV • The ECMV consists of a pressure regulator valve and a fill switch. After receiving the command current from the controller. Current-Propulsion force characteristics of propotional solenoid Propulsion force-Hydraulic pressure characteristics of proportional solenoid A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range). it produces an oil pressure shown in the graph below. • Fill switch Detects that the clutch is filled with oil. By this signal. to an oil pressure. the thrust is changed to operate the pressure control valve. HD605-7 10-31 (9) .STRUCTURE. the oil pressure starts build-up. it produces thrust shown in the graph below. When the clutch is filled with oil. 1. ECMV and proportional solenoid • One proportional solenoid is installed for one ECMV. a signal (the fill signal) is sent to the controller to notify that filling is finished.

A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range). clutch input pressure and output signal of the fill switch is shown in the graph below. 10-32 (9) HD465-7. Before shifting gear (when drained) (A range in chart) • When no current is supplied to the proportional solenoid (1). the fill switch (5) is "OFF". the pressure control valve (3) is draining oil from the clutch port A through the drain port T. The relationship between the proportional command current for the ECMV.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD ECMV ECMV operation • The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. HD605-7 . Since no oil pressure works to the pressure detection valve (4).

• When a current is supplied to the proportional solenoid (1). the solenoid generates a thrust in proportion to the current. and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure. the valve starts filling the clutch with oil.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD ECMV Filling (B range in chart) Pressure regulation (C range in chart) • When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil. The solenoid thrust. and when the clutch fills with oil. the pump port P and the clutch port A open. an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. HD605-7 10-33 (9) . the fill switch (5) is turned "ON". Then. HD465-7.

Fill switch 5. Fill switch connector 2. FUNCTION AND MAINTENANCE STANDARD ECMV (FOR LOW. 3rd. 4TH.STRUCTURE. Proportional solenoid 6. HD605-7 . Pressure control valve 7. Nameplate (*1) *1: Applicable clutch Low. Proportional solenoid connector 3. Pressure detection valve 4. 2nd Character on nameplate D******* A : To clutch P : From pump T : Drain DR: Drain P1 : Clutch pressure pick-up port P2 : Pilot pressure pick-up port 10-34 (9) HD465-7. 3RD AND 2ND CLUTCHES WITH FLOW DETECTION VALVE) 1. 4th.

By controlling the amount of command current. It has the functions below. to an oil pressure. the fill switch is turned "ON" by the pressure of the clutch. controlling the oil flow and oil pressure. ECMV and fill switch • One fill switch is installed for one ECMV. 1. the oil pressure starts build-up. • Fill switch Detects that the clutch is filled with oil. it produces thrust shown in the graph below. After receiving the command current from the controller. FUNCTION AND MAINTENANCE STANDARD ECMV ECMV FOR SPEED RANGE CLUTCH Outline of ECMV • The ECMV consists of a pressure regulator valve and a fill switch. a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. When the clutch is filled with oil. HD465-7. it produces an oil pressure shown in the graph below. the thrust is changed to operate the pressure control valve. ECMV and proportional solenoid • One proportional solenoid is installed for one ECMV. By making the proportional solenoid-produced thrust act on the pressure control valve spool. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve. 2. If the clutch finishes filling.STRUCTURE. While oil pressure is being applied to the clutch. HD605-7 10-35 (9) . Current-Propulsion force characteristics of propotional solenoid Propulsion force-Hydraulic pressure characteristics of proportional solenoid A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (tiggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range). By this signal. a signal (the fill signal) is sent to the controller to notify that filling is finished.

Before shifting gear (when drained) (A range in chart) • A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point : Start of filling F point : Finish of filling a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range). the fill switch (5) is "OFF". Since no oil pressure works to the flow detection valve (4). HD605-7 . 10-36 (9) HD465-7. FUNCTION AND MAINTENANCE STANDARD ECMV ECMV operation • The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. When no current is supplied to the proportional solenoid (1).STRUCTURE. the pressure control valve (3) is draining oil from the clutch port A through the drain port T. clutch input pressure and output signal of the fill switch is shown in the graph below. The relationship between the proportional command current for the ECMV.

Then. HD605-7 10-37 (9) . an oil pressure balancing with the solenoid force works to Chamber B and pushes the pressure control valve (3) to the left. a differential pressure occurs between the upper stream and the lower stream of the orifice a of the flow detection valve spool. the solenoid generates a thrust in proportion to the current. At the time. When a current is supplied to the proportional solenoid (1). The solenoid thrust. When the clutch chamber is filled with oil and oil no longer comes to flow from the pump port P to the clutch port A. HD465-7. and the sum of the clutch port thrust by oil pressure and bouncing force of the pressure control valve spring (2) is balanced for adjusting pressure. FUNCTION AND MAINTENANCE STANDARD ECMV Filling (B range in chart) Pressure regulation (C range in chart) • • When any current is supplied to the proportional solenoid (1) and when the clutch contains no oil.STRUCTURE. and the fill switch (5) is turned "ON". the differential pressure disappears on both sides of the orifice a of the flow detection valve spool (4) and the flow detection valve spool (4) is pushed to the right by oil pressure force. the valve starts filling the clutch chamber with oil from the pump port P through the orifice a of the flow detection valve spool (4). The differential pressure pushes the flow detection valve spool (4) to the left.

130 Repair limit — Remedy Repair or replace 10-38 (10) HD465-7. 2 Check item Standard size Wear of oil seal sliding surface 280 Criteria Tolerance 0 –0.STRUCTURE. Wheel hub Unit: mm No. FUNCTION AND MAINTENANCE STANDARD AXLE AXLE FRONT 1. HD605-7 .

STRUCTURE. Differential 2. Axle housing 3. Brake 4. Final drive Specifications Reduction ratio Differential: 3.00-35 (HD465-7) 24.00-35 HD465-7.00R35 (HD605-7) Rim size: 17. FUNCTION AND MAINTENANCE STANDARD AXLE REAR 1.737 Oil Differential: EO30-CD (95 liters) Final drive : EO30-CD (32 liters each side) Tire size : 24.538 Final drive : 4. HD605-7 10-41 .

HD605-7 . Side gear (No. Coupling 2. of teeth: 13) Specifications Type: Spiral bevel gear. FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL DIFFERENTIAL 1. Cross shaft 3. Bevel gear (No.STRUCTURE. splash-type lubrication Reduction ratio: 3. of teeth: 46) 4. of teeth: 24) 5. of teeth: 17) 6. Bevel pinion (No. splash-type lubrication Oil: EO30-CD (95 liters) 10-42 HD465-7. Pinion gear (No.538 Differential: Straight bevel gear.

5 Remedy Repair or replace 8 9 Replace Adjust HD465-7. HD605-7 10-43 .STRUCTURE.41 – 0. 7 Check item Standard size Wear of oil seal contact surface of coupling Thickness of side gear thrust washer Backlash between bevel gear and pinion 150 6 Criteria Tolerance 0 –0.100 0 –0.56 Repair limit — 5. FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL Unit: mm No.050 0.

of teeth: 87) 5. Inner hub 6. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE FINAL DRIVE 1.STRUCTURE. Planet gear (No. Drive shaft Specification Type: Planetary gear. Ring gear (No. HD605-7 . of teeth: 19) 2. Wheel hub 7. of teeth: 31) 3. Sun gear (No. splash-type lubrication Reduction ratio: 4. Planet gear shaft 4.737 Oil: EO30-CD (32 liters each side) 10-44 HD465-7.

0 Repair limit: 1.28 – 0.5 50 Replace HD465-7.1 Repair limit Remedy Replace 9 10 Repair or replace 11 Thickness of spacer 51.STRUCTURE.5 TIR Tolerance ±0.22 – 0. HD605-7 10-45 . 8 Check item Standard backlash Backlash between planet gear and sun gear Backlash between planet gear and ring gear Curvature of drive shaft Standard size 0.77 Criteria Repair limit 0.8 1.67 0. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE Unit: mm No.

STRUCTURE. Rim assembly 3. FUNCTION AND MAINTENANCE STANDARD WHEELS WHEELS FRONT WHEEL 1. Valve Specifications Rim size: 17.00 × 35 Tire size : 24.00-35 (HD465-7) 24.00R35 (HD605-7) REAR WHEEL 1. HD605-7 . Tire 2. Extension Specifications Rim size: 17.00-35 (HD465-7) 24. Rim assembly 2. Valve 3.00 × 35 Tire size : 24.00R35 (HD605-7) 10-46 HD465-7.

FUNCTION AND MAINTENANCE STANDARD SUSPENSION SUSPENSION 1. it allows the machine to demonstrate its full performance in items such as acceleration. braking. This further increases the stability and riding comfort of the machine. the suspension cylinder is charged (sealed) with oil and nitrogen gas. the front suspension employs an automatic suspension system. it maintains the stability of the machine by ensuring that all four wheels are always in contact with the ground surface. HD465-7.STRUCTURE. and absorbs the shock from uneven road surfaces to provide a comfortable ride for the operator. Front suspension cylinder 2. Rear suspension cylinder 4. In this system. Radius rod (Lower rod) 5. HD605-7 10-48 (10) . With • hydropneumatic cylinders. At the same time. even when traveling at high speed. and turning. the force of the suspension is automatically changed by selecting the dumping force to match the travel conditions and load conditions. In addition to these functions. This acts as a shock absorber (spring and damper) by contracting and expanding the nitrogen gas and oil to absorb the load from the road surface. Radius rod (Upper rod) 3. Arm (A-frame) Outline • The suspension system supports the weight of the chassis. In this way. • Hydropneumatic cylinders are used for the suspension cylinders to reduce the shock.

Rear suspension The differential housing is supported by the frame and two radius rods at the bottom. HD465-7. 2. Front suspension The front suspension cylinder functions as a shock absorber and spring. It transmits the load and motive force through the top and bottom rods. The wheels move up and down in accordance with the retraction and extension of the suspension cylinder to maintain the proper alignment for the wheels and to improve the stability of the machine. FUNCTION AND MAINTENANCE STANDARD SUSPENSION Function 1. and at the top by two inverted-V-shaped rods and two suspension cylinders. Employment of the inverted-V-shaped link improves the rolling steering characteristics. HD605-7 10-49 (6) . and is connected by spherical bearings to the lower arm (A-frame) and main frame. It is connected to these at both ends by spherical bearings.STRUCTURE. The inverted-V-shaped rods at the top also function to maintain the center of the machine (axle).

3. 2. Tube 7.STRUCTURE. 9. 8. 4. Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) 5. FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER SUSPENSION CYLINDER FRONT 1. Air bleeding valve 6. HD605-7 . 10. Air cylinder Valve assembly Damping force selector valve Damping force selector valve lever A : Port B : Port 10-50 (10) HD465-7.

7 0.360 +0. 5 mm Protrusion: Max.240 0 +0. Check item Standard size Criteria Tolerance Standard clearance 0. Elongation : Max.106 –0. FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER Unit: mm No.540 +0.26 Hole +0.043 –0. 2 mm No cracks 15 Deformation of stopper HD465-7.05 – 0.043 –0.106 –0.403 – 0.3 mm Replace Measuring method: Measure protrusion and elongation of stopper.115 0 Replace bushing 0. All the conditions below must be fulfilled. HD605-7 10-51 (10) .STRUCTURE.8 Repair limit Replace bushing Replace wear ring 12 13 Clearance between piston rod and bushing Clearance between cylinder and wear ring 160 200 14 Elasticity of leaf spring Max.646 0.375 Clearance limit Remedy 11 Clearance between piston rod and bushing 160 Shaft –0.043 – 0. 0.05 –0.346 0.4 0.

and the oil in oil chamber C passes through tube (6) and valve (8) and flows to oil chamber B. and create a damping force. i) Action when retracting When the nitrogen gas is compressed by the external force from the road surface.STRUCTURE. ii) Action when extending When the external force from the road surface gets weak. the wheels follow the unevenness of the road surface. and oil chamber B which is filled with oil. b Principle of generation of damping force Inside valve body (8) are orifice plate (8a) and leaf springs (8b) and (8c). The oil inside the valve flows from direction X and passes through two orifices from orifice plate (8a) to generate a damping force. and absorbs the external force. a Nitrogen gas When the machine is traveling. HD605-7 . FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER Structure and operation The suspension cylinder acts as a shock absorber and spring. 10-52 (10) HD465-7. Oil chamber B and oil chamber C are conmected by tube (6) and valve body (8). the pressure of the nitrogen gas extends the rod. They restrict the flow of oil between oil chamber B and oil chamber C. The oil flowing through the valve from direction Z to orifice plate (8a) is throttled by orifices in four places to generate a damping force. and acts as an air spring. The inside of the cylinder is divided into gas chamber A which is charged with nitrogen gas. When this happens. so it is always subjected to a pressure corresponding to the external force. The nitrogen gas is sealed by a rod and oil. the volume of the nitrogen in gas chamber A changes elastically under the input force. and an external force in the updown direction is applied to the suspension cylinder. the oil in oil chamber B flows from oil chamber B through the valve (8) and tube (6) to oil chamber C.

The shaft is connected to an air cylinder driven by a signal from the retarder controller. FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER c. and flows to oil chamber C or oil chamber B according to whether it is retracting or extending. HD605-7 10-53 (6) . The oil flowing through bypass circuit D passes through a shaft with orifices at two places on the inside circumference. bypass circuit D is provided before and after orifice plate (8a). and the size of the orifices automatically changes according to the condition of the machine. HD465-7. SOFT) according to the size of the orifices through which the oil is passing. Variable shaft mechanism In the valve body. so the oil flow is divided into oil flowing through orifice plate (8a) and oil flowing through the bypass circuit D. The damping force is set at three levels (MEDIUM.STRUCTURE. HARD.

HD605-7 . 2. 4. 5.STRUCTURE. Feed valve Cylinder Rod Valve (for bleeding air and mounting pressure sensor) Ball 10-54 (10) HD465-7. FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER REAR 1. 3.

When this happens. and cavity (2) is filled more quickly than when extending.043 – 0.4 0.STRUCTURE. and the cylinder rod is pushed inside the cylinder. As a result.043 – 0. Valve (for bleeding and mounting pressure sensor) 2. the nitrogen gas inside chamber (7) is compressed. a) Retracting action When the machine is traveling and it hits a bump or object on the road.4 Replace 0. 1. 10. Check ball 4. Nitrogen gas chamber Cylinder rod Cylinder Feed valve a : When extending b : When retracting HD465-7.246 0 +0. Cavity 3. HD605-7 10-55 (10) . FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER Unit: mm No. so the flow of oil passing through the orifice is controlled so that it is less than during retraction.043 –0.246 0 +0.106 –0. Oil chamber 7. 8. the oil is throttled by the orifices and a shock-absorbing effect is obtained.260 Hole +0.008 0.106 –0. 9. When a fixed amount of oil is sent from oil chamber (6) through orifices (4) and (5) to cavity (2). b) Extending action When the machine has passed any bump or object on the road surface.352 0. Orifice 5. the amount of oil in cavity (2) is reduced.05 – 0. In this way. the oil in chamber (6) is sent through both orifices (4) and (5) to cavity (2). the amount of oil returning to chamber (6) is restricted to provide a shock absorbing effect.375 Clearance limit Remedy 6 Clearance between piston rod and bushing 180 Shaft –0. Check item Standard size Criteria Tolerance Standard clearance 0. This pressurized oil closes orifice (4) with check ball (3).043 –0. Orifice 6. the wheels are pushed up.352 0.115 –0. the cylinder rod is pushed up by the weight of the wheels and axle and the pressure of the nitrogen inside chamber (7).050 –0. and pressure is applied to the oil remaining in cavity (2). and is sent to chamber (6) through only orifice (5).8 7 8 Clearance between piston rod and bushing Clearance between cylinder and wear ring 180 220 Structure and operation The suspension cylinder has the function of both a shock absorber and spring.

Rod 3. Suspension cylinder 10-56 (6) HD465-7. Rod 2.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD REAR AXLE SUPPORT REAR AXLE SUPPORT 1. HD605-7 . Axle 4.

Check item Standard size Criteria Tolerance Standard clearance 0.046 0 0.180 Clearance limit Remedy 5 Clearance between rod mounting pin and bushing 70 Shaft –0.3 8 100 0. HD605-7 10-57 (10) .046 0 0.030 –0.3 0.180 –0.030 –0.5 Replace 6 Clearance between inner and outer bushing Clearance between suspension cylinder mounting pin and frame or axle Clearance between inner and outer bushing 100 7 70 0.110 – 0.5 HD465-7.122 0.076 Hole +0. FUNCTION AND MAINTENANCE STANDARD REAR AXLE SUPPORT Unit: mm No.110 – 0.STRUCTURE.076 +0.030 – 0.030 – 0.122 0.

Steering column 3. FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN STEERING COLUMN 1. Steering valve 10-58 (6) HD465-7. Lock lever 4. Yoke 5. Steering shaft 2. HD605-7 .STRUCTURE. Joint shaft 6.

Center lever 2. HD605-7 10-59 (6) . Arm (A-frame) 4.STRUCTURE. Tie rod 3. Knuckle arm HD465-7. FUNCTION AND MAINTENANCE STANDARD STEERING LINKAGE STEERING LINKAGE 1.

STRUCTURE. HD605-7 . FUNCTION AND MAINTENANCE STANDARD STEERING LINKAGE 10-60 (6) HD465-7.

069 +0. HD605-7 10-61 (10) .152 0.3 0.300 0 –0.075 – 0.076 +0.055 – 0. FUNCTION AND MAINTENANCE STANDARD STEERING LINKAGE Unit: mm No.133 0.STRUCTURE.055 – 0.4 Replace 0.3 8 9 10 11 12 13 80 40 110 55 100 70 0.120 – 0.3 6 Clearance between bushing and pin Clearance between steering cylinder mounting pin and bushing Clearance between inner and outer bushing Clearance between tie rod mounting pin and bushing Clearance between inner and outer bushing Clearance between arm mounting pin and bushing Clearance between inner and outer bushing Clearance between arm mounting pin and bushing Clearance between center lever mounting pin and bushing Clearance between inner and outer bushing Clearance between tie rod mounting pin and bushing Clearance between suspension cylinder mounting pin and bushing 85 7 45 0.4 0.089 0.5 0.3 14 55 1.273 0.250 –0.025 –0.030 –0.133 0.3 HD465-7.133 0.069 +0.3 0. Check item Standard size Criteria Tolerance Standard clearance 0.076 +0.055 – 0.035 –0.150 – 0.030 –0.054 0 +0.030 0– 0.0 15 16 80 40 0.064 +0.137 0.030 –0.060 – 0.025 –0.064 –0.045 +0.4 0.025 –0.3 17 60 0.091 +0.250 –0.069 +0.030 +0.197 +0.064 +0.076 –0.122 Clearance limit Remedy 5 Clearance between inner and outer for knuckle arm bushing 165 Shaft Hole 0.030 0.180 –0.7 0.250 –0.030 0.046 0 0.030 –0.030 – 0.120 – 0.076 +0.076 +0.167 – 0.110 – 0.120 – 0.167 0.

FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING BRAKE PIPING HD465-7 Serial No. HD605-7 .: 7001 – 7265 HD605-7 Serial No.: 7001 – 7112 10-62 (12) HD465-7.STRUCTURE.

11. Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder) HD465-7. 3. HD605-7 10-63 (10) . 4. FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING 1. 9. 10. 2. 8. 6. 7.STRUCTURE. 5.

STRUCTURE.: 7266 and up HD605-7 Serial No.: 7113 and up 10-63-1 (12) HD465-7. FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING HD465-7 Serial No. HD605-7 .

8. 6. 2. 5. FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING 1. Front brake OFF valve Relay valve Slack adjuster Emergency brake valve Brake valve Parking brake valve Accumulator charge valve Accumulator (parking brake) Accumulator (rear brake) Accumulator (front brake) Proportional reducing valve (for retarder) Reducing valve HD465-7.STRUCTURE. 4. 10. 7. 3. 11. 9. HD605-7 10-63-2 (12) . 12.

Rod 3. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE BRAKE VALVE 1. Spool 5. HD605-7 . Pilot piston 2. Lower cylinder 4.STRUCTURE. Spool A : To rear brake B : To front brake C : To transmission oil pan D : From front accumulator E : From rear accumulator 10-64 (6) HD465-7. Upper cylinder 6.

drain port b is closed. When this happens. the oil entering port H from orifice e of spool (3) pushes against spring (4). spool (5) is moved down mechanically when pedal (1) is depressed. the upper portion is actuated normally. and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders. The upper brake is not actuated. the operating force is transmitted to spool (3) through rod (2) and spring (4). Applying brake when upper valve fails • Even if there is leakage of oil in the upper piping. HD465-7. the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down. and the lower portion is actuated normally. drain port a stays closed. It pushes up spool (3) and shuts off the circuit between port A and port C . When actuation is balanced Upper portion • When oil fills the rear brake cylinders and the pressure between port A and port C becomes high. drain port a is closed. When spool (3) goes down. spool (5) is also pushed down by plunger (6). HD605-7 10-65 (6) . When this happens. and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE Operation Upper portion • When brake pedal (1) is depressed.STRUCTURE. Applying brake when lower valve fails • Even if there is leakage of oil in the lower piping. Lower portion • When brake pedal (1) is depressed. so the oil entering the brake cylinder is held and the brake remains applied.

up to the point where the piston moves to the end of its stroke. Drain port b is closed. At the same time. 10-66 (6) HD465-7. Brake released Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool. HD605-7 . the effect of the brake can be adjusted by the amount that the pedal is depressed. Lower portion • When the pedal is released. and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. so the oil entering the brake cylinder is held. the circuits between ports A and C and between ports B and D are fully opened. the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. spool (3) in the upper portion moves up. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE Lower portion • When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off. Therefore. and the brake is applied. so the pressure in the circuit between port B and port D rises. Drain port b is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the front brake. When spools (3) and (5) move to the end of their stroke. the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves. Drain port a is opened and the oil from the brake cylinder flows to the transmission oil pan return circuit to release the rear brakes. oil also fills the front brake cylinder at the same time. • The pressure in the space in the upper portion is balanced with the operating force of the pedal.STRUCTURE. and shuts off port B and port D .

STRUCTURE. Cylinder A. HD465-7. FUNCTION AND MAINTENANCE STANDARD EMERGENCY BRAKE VALVE EMERGENCY BRAKE VALVE 1. To parking brake valve P. To transmission oil pan Function • This valve operates the brake depending on the parking brake release pressure controlled by the emergency brake pedal. From accumulator T. Spool 3. HD605-7 10-67 (10) . Rod 2.

Upper cylinder 3. 10-68 (10) HD465-7. Lower cylinder 4.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD RELAY VALVE RELAY VALVE 1. Spool A : To front brake P : From accumulator Pp: From emergency brake valve T : To transmission oil pan Function • This valve operates the front brake depending on the parking brake release pressure controlled by the emergency brake pedal. HD605-7 . Spool 2.

and the valve cuts off the circuit between the brake valve and the front brake. When the front brake off switch of the operator's seat is pressed. HD465-7.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD FRONT BRAKE OFF VALVE FRONT BRAKE OFF VALVE WHITE 1. HD605-7 10-69 (6) . the solenoid is energized. Solenoid A : To front brake P : From brake valve T : To transmission oil pan Function • This valve is installed on the brake oil circuit between the brake valve and the front brake. Connector 2.

2 MPa {145 kg/cm2} • Cut out pressure: 20.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE ACCUMULATOR CHARGE VALVE ACC : To accumulator P : From hydraulic pump PP : From accumulator T : To transmission oil pan H1 : Relief valve R1 : Relief valve R3 : Main relief valve Specification • Cut in pressure : 14. • When the oil pressure reaches the specified pressure.6 MPa {210 kg/cm2} Function • The accumulator charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. HD605-7 10-71 (10) . the oil from the pump is connected to the drain circuit to reduce the load of the pump. HD465-7.

Filter 10-72 (6) HD465-7. Filter 6. Relief valve (R1) 4. Relief valve (H1) 5. Valve body 3. FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE 1.STRUCTURE. Main relief valve (R3) 2. HD605-7 .

so the pressure rises. HD605-7 10-73 (6) . and the pressure at port P also rises in the same way. The oil from the pump enters port P. When oil supplied to accumulator 1) Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1). Valve seat (7) and poppet (6) are brought into tight contact. so the pressure becomes the brake oil tank pressure. When no oil is being supplied to accumulator (cut-out condition) • The pressure at port B is higher than the set pressure of the relief valve (R1). so port C and port T are short circuited. FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE Operation 1. and flows to the brake oil tank. pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). • When the pressure at port P goes above the pressure at port B (accumulator pressure). piston (8) is pushed back down by spring (5). the supply of oil to the accumulator starts immediately.STRUCTURE. it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. In this case. 2. and port C and port T are shut off. HD465-7. (18) and (16). • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1). A fixed amount is supplied regardless of the engine speed. so piston (8) is forcibly pushed up by the oil pressure at port B. • The spring chamber at the right end of spool (15) is also shut off from port T. It also passes through orifices (17). Poppet (6) is opened.

• When the circuit is relieved. so the supply of oil to port B is stopped. so this set the maximum pressure in the brake circuit and protects the circuit. a pressure difference is generated above and below piston (8). • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1). HD605-7 . FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE 2) When cut-out pressure is reached • When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1). and port C and port T are short circuited. Main relief valve (R3) • If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3). poppet (6) separates from valve seat (7). • The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14). so the pressure becomes the brake oil tank pressure. 10-74 (6) HD465-7. so an oil flow is generated and the circuit is relieved. Ball (11) is pushed up and the oil flows to the brake oil tank circuit.STRUCTURE. 3. the oil from the pump pushes spring (3). so piston (8) moves up. poppet (6) is forcibly opened.

Specifications Front brake Gas used : Nitrogen gas Charge amount : 3.500 cc Charging pressure: 11. Valve 2. Piston Function • The accumulator is installed between the accumulator charge valve and the brake valve. HD605-7 10-75 (6) .9 MPa {70 kg/cm2} HD465-7. FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR ACCUMULATOR 1. It is charged with nitrogen gas between cylinder (3) and free piston (4). Cylinder 4. and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.STRUCTURE.8 MPa {120 kg/cm2} Rear brake. Parking brake Gas used : Nitrogen gas Charge amount : 4. Top cover 3.000 cc Charging pressure: 6.

1 ± 0. Piston A : Inlet port B : Outlet port Specifications Piston operation pressure: 9.25 Replace 5 Slack adjuster spring Spring coefficient 0. Check item Standard size Criteria Tolerance Standard clearance 0.5 kg/cm2} Unit: mm No.09 ± 0.05 MPa {17.150 Repair limit Installed load 45.8 ± 0.5 kg/cm2} Check valve closing pressure: 1.STRUCTURE.45 N/mm {0.1 – 0. Cylinder 2.2 kg/cm2} Check valve cracking pressure (When cooling pressure is 0): 1. HD605-7 . FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER SLACK ADJUSTER 1.05 MPa {11.046 kg/mm} Installed length 97 10-76 (10) HD465-7.030 –0.8 – 19.7 kg} Free length – Installed load – Clearance limit Remedy 4 Clearance between body and piston 55 Shaft –0.030 – 0. Check valve 3.076 Standard size Hole +0.74 ± 0.6 kPa {0.074 0 0.6 N {4.

• If the brake pedal is depressed further. and the brake is released. Operation 1. in this way it acts to keep a constant time lag when the brake is operated. HD465-7. When the brake pedal is depressed. FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER Function • The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. when the brake is applied. the time lag is a fixed value. piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for the stroke S . the closer the clearance between the brake piston and dics is to 0. In this condition. In other words. • When this is done. The time lag of the brake is always kept constant regardless of the wear of the brake disc. return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2). 2.STRUCTURE. When brake pedal is released • When the brake is released. When brake pedal is depressed • Before the brake is depressed. and the oil pressure discharged from the brake valve goes above to set pressure. HD605-7 10-77 (6) . the greater the braking force becomes. where it moves piston (4) by stroke S to the left and right. Therefore. brake piston (7) moves by a distance of stroke S. piston (4) is returned by the distance of stoke S (full stroke). It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. check valve (3) opens and the pressure is applied to port C to act as the braking force.

Pad 3. HD605-7 . FUNCTION AND MAINTENANCE STANDARD BRAKE BRAKE FRONT 1.STRUCTURE. Disc 10-78 (6) HD465-7. Piston 2.

HD605-7 10-79 (9) . or there is protrusion. the disc has been rubbed by mistake by the pad rear plate. the rear plate metal is melted to the disc. check the front wheel bearing also. 4 Check item Standard size Wear of pad (remaining thickness of wear material) 19.STRUCTURE.5 mm. • If the whole pad is worn. HD465-7.50 Less than 27 Remedy Replace 5 6 7 Missing portion of pad Face runout of disc (Note 1) Wear of disc (thickness of disc) Co r re c t o r replace Replace Open crack in radial direction 8 Damage to disc surface – Electric wear. marked damage (Note 2) Correct Note 1: • If there is excessive face runout of the disc.0 Ratio of surface: 10% 0. • If there are vertical scratches other than concentric scratches.5 – 0. FUNCTION AND MAINTENANCE STANDARD BRAKE Unit: mm No. Note 2: • If the depth of the scratch exceeds 1.15 30 Criteria Repair limit 3.

6. 5. 4. 8. 10. 2. FUNCTION AND MAINTENANCE STANDARD BRAKE REAR 1. 7.STRUCTURE. HD605-7 . Inner gear Retainer Outer gear Plate Disc Damper Piston Spring (for parking brake) Cylinder Cylinder (for parking brake) 10-80 (6) HD465-7. 9. 3.

4 Standard distortion Max.50 Standard size 93.1 6.45 Max.15 4.2 Remedy 12 13 14 15 16 17 Thickness of disc Thickness of damper Thickness of damper Distortion of disc friction surface Distortion of plate and damper friction surface Assemble thickness of plate and disc 5.64 0.9 Replace 18 19 HD465-7.0 Repair limit 0.9 3.4 Standard size 0.21 – 0. HD605-7 10-81 (10) . 0. 11 Check item Backlash between outer gear and plate Backlash between inner gear and disc Thickness of plate 2.STRUCTURE.2 2.21 – 0. FUNCTION AND MAINTENANCE STANDARD BRAKE Unit: mm No. 0.6 5.2 Repair limit 2.7 Repair limit 86.7 0.1 3.64 Standard size Criteria Repair limit 2.

brake piston (7). • With the parking brake switch in the parking position. The wheel is rotating together with the disc. pressure oil from the brake valve moves brake piston (7) to the right in the direction of the arrow. and disk (5) pressed by spring force. Operation of parking brake • The parking brake contained in the rear brake is structurally designed to operate mechanically by spring (8) force and to be released by hydraulic pressure. so the piston is moved to the left in the direction of the arrow by the internal pressure. • With the parking brake switch at the driver's seat in the travel position. so this friction reduces the travel speed and stops the machine. Operation of brake • When the brake pedal is depressed. and it operates as a parking brake by use of spring. the parking brake is engaged through the parking brake piston (10). the parking brake solenoid is demagnetized and the parking releasing hydraulic pressure is released. • When the brake pedal is released. and this releases the brake. This presses disc (5) and plate (4) together and generates friction between the disc and plate. the pressure at the back face of brake piston (7) is released. plate (4). 10-82 (6) HD465-7. • The parking releasing hydraulic pressure acts on the parking brake piston (10) from the accumulator through the brake valve and parking brake solenoid. FUNCTION AND MAINTENANCE STANDARD BRAKE Function • The rear brake is of an oil cooled multiple disc type. the parking releasing hydraulic pressure releases the parking brake by pressing the parking brake piston (10) and retracting the spring (8). Then.STRUCTURE. HD605-7 .

FUNCTION AND MAINTENANCE STANDARD PROPORTIONAL REDUCING VALVE PROPORTIONAL REDUCING VALVE 1. Filter 2. It varies the discharge pressure of the pressure oil in accordance with the turning angle of the retarder control lever. Connector 3. so the retarder control can be carried out as desired. Solenoid assembly A : To slack adjuster P : From accumulator T : To transmission oil pan Function • The proportional reducing valve is a valve used for retarder control. HD465-7. It is installed between the accumulator and the slack adjuster in the brake circuit.STRUCTURE. HD605-7 10-83 (10) .

Solenoid B : To parking brake P : From emergency brake valve T : To transmission oil pan Function • The parking brake solenoid is installed in the brake oil circuit between the emergency brake valve and the rear brake. Then.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE PARKING BRAKE SOLENOID VALVE 1. the solenoid valve is demagnetized and cut off the parking brake release oil pressure. the spring force of brake will operate the parking brake. 10-84 (10) HD465-7. Connector 2. When the parking brake switch is set to PARK. HD605-7 .

HD605-7 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD STEERING AND HOIST HYDRAULIC PIPING STEERING AND HOIST HYDRAULIC PIPING 10-86 (6) HD465-7.

STRUCTURE. Steering hoist filter 9. Hoist cylinder 7. Hydraulic pump (SAR(3)80+80+(1)6) 4. Demand valve 5. Cross-over relief valve 2. Hydraulic tank 8. HD605-7 10-87 . Steering control valve HD465-7. Steering cylinder 3. FUNCTION AND MAINTENANCE STANDARD STEERING AND HOIST HYDRAULIC PIPING 1. Hoist valve 6.

HD605-7 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM 10-88 (6) HD465-7.

FUNCTION AND MAINTENANCE STANDARD STEERING AND HOIST HYDRAULIC SYSTEM DIAGRAM HD465-7.STRUCTURE. HD605-7 10-89 (6) .

10-90 (10) HD465-7. HD605-7 . • The signal from the dump lever is controlled by the retarder controller. Dump lever Hydraulic pump (SAR(3)80+80+(1)6) Hoist valve EPC valve Body positioner sensor Hoist cylinder Function • The positioner sensor senses the body operation. and actuates the EPC valve. 2. and from this data the retarder controller controls output to the EPC valve. 6. FUNCTION AND MAINTENANCE STANDARD DUMP BODY CONTROL DUMP BODY CONTROL 1. 4. 3. The pilot pressure generated by the EPC valve moves the spool of the hoist valve and controls the hoist cylinder. 5.STRUCTURE.

FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK HYDRAULIC TANK 1. Breather 2.STRUCTURE. Oil level gauge HD465-7. HD605-7 10-91 (6) . Drain 3.

HD605-7 . 7. 13. 10. 14. Ball Torsion bar Link Sleeve Rotor Manifold Commutator a : From demand valve (P port) b : To tank (R port) c : To steering cylinder (RT port) d : To hoist valve (AUX port) e : To steering cylinder (LT port) 10-92 HD465-7. 3.STRUCTURE. 6. 11. 12. FUNCTION AND MAINTENANCE STANDARD STEERING CONTROL VALVE STEERING CONTROL VALVE 1. 9. Input shaft Upper cover Valve spool Housing Ball Stator Lower cover 8. 5. 2. 4.

the steering is at neutral. As a result. HD605-7 10-93 . HD465-7. so the oil from the pump all flows to the hoist control valve. so valve spool (3) does not move. Ports H and J. When this happens.STRUCTURE. and port I are open. FUNCTION AND MAINTENANCE STANDARD STEERING CONTROL VALVE Operation 1. all ports to the steering cylinders are closed. when steering is at neutral • The oil from the pump passes through the demand valve and enters port A of the steering valve. and no oil flows to the cylinders.

From here it flows from hole a of valve spool (3) through port • • G and goes to the steering cylinders. Steering to right (When steering wheel is turned to the right) • When the machine is steered to the right (when the steering wheel is turned to the right). and the wheels turn to the right. As a result. FUNCTION AND MAINTENANCE STANDARD STEERING CONTROL VALVE 2. 12). When this happens. the two steering cylinders are actuated. The oil remaining in the steering circuit enters port I from port J and flows to the hoist control valve. HD605-7 . valve spool (3) moves down. 10-94 HD465-7. the oil from the pump flows from port A through port B and enters the metering positions (6. The return oil from the steering cylinder flows from port C through port D and port E. and return to the tank. Here the flow of oil to the steering cylinders is measured. and it then passes through the steering valve.STRUCTURE.

• • As a result. and it then flows from port B to port C and flows to the steering cylinder. The return oil from the steering cylinder flows from port G through port F and port E. passes through the steering valve and enters the metering portions. and the wheels turned to the left. the two steering cylinders are actuated. and return to the tank. FUNCTION AND MAINTENANCE STANDARD STEERING CONTROL VALVE 3. Here the flow of oil to the steering cylinder is measured. When this happens.STRUCTURE. HD465-7. valve spool (3) moves up.) • When the machine is steered to the left (when the steering wheel is turned to the left). The oil remaining in the steering circuit enters port I from port H and flows to the hoist control valve. HD605-7 10-95 . the oil from the pump flows from port H through hole a. Steering to left (When the steering wheel is turned to the left.

FUNCTION AND MAINTENANCE STANDARD CROSSOVER RELIEF VALVE CROSSOVER RELIEF VALVE SC1 : To steering cylinder SC2 : To steering cylinder SC3 : To steering cylinder SC4 : To steering cylinder SV1 : To steering valve SV2 : To steering valve 1. Valve spring 5. Lock nut 10-96 HD465-7. Relief valve 4. HD605-7 . Adjustment screw 7.STRUCTURE. Valve seat 3. Sleeve 6. Valve body 2.

036 – 0.030 –0.267 – Clearance limit Remedy 1 Clearance between piston rod and bushing 55 Shaft –0. Check item Standard size Criteria Tolerance Standard clearance 0.039 0 +0.163 +0.567 1.0 HD465-7.006 +0.104 – Hole +0. FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER STEERING CYLINDER Unit: mm No.039 0 Replace bushing 0.0 Replace 2 Clearance between piston rod supports shaft and bushing Clearance between cylinder bottom support shaft and bushing 45 3 45 – – 1. HD605-7 10-97 (9) .STRUCTURE.

HD605-7 . FUNCTION AND MAINTENANCE STANDARD DEMAND VALVE DEMAND VALVE 10-98 HD465-7.STRUCTURE.

FUNCTION AND MAINTENANCE STANDARD DEMAND VALVE P1 : From hydraulic pump P2 : From hydraulic pump PH : To hoist control valve PE : From emergency steering pump PT : To tank PST: To steering control valve 1.3 kg} 3.6 N {12.3 kg} 3. 2.2 x 29. 3. HD605-7 10-99 (10) .1 N {0. 5.5 Replace 13 Check valve spring 42. 4.STRUCTURE.7 Installed length 140 33.4 N {13.2 x 17 HD465-7.D 172.315 kg} Remedy 12 Spool return spring Free length x O. 11. 6.345 kg} Free length – – Installed load 120. 8. Check item Standard size Criteria Repair limit Installed load 130. 10. 9. 7.4 N {0. Spool return spring Demand spool Check valve Check valve spring Valve body Main relief valve Main relief valve spring Pilot poppet Pilot poppet spring Lock nut Adjustment screw Unit: mm No.

and merges with oil from the steering pump. • When the oil pressure to the steering circuit rises. Also. • Therefore. When the engine runs at medium speed • Oil from the steering pump flows into port A. 3. the oil flows also into port C through the orifice a of the demand spool (2). pushes to open the check valve (3). the demand spool (2) will be pushed to the right and port B and port D will open. HD605-7 . 2. part of the oil from the work equipment pump flows into the work equipment 10-100 HD465-7. • At the same time. The whole oil of the steering pump and part of oil from the work equipment pump flow into the steering circuit. the oil pushes to open the check valve (3) and flows into port A. Also. • When the pressure of port C increases more than the force of the spring (1). When the engine runs at low speed • Oil from the steering pump flows into port A. Operation 1. • The whole oil of the work equipment pump and part of oil of the steering pump flow into the work equipment circuit. • Therefore. circuit directly through the port D. oil from the work equipment pump flows into port B. to the steering circuit and to the work equipment circuit depending on the engine speed (pump delivery). FUNCTION AND MAINTENANCE STANDARD DEMAND VALVE Function • This valve distributes oil which comes from the steering pump and from the work equipment pump . but since the demand spool (2) is closed. flows into port A and merges with the oil from the steering valve. oil from the steering pump and oil from the work equipment pump flow into port A and port B.STRUCTURE. the pressure at port C rises more and moves the demand spool (2) further to the right. • Therefore. oil from the steering pump and oil from the work equipment pump flow into the steering control valve. When the engine runs at high speed • In addition. the pressure of the oil entered into port C through the orifice a of the demand spool (2) rises as well. oil from the work equipment pump flows into port B.

HD605-7 10-101 . 4. 2.) Operation • Port A is connected to the pump circuit. Main valve Valve seat Pilot poppet Spring Adjustment screw • When the pressure in port B lowers. • Oil flows through the orifice of the main valve (1).STRUCTURE. or when an abnormal pressure occurs. and the pressure in port A pushes to opens the main valve (1) to release oil from port A. the orifice of the main valve (1) generates a differential pressure between ports A and B. • Also. HD465-7. Function • This valve is located in the demand valve and release oil from the pump to prevent the pump from being damaged when the steering cylinder comes to the stroke end. the pilot poppet (3) is seated to the valve seat (2). FUNCTION AND MAINTENANCE STANDARD DEMAND VALVE STEERING RELIEF VALVE • When the pressures in port A and port B balance with the poppet spring force (set pressure). Oil in port B will escape through port D to port C. 1. (This valve sets the maximum pressure of the circuit. and port C is connected to the tank drain circuit. the pilot poppet (3) will open. and the pressure in port B will lower. and port B is filled with oil. 5. 3.

HD605-7 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE HOIST VALVE 10-102 HD465-7.

9. 6.8 kg} 40 N {4. : To tank : From flow amplifier : To hoist cylinder bottom : To hoist cylinder head : From EPC valve (pressurized side in lowering or floating operation) : From EPC valve (pressurized side in lifting operation) Body Spool Retainer Spring (lifting) Relief valve Spring (floating) Spring (lowering) Retainer Retainer Retainer Check valve Unit: mm No. replace the spring HD465-7.STRUCTURE.3 34.4 kg} 44 N {4.D.2 74.5 50 32 55.3 Installed length 41.7 × 36.5 kg} Free length – – – – – Installed load 233 N {23.5 × 28. 7.3 kg} 112 N {11. 5.0 13 14 15 16 Check valve spring Spool return spring (lifting) Spool return spring (lowering) Spool return spring (floating) 32. HD605-7 10-103 .9 × 34. 2. 10.9 24.5 × 12.4 kg} 849 N {85. 11.0 If damaged or deformated.6 51. 3.1 kg}\ Remedy 12 Relief valve poppet spring Free length × O.8 × 10.7 kg} 927 N {94. Check item Standard size Criteria Repair limit Installed load 259 N {26.1 kg} 140 N {14. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE T P A1 B1 PA PB 1. 4.9 kg} 124 N {12.5 kg} 156 N {15. 8. 49.

Since the hoist spool (2) blocks the path to the hoist cylinder. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE Operation 1. oil flows through chamber D to the tank. 10-104 HD465-7.STRUCTURE. • Since both the bottom side port and the head side port of the hoist cylinder are blocked. Hoist valve HOLD Position • Oil from the demand valve flows into chamber C. the hoist cylinder is locked where it is. HD605-7 .

HD605-7 10-105 (10) . extends the hoist cylinder and raise the body. Hoist valve at LIFT Position • • When the hoist lever in the cab is set to the RAISE position. HD465-7. Therefore.STRUCTURE. pressurized oil from the solenoid valve pushes the hoist spool (2) to the left. oil from chamber C opens the check valve (11) and flows into chamber A. flows in the bottom side of the hoist cylinder. flows into chamber D and to the tank circuit. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE 2. the return oil from the head side flows out of chamber B. • • Oil flows out of chamber A. On the other hand.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE 3. pressurized oil from the solenoid valve pushes the hoist spool (2) to the right. HD605-7 10-106 (10) . HD465-7. Then. • • Oil from the demand valve flows from chamber C through chamber B to the host cylinder and from chamber C through chamber D to the oil cooler circuit. the hoist cylinder is in a free state. chambers C. H and D are all connected. D. B. Hoist valve at FLOAT Position • When the hoist lever in the cab is set to the FLOAT position. Since the bottom side and the head side of the hoist cylinder are connected through the hoist valve.

Therefore. pressurized oil from the solenoid valve pushes the hoist spool (2) to the right further from the FLOAT position. retracts the hoist cylinder and lowers the body.STRUCTURE. HD465-7. Then. • • On the other hand. FUNCTION AND MAINTENANCE STANDARD HOIST VALVE 4. the return oil from the head side of the hoist cylinder flows out of chamber A and flows into chamber H. oil flows into the head side of the hoist cylinder through chamber B. oil from chamber C pushes to open the check valve (11) and flows into chamber B. the output pressure of the solenoid valve rises over the cracking pressure of the pilot check valve. Hoist valve at LOWER Position • • When the hoist lever in the cab is set from the FLOAT position to the LOWER position. and therefore. At the time of lowering. HD605-7 10-107 (10) . the return oil from chamber H returns through chamber D to the tank.

and controls pressure. Solenoid assembly A : To hoist valve B : From hoist valve P1 : From hydraulic tank T1 : To hydraulic tank T2 : To hydraulic tank Function • The EPC valve controlled by the retarder controller switches the pilot pressure of the hoist valve. HD605-7 . Manual operation button 2. FUNCTION AND MAINTENANCE STANDARD EPC VALVE EPC VALVE 1.STRUCTURE. and controls the hoist valve. Solenoid assembly 3. 10-108 HD465-7.

0 Replace 2 3 4 Clearance between piston rod and bushing Clearance between piston rod support pin and bushing Clearance between cylinder support pin and bushing 100 70 70 HD465-7. FUNCTION AND MAINTENANCE STANDARD HOIST CYLINDER HOIST CYLINDER Unit: mm No.STRUCTURE.693 1.019 0. HD605-7 10-109 (9) .407 0.207 +0. Check item Standard size Criteria Tolerance Standard clearance 0.067 +0.019 +0.004 –0.707 0.046 +0.103 – 0.393 – – Clearance limit Remedy 1 Clearance between cylinder and bushing 170 Shaft –0.043 –0.089 – 0.264 +0.143 –0.0 1.036 –0.123 – – Hole +0.004 –0.

HD605-7 .19 0.6 – 2.5 Nm {1.500 20. HOIST AND HOIST CONTROL PUMP SAR(3)80+80+(1)6 Unit: mm No.06 – 0.10 – 0.144 Standard size 13 10 Tolerance 0 –0.20 Repair limit 3 Depth to knock in pin SAR(3)-80 SAR(1)-6 – 4 Rotating torque of spline shaft Model 15.9 kgm} Rotating speed (rpm) Delivery pressure MPa {kg/cm2} Delivery amount limit ( /min) 170 12.10 – 0.060 – 0.6 – Discharge amount Oil: EO10-CD Oil temperature: 45–55°C – SAR(3)-80 SAR(3)-80 SAR(1)-6 2.20 Remedy 1 Side clearance 2 Clearance between inside diameter of plain bearing and outside of diameter of gear shaft Replace 0.6 {210} 10-110 (10) HD465-7. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP HYDRAULIC PUMP STEERING.8 – 28.2 Clearance limit 0.149 0.5 Standard delivery amount ( /min) 184 13. Check item Model SAR(3)-80 SAR(3)-80 SAR(1)-6 SAR(3)-80 SAR(3)-80 SAR(1)-6 Model SAR(3)-80 Criteria Standard clearance 0.15 0.STRUCTURE.5 0 –0.15 0.19 0.

4 – 2.13 – 0. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP RETARDER COOLING PUMP SAR(3)100+100 Unit: mm No.7 – 23.22 0.) 236 Delivery amount limit ( /min. gear Clearance between inside diameter of plain bearing and outside diameter of gear shaft Model SAR(3)-100 SAR(3)-100 Model Criteria Standard clearance 0.500 Standard delivery amount ( /min.149 Standard size 14 Tolerance 0 –0.5 Clearance limit 0.20 Remedy 2 Replace Repair limit – 3 Depth to knock in pin SAR(3)-100 4 Rotating torque of splined shaft 13.9 MPa {40 kg/cm2} – SAR(3)-100 HD465-7.18 0.) 216 – Delivery amount Oil: EO10-CD Oil temperature: 45 – 55°C Model Delivery pressure 3. 1 Check item Clearance between gear case and side plate.5 Nm {1. HD605-7 10-111 .06 – 0.STRUCTURE.4 kgm} Rotating speed (rpm) 2.

19 Remedy 2 Replace 3 4 5 8.18 0.144 Standard size 14 10 Tolerance 0 –0.21 0.6 {210} Standard delivery amount ( /min) 231.7 kgm} Rotating speed (rpm) 2.5 – 0.9 – 1. HD605-7 .06 – 0.0 Delivery amount limit ( /min) 213.15 0.5 50.9 – 16.7 Nm {0. 1 Check item Model Side clearance Clearance between inside diameter of plain bearing and outside of diameter of gear shaft Depth to knock in pin Rotating torque of spline shaft Model SAR(3)-100 SAR(1)-25 SAR(3)-100 SAR(1)-25 SAR(3)-100 SAR(1)-25 Model SAR(3)-100 SAR(1)-25 Criteria Standard clearance 0.7 – Discharge amount Oil: EO10-CD Oil temperature: 45–55°C – 10-112 (10) HD465-7.5 57.STRUCTURE. TRANSMISSION.20 Clearance limit 0.149 0.13 – 0.06 – 0. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP TORQUE CONVERTER.10 – 0.500 Delivery pressure MPa {kg/cm2} 20. RETERDER COOLING AND BRAKE PUMP SAR(3)100+(1)25 Unit: mm No.6 {210} 20.

2 – 0.4 – Delivery amount Oil: EO10-CD Temperature: 45 – 55°C Model Delivery pressure 20. HD605-7 10-113 .5 Clearance limit 0.10 – 0.06 – 0.0 – 4.7 Delivery amount limit ( /min.119 Standard size 10 Tolerance 0 –0. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP EMERGENCY STEERING PUMP SBL(1)-014 Unit: mm No.9 Nm {0.19 0. 1 Check item Model Clearance between gear case and side plate.15 0.) 42. gear Clearance between inside diameter of plain bearing and outside diameter of gear shaft SBL(1)-014 SBL(1)-014 Model Criteria Standard clearance 0.) 45.20 Remedy 2 Replace Repair limit – 3 Depth to knock in pin SBL(1)-014 4 Rotating torque of splined shaft 2.6 MPa {210 kg/cm2} – SBL(1)-014 HD465-7.5 kgm} Rotating speed (rpm) 3.500 Standard delivery amount ( /min.STRUCTURE.

Cooling • The refrigerant gas compressed and pressurized by the air conditioner compressor enters the air conditioner condenser where it is cooled by dissipating the heat It then enters the air conditioner unit and cold air is blown out by the fan. Compressor 4. Function • The air conditioner makes a pleasant operating environment for the operator and acts to reduce fatigue. Air conditioner unit 3. FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER AIR CONDITIONER 1. and hot air is blown out by a fan. Receiver dryer 2. Condenser Heating • Heating is carried out using the coolant from the engine. 10-114 (10) HD465-7. HD605-7 . When the temperature of the refrigerant gas rises. When the temperature of the coolant drops. it is returned to the compressor. it is returned to the hot water return port and flows as coolant for the engine.STRUCTURE. High-temperature coolant from the hot water takeoff port flows to the air conditioner unit.

HD605-7 10-115 (10) . FRESH/RECIRC selector damper 2. Blower motor A : Hot water inlet port B : Hot water outlet port C : Refrigerant gas inlet port D : Refrigerant gas outlet port E : Dehumidified water drain port HD465-7.STRUCTURE. Evaporator 3. Heater core 4. FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER AIR CONDITIONER UNIT 1.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER

RECEIVER DRYER

1. Body 2. Dryer

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AIR CONDITIONER

CONDENSER

1. Fin 2. Tube A : Refrigerant gas inlet port B : Refrigerant gas outlet port

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AIR CONDITIONER

COMPRESSOR

1. Case 2. Clutch A : Suction service valve B : Discharge service valve

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MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM

Network data 1. From machine monitor to each controller • Switch input data • Option setting data 2. From each controller to machine monitor • Display data related to each controller • Service mode data • Troubleshooting data 3. From transmission controller to machine monitor • Model selection data

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Outline • With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the machine to observe and control the condition of the machine and transmit that data as network data to the machine monitor. • The machine monitor is a system to display these data and inform the operator of the condition of the machine. • There are two types of display on the machine monitor: the normal mode and the service mode. • The items that are always displayed for the operator are the normal mode items. Their main content is as follows. 1. Normal display items • Meters (speedometer, tachometer) • Gauges (engine water temperature, torque converter oil temperature, retarder oil temperature, fuel level) • Pilot display • Service meter, odometer (character display) 2. Items displayed when there is abnormality Caution, action code display (if an action code is being displayed, press machine monitor mode selector switch (2), then release it. A failure code (6-digit) is then displayed.) 3. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character display. 4. Other functions using the character display and the machine monitor mode selector switch to operate include the following: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and language selection. • To make it easier to carry out troubleshooting of the controllers (including the monitor panel itself), a service mode function is provided. Its main content is as follows. 1. Displaying failure history for electrical system, deleting from memory • Displays failure history for electrical system from each controller that is saved in machine monitor • Deletes data from memory 2. Failure history for machine system • Displays failure history for machine system from each controller that is saved in machine monitor 3. Real-time monitor • Takes input and output signal values recognized by each controller on network and displays in real time.

4. ECMV compensation This is used for the initial adjustment of the transmission. 5. Changing replacement time for filter, oil. This changes the original setting for the replacement interval. 6. Snapshot For details, see "TESTING AND ADJUSTING, Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7. Controller initialize This function is used to set the machine monitor when the machine is shipped from the factory. • The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and the sensors inputting data to the monitor panel. If the payload meter (having VHMS) is set optionally, execute display of load mass and setting of items related to the payload meter, too. For details, see "OPERATION AND MAINTENANCE MANUAL" and "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)".

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MACHINE MONITOR SYSTEM

MACHINE MONITOR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Speedometer Engine tachometer Retarder oil temperature gauge Torque converter oil temperature gauge Coolant temperature gauge Fuel gauge Character display Centralized warning lamp Retarder oil temperature caution lamp Torque converter oil temperature caution lamp Coolant temperature caution lamp Fuel level caution lamp Maintenance caution lamp Battery charging circuit caution lamp Steering oil temperature caution lamp (if equipped) Engine oil pressure caution lamp Retarder oil pressure caution lamp Parking brake caution lamp Machine monitor option system caution lamp Engine system caution lamp Transmission system caution lamp Retarder system caution lamp Inclination caution lamp

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42 43. 44. 45.

Seat belt caution lamp Body caution lamp Emergency steering pilot lamp Turn signal pilot lamp (right) Turn signal pilot lamp (left) Headlamp highbeem pilot lamp Shift lever position pilot lamp Shift indicator Retarder pilot lamp Lockup pilot lamp Output mode pilot lamp (power mode) Output mode pilot lamp (economy mode) Suspension mode pilot lamp (hard) (if equipped) Suspension mode pilot lamp (medium) (if equipped) Suspension mode pilot lamp (soft) (if equipped) ABS pilot lamp (if equipped) ASR pilot lamp (if equipped) Preheater pilot lamp Automatic retarder READY pilot lamp Automatic retarder set speed indicator Automatic retarder set speed unit indicator (km/h) Automatic retarder set speed unit indicator (MPH)

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41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51.

Travel speed compensation switch [SW1] Rotary switch [SW2] Rotary switch [SW3] Dipswitch [SW5-4] Dipswitch [SW5-3] Dipswitch [SW5-2] Dipswitch [SW5-1] Dipswitch [SW6-4] Dipswitch [SW6-3] Dipswitch [SW6-2] Dipswitch (SW6-1]

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MACHINE MONITOR SYSTEM

OPTION SETTING CONNECTOR DIAGRAM

52. 53. 54. 55. 56. 57. 58.

Option setting connector [OP1] Option setting connector [OP2] Option setting connector [OP3] Option setting connector [OP4] Option setting connector [OP5] Option setting connector [OP6] Setting connector [OP7]

ADJUSTING MACHINE MONITOR 1. For details of the setting of the rotary switches, the switches, and options setting connectors at the rear face of the machine monitor, see TESTING AND ADJUSTING, Adjusting machine monitor. 2. Precautions 1) When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and do not change them. 2) When moving the switches, use a precision screwdriver and turn slowly. 3) Be careful not to touch anything except the switches inside the grommet. 4) Be careful not to let any dirt or dust get in. 5) After completing the setting, return the grommet securely to its original position.

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MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
: Lighted up : Discontinuous sounds ✩1: The mark shows that the light is lit up while the machine monitor check switch is ON. ✩2: The mark shows that all lights are lit up for 2 seconds at start-up and then go off for 1 second.
✩1 When ✩2 machine Immediately Central Warn- monitor check after warning switch is turning ing buzzer oper- key ON. lamp ated. Related operation

No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

Remarks

Meter 1 Machine speed

Movement

Scale: white Background color: black

0 – 80 km/h or 0 – 50 MPH (MPH is displayed when nonSI is used.)

Analog display

(Note)

Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

Backlight

LED

Amber

When the small lamp is lit up.

Lit up during operation Analog display * When the overrun prevention brake is operated, the buzzer and central warning lamp is lit up. Lit up during operation

— Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

Meter 2 Engine speed

Scale: white, red MoveBackment ground color: black

0 – 3,400 rpm

(Note)

Backlight

LED

Amber

When the small lamp is lit up.

— Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

Gauge 3 9 Oil temperature of retarder Warning Backlight

Scale: white, red 50 – 150°C MoveBack(120°C or higher ment ground in the red zone) color: black

Analog display

(Note)

LED LED

Red Amber

At 120°C or higher When the small lamp is lit up.

Lit up during warning Lit up during operation. — — Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

Gauge Oil tem4 perature 10 of torque converter Warning Backlight

Scale: white, red Back50 – 135°C Moveground (120°C or higher ment color: in the red zone) black

Analog display

(Note)

LED LED

Red Amber

At 120°C or higher When the small lamp is lit up.

Lit up during warning Lit up during operation.  

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No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

When machine Immedimonitor ately check after Central switch is turning warn- Warn- opering key ON. ing ated. lamp buzzer Related operation

Remarks

Gauge Engine 5 coolant tempera11 ture Warning Backlight

Scale: white, red 50 – 135°C MoveBack(102°C or higher ment ground in the red zone) color: black

Analog display

(Note)

Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

LED LED

Red Amber

At 102°C or higher When the small lamp is lit up.

Lit up during warning Lit up during operation. — — Note: When operating the machine monitor check switch, turn switch knob back and forth one time, as starting from the current position and return to the starting position.

Gauge

Scale: white, red MoveBackment ground color: black

EMPTY – FULL

Analog display

(Note)

6 12

Fuel level Specified level or less (remaining quantity in the tank at 120 or less) When the small lamp is lit up. 0 – 65535.0h Service meter Lit up during operation Lit up during operation. Operates when the engine is running. 1:1 against clock time

Warning

LED

Red

Backlight Service meter (Regular display item)

LED

Amber

* Displayed in the
"upper column" on the character display

When 65535.0h is exceeded, fixed at 65535.

Odometer (Regular Odometer display item)

* Displayed in the "lower col- Operates durumn" on the char- ing traveling. acter display
When any problem or When any prob- failure occurs, lem or failure the action Display occurs on the code is discharacter: machine, * Dis- played in the black upper column played in the Backupper and lower and remedies ground columns on the or description color: character display. of problem in green the lower column. Press machine monitor mode selector switch > during the occurrence of the problem or failure on the machine. * Appears in the upper and lower columns on the character display. The failure code (6 digits) and detection controller are displayed in the upper column and the faulty system or description of problem in the lower column.

When 999999.9 km is exceeded, fixed at 999999.9 km.

7

Action code

Action code

LCD

Note 1

Note 1:"HD-465" is displayed in the upper column. Note 2: "KOMATSU" is Note 2 displayed in the upper column and "SYSTEM CHECK" in the lower column.

Failure code

Failure code

For information on how to operate display, see the Operation & Maintenance Manual.

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No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation

Remarks

7

Reverse travel integrating meter Reset of time to Other displays change filter and oil. Telephone number setting Language selection Night lighting Central warning lamp

LCD

Display character: black Background color: green

Press machine monitor mode selector switch " "

Switch screen by operating machine monitor mode selector switch ">" or "<".

For details, see the Operation & Maintenance Manual.

Backlight

LED

Green

When the small lamp is lit up. During system is abnormal

Dimmed down by a step when the small lamp is lit up. Lit up during warning.

8

LED

Red

13

Maintenance warning

LED

Red

When maintenance-related alarm is given or the time to change filter and oil has elapsed.

Lit up or turn ON and OFF

Note 1:The moment when the lamp lights up, the action code: E01 and the location where an alarm has been given appear on the character display. Note 2:For details on the target items, etc., see the Operation & Maintenance Manual.

14

Battery charging circuit warning

LED

Red

During battery charging circuit being abnormal When the steering oil temperature rises. When the engine oil pressure drops. When the retarder oil pressure drops. When the parking brake is operated. During being abnormal in machine monitor or optional controller system During being abnormal in engine control system.

Lit up during warning.

Steering oil tempera15 ture warning (option) 16 Engine oil pressure warning Retarder oil pressure warning Parking brake warning

Warning

LED

Red

Lit up during warning.

LED

Red

Lit up during warning. Lit up during being abnormal. Operates when the alternator R terminal is ON. Operates when the parking brake is operated and the shift lever is in other than the "N" position. Under present conditions, used in the event of failure of the machine monitor.

17

LED

Red

(Note) (Note)

18

LED

Red

Lit up during operation.

(Note) (Note)

Machine monitor or 19 optional system warning 20 Engine system warning

LED

Red

Lit up during warning.

LED

Red

Lit up during warning.

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No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

When machine Immediately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp Related operation

Remarks

21

Transmission system warning Retarder system warning Inclination warning

LED

Red

Being abnormal in transmission control system During being abnormal in retarder control system When the body is lifted and inclined excessively from side to side.

Lit up during warning.

22

LED

Red

Lit up during warning.

23

LED Warning

Red

Lit up during warning. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. During operation: lit up During nonoperation: turned OFF. Lit up (*)

24

Seatbelt warning

LED

Red

When the seatbelt is not worn.

25

Body warning

LED

Red

See the instruction manual

(Note) (Note)

Note: Operates when the shift lever is in other than the "N" position.

26

Emergency steering

LED

Red

When the emergency steering is operated.

27

Turn signal, right

LED

Green

During operation

28

Turn signal, left

LED

Green

During operation

29

Headlight, high beam

LED Pilot

Blue

During operation

Shift 30 lever (R) position R Shift 30 lever (N) position N Shift 30 lever (D) position D 30 (6) Shift lever position 6 Shift lever position 5

LED

Green

When the shift lever is in the "R" position When the shift lever is in the "N" position When the shift lever is in the "D" position When the shift lever is in the "6" position When the shift lever is in the "5" position

* Blinks when the neutral safety is operated.

LED

Orange

Lit up

LED

Green

Lit up (*)

* Blinks when the neutral safety is operated.

LED

Green

Lit up (*)

* Blinks when the neutral safety is operated.

30 (5)

LED

Green

Lit up (*)

* Blinks when the neutral safety is operated.

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No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp — —

Remarks

Shift 30 lever (4) position 4 Shift 30 lever (3) position 3 Shift 30 lever (2) position 2 Shift 30 lever (L) position L

LED

Green

When the shift lever is in the "4" position When the shift lever is in the "3" position When the shift lever is in the "2" position When the shift lever is in the "L" position F1, F2, F3, F4, F5, F6, F7, N, R * According to the gear shift signal received from the transmission controller. * When an alarm is raised in the event of emergency escape, "E-" and the "gear speed range" are alternatively displayed. When the small lamp is lighted up. When the retarder brake is operated.

Lit up (*)

* Blinks when the neutral safety is operated.

LED

Green

Lit up (*)

* Blinks when the neu— — tral safety is operated.

LED

Green

Lit up (*)

* Blinks when the neu— — tral safety is operated.

LED Pilot

Green

Lit up (*)

* Blinks when the neu— — tral safety is operated.

Shift indicator 31

LCD

Background color: gray

When the gear shift range signal is received from the transmission controller.

All lit up.

All lit up.

Night lighting

Backlight

LED

Amber

During operation: lit up During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF High-power mode in operation: lit up During nonoperation: turned OFF Economy mode in operation: lit up During nonoperation: turned OFF Lit up in "hard" mode

32 Retarder

LED

Orange

33

Lockup

LED

Green

When lockup of the torque converter is activated and direct drive is effective

34

Output mode (power mode)

Pilot

LED

Green

At high-power mode

35

Output mode (economy mode) Suspension mode (hard) (option)

LED

Green

At economy mode

36

LED

Green

At suspension "hard" mode

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No.

Display item

Display category

Device

Color

Display range/ conditions

Display method

Related opera- When machine Immedition ately monitor check after Central switch is turning Warnwarnoper- key ON. ing ing ated. buzzer lamp

Remarks

Suspension mode 37 (medium) (if equipped) Suspension 38 mode (soft) (if equipped)

LED

Green

In suspension "medium" mode

Lit up in "medium" mode

LED

Green

In suspension "soft" mode

Lit up in "soft" mode

39

ABS (if equipped)

LED

Orange

When ABS is operated.

During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF When ready to be operated: lit up

40

ASR (if equipped)

LED

Orange

When ASR is operated.

41

Preheating

LED Pilot

Red

When electric intake air heater for preheating engine is operated. When automatic retarder is ready to be operated.

42

Automatic retarder being ready Automatic retarder set speed

LED

Green

43

LCD

Background color: gray

When automatic Display of set retarder switch is speed (*) turned ON.

* Zero is displayed
— — when the set speed is cancelled.

44

Automatic retarder unit display (km/h) automatic retarder display unit (MPH)

LED

Green

When automatic retarder switch is turned ON and the unit km/h is selected.

During operation: lit up During nonoperation: turned OFF During operation: lit up During nonoperation: turned OFF

45

LED

Green

When automatic retarder switch is turned on and the unit km/h is selected.

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Self-diagnostic function when operating starting switch 1. When the starting switch is turned to the ON position before starting the engine, the system check is carried out for 3 seconds. 2. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch at the ON position, everything will go to the normal operating condition. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have passed after the starting switch was turned to the ON position. Check function of central warning lamp, alarm buzzer, monitor lamps, and meters To check the normal display function of the machine monitor, press the machine monitor check switch to check the actuation. For details of the actuation, see "When operating machine monitor normal display functions with machine monitor check switch".

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OUTLINE OF SERVICE MODE 1. Outline 1) Failure history for electrical system The system is used to check the failure history for the electrical system of each controller saved in the machine monitor. For details of the failure codes displayed for the failure history of the electrical system, see the troubleshooting section. After repairing the failure, check that the system works properly, then delete the failure history. The failure history display for the electrical system is displayed on the character display as shown below. *** : Displays order of failure history items ###### : Displays failure code $$$ : Displays number of times that applicable failure code has occurred %%%%% :Displays time that has elapsed since failure first occurr ed (Present service meter reading Service meter reading when problem first occurred = Time elapsed) @@@@@ : Displays time that has elapsed s i nc e fa i l ur e l a s t o c c ur r ed (Present service meter reading - Service meter reading when problem last occurred = Time elapsed) The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory. 2) Failure history for machine system The system is used to check the failure history for the machine system of each controller saved in the machine monitor. For details of the failure codes displayed for the failure history of the machine system, see the troubleshooting section. After repairing the failure, check that the system works properly, then delete the trouble data. The failure history display for the machine system is displayed on the character display as shown below. *** : Displays order of failure history items ###### : Displays failure code $$$ : Displays number of times that applicable failure code has occurred %%%%% : Displays time that has elapsed since failure first occurred

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@@@@@ : Displays time that has elapsed since failure last occurred The failure code flashes for failures that are still occurring at present. The number of times that the failure code for the machine system has occurred is saved in memory. 3) Real-time monitor This function is used when checking the input and output signals recognized by the controllers on the network. The real-time monitor display on the character display is as shown right. *** : Displays name of item ##### : Displays ID No. given to each item %%% : Displays data. If units are used, the unit is displayed on the right side of the data By specifying the ID No. given to each item, it is possible to display the desired 2 items at the same time. The character display when a second item is displayed at the same time is as shown right ##### : Displays specified ID No. %%% : Displays data. If units are used, theunit is displayed on the right side of the data 4) ECMV compensation For details of this function, see TESTING AND ADJUSTING, SPECIAL FUNCTIONS OF MACHINE MONITOR. 5) Changing filter, oil replacement time For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter, oil replacement time display. This is used when changing the replacement interval. 6) Snapshot function When the VHMS controller is installed, this menu is displayed. For details, see "TESTING AND ADJUSTING, [Items related to PM Clinic], Execution of Pm Clinic with Manual Snapshot (another name: Quick PM)". 7) PLM setting function When payload meter (having VHMS) is set optionally, this menu is displayed. For details, see "STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Payload meter (having VHMS)". 8) Controller initialize This function is used only at the factory, so do not touch it.

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2. Method of operation For details of the method of operating each ser vice mode function, see TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR.

REMARK : When the starting switch is turned OFF, it returns to the normal mode.

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ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM
SYSTEM DRAWING

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ENGINE CONTROL SYSTEM

With the control system using engine controller, the signals detected by the sensers are input and the engine controller calculates these. It then outputs the signal for the results to the actuators to control the fuel injection amount and the fuel injection timing. The machine monitor stores data transmitted from engine controller, as common data.

AISS (Automatic Idle Setting system)
Outline • The AISS is a system which sets the engine low idle speed at manual or automatic to two levels according to the operating conditions of the machine. In this way it is possible to imoprove the fuel consumption and the starting and acceleration ability. Set idle speeds Low idle speed : 750 rpm High idle speed : 945 rpm High, low speed set conditions
Conditions Set to low position Engine coolant temperature above 50°C and parking brake applied Engine coolant temperature above 50°C and retarder lever actuated Engine coolant temperature less than 50°C Parking brake released and retarder lever not actuated Operating methods Manual Automatic High/low category

Low speed

Automatic

Automatic High speed Automatic

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AUTOMATIC SHIFT CONTROL SYSTEM

AUTOMATIC SHIFT CONTROL SYSTEM
(Transmission control system with all-range electronic modulation)

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AUTOMATIC SHIFT CONTROL SYSTEM

Outline • The transmission controller receives the shift position signal for the gearshift lever, the accelerator signal for the accelerator pedal, the speed signal for the transmission, and the other signals from the switches and sensors. It then automatically controls the transmission and shifts it to the optimum speed range. • In addition to the shift control, the transmission controller also controls the torque converter lockup solenoid and operates the brake to prevent overrun. Each clutch pack of the clutch packs and torque converter lock-up clutch in the transmission is equipped with an electronically controlled modulation valve, and each clutch pack is independently controlled. In this way, the initial pressure, build-up ratio, and torque-off time for each clutch is controlled according to the condition of the machine. This reduces the gearshifting shock and prevents shift hunting, and in this way contributes to improving the durability of the clutches. • The transmission shift controller uses the signals from the switches and sensors to drive the machine monitor displays and caution and pilot lamps, and transmits these data to the network.

HD465-7, HD605-7

10-137

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AUTOMATIC SHIFT CONTROL SYSTEM

TRANSMISSION CONTROLLER

1. Self-diagnostic display window 2. Connector 3. Case 4. Motherboard 5. Model selector switch (rotary switch 1) 6. Model selector switch (rotary switch 2) Outline • The transmission controller controls the transmission system. It has the following features and functions. 1. It has a high power mode and economy mode, and the gearshifting pattern can be selected. 2. The braking mode is the mode when the brake is used. By raising the gearshifting point and increasing the speed of the brake cooling pump, it is possible to raise the cooling effect of the retarder and make effective use of the engine brake. 3. It controls the torque converter lock-up solenoid valve and overrun prevention brake. 4. To reduce the shock when shifting gear, it outputs the throttle correction command to the engine controller when shifting gear and limits the engine speed.

5. Speed sensors are installed at three places (transmission input shaft, intermediate shaft, and output shaft). This makes it possible to detect slippage of the transmission clutches and to protect the transmission when there is any abnormality in the hydraulic system. 6. It connects to the network and shares various data with other controllers. 7. It receives input of the model selection data (what model it is mounted on), and uses the network to contact other controllers. (For details of the method of setting, see TESTING AND ADJUSTING, AND TROUBLESHOOTING.) 8. It has a self-diagnostic function which divides the input and output systems further into small parts. 9. The self-diagnostic function is displayed in two digits. 10. When an abnormality is detected, it transmits the details to the network and displays it on the other displays. 11. It uses the machine monitor to display if the failure is still existing. 12. It provides an escape function for use when there is a failure in the electrical system.

10-138
(10)

HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AUTOMATIC SHIFT CONTROL SYSTEM

CN1 (MIC 17-POLE) Machine Connector Number : ATC1_MIC
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Specification
ON/OFF OUT (POWER) 0 ON/OFF OUT (POWER) 2 ON/OFF OUT (POWER) 4 ON/OFF OUT (POWER) 6H ON/OFF OUT (POWER) 7H ON/OFF OUT (SIG) 8 Battery direct power supply (+24V) Controller power supply (GND) Controller power supply (+24V) ON/OFF OUT (POWER) 1 ON/OFF OUT (POWER) 3 ON/OFF OUT (POWER) 5 ON/OFF OUT (POWER) 6L ON/OFF OUT (POWER) 7L ON/OFF OUT (SIG) 9 Controller power supply (GND) Controller power supply (+24V) N.C N.C

Signal name

Remarks

Power output (+24V) for torque converter oil pressure sensor Power input (+24V) for overrun prevention brake output Power input (+24V) for transmission cut relay output Droop mode output 3 (Idling controll) Battery direct power supply (+24V) GND Power supply voltage (+24V) N.C N.C N.C Overrun prevention brake output command Transmission cut relay output Droop mode output 2 (Power/Economy selection) GND Power supply voltage (+24V)

POWER SUPPLY (+24V) FOR T/C POWER INPUT (+24V) FOR OVERRUN POWER INPUT (+24V) T/M CUT RELAY DROOP MODE OUT 3 FOR ENG BATTERY DIRECT (+24V) INPUT GND POWER INPUT (+24V)

OVERRUN OUT T/M CUT RELAY DROOP MODE OUT 2 FOR ENG INPUT GND POWER INPUT (+24V)

HD465-7, HD605-7

10-139

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AUTOMATIC SHIFT CONTROL SYSTEM

CN2 (MIC 21-POLE) Machine Connector Number : ATC2_MIC
Pin No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Specification
SOL power supply (+24V) SOL_OUT 4A+ SOL_OUT 4B+ SOL_OUT 5A+ SOL_OUT 5B+ A_OUT 0 SOL_OUT 0+ SOL_OUT 1+ SOL_OUT 2+ SOL_OUT 3+ A_OUT 1 SOL power supply (+24V) SOL_OUT 4A–, 4B– VDD_OUT (24V) SOL_OUT 5A–, 5B– VDD_OUT (+5V) SOL_OUT 0– SOL_OUT 1– SOL_OUT 2– SOL_OUT 3– Power GND

Signal name
SOL power input (+24V) ECMV current output (+) "1st clutch" ECMV current output (+) "4th clutch" ECMV current output (+) "2nd clutch" ECMV current output (+) "Rev clutch" N.C ECMV current output (+) "Low clutch" ECMV current output (+) "3rd clutch" ECMV current output (+) "High clutch" ECMV current output (+) "lockup clutch" N.C SOL power input (+24V) ECMV current output (–) "1st, 4th clutch" N.C ECMV current output (–) "2nd, Rev clutch" N.C ECMV current output (–) "Low clutch" ECMV current output (–) "3rd clutch" ECMV current output (–) "High clutch" ECMV current output (–) "lockup clutch" GND

Remarks
POWER INPUT (+24V) FOR SOLENOID ECMV SOLENOID "1ST" (+) ECMV SOLENOID "4TH" (+) ECMV SOLENOID "2ND" (+) ECMV SOLENOID "REV" (+)

ECMV SOLENOID "LOW" (+) ECMV SOLENOID "3RD" (+) ECMV SOLENOID "HIGH" (+) ECMV SOLENOID "L/U" (+)

POWER INPUT (+24V) FOR SOLENOID ECMV SOLENOID "1ST, 4TH" (–)

ECMV SOLENOID "2ND, REV" (–)

ECMV SOLENOID "LOW" (–) ECMV SOLENOID "3RD" (–) ECMV SOLENOID "HIGH" (–) ECMV SOLENOID "L/U" (–) INPUT GND

10-140

HD465-7, HD605-7

C Transmission oil level switch (if equipped) Emergency escape signal Steering oil temperature switch (if equipped) Transmission intermediate shaft speed sensor Engine speed sensor GND N.C Electrolyte level switch (if equipped) Fuel level sensor N.C TRANSMISSION INPUT SPEED TRANSMISSION OUTPUT SPEED THROTTLE MODIFICATION SENSOR POWER SUPPLY (+5V) TORQUE CONVERTER PRESS SENSOR TRANSMISSION OIL LEVEL SW (if equipped) LIMP HOME SW STEERING OIL TEMP SW (if equipped) TRANSMISSION MIDDLE SPEED ENGINE SPEED SPEED GND ON/OFF INPUT 35 PULS INPUT 2 PULS INPUT 3 PULS GND PWM_OUT Analog GND Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT ANALOG SENSOR GND INPUT ANALOG SENSOR GND AIR CLEANER SW ALTERNATOR R BATTERY LEVEL SW (if equipped) FUEL LEVEL Analog_INPUT 10 Analog_INPUT 11 Analog_INPUT 12 Analog_INPUT 13 Analog_INPUT 14 Analog_INPUT 15 Analog_INPUT 16 Analog_INPUT 17 Analog_INPUT 18 Analog_INPUT 19 Analog_INPUT 20 Analog_INPUT 21 TORQUE CONVERTER OIL TEMP ECMV OIL TEMP ACCEL SIGNAL HD465-7.C N.C Transmission valve oil temperature sensor N.C Signal name Remarks Transmission input shaft speed sensor Transmission output shaft speed sensor N.C Alternator Terminal R voltage N.C N. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM CN3 (040 20+16-POLE) Machine Connector Number : ATCA_040.C N.C Torque converter oil temperature sensor N.C GND for sensor 0(–) 1(–) 4 5 6 7 8 9 GND (Analog GND is connected) N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Specification CN_CHKO PULS INPUT 0 PULS INPUT 1 PWM_IN PULS OUTPUT Sensor power supply (+5V) Analog_INPUT Analog_INPUT Analog_INPUT Analog_INPUT 0(+) 1(+) 2 3 N.C Air cleaner clogging switch N.STRUCTURE. HD605-7 10-141 (10) . ATC3B_040 Pin No.C N.C Accelerator pedal signal N.C Throttle modification signal output Potentio power supply Torque converter oil pressure sensor N.C N.

1 2 3 4 5 6 7 8 9 10 11 12 Specification RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX (–) Flash write switch RS422 RX (–) RS232 C/S-NET GND RS485 (–) S-NET (+) S-NET (+) S-NET GND S-NET (+) Signal name Remarks — 10-142 HD465-7. HD605-7 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM CN4 (040 12-POLE) Machine Connector Number : ATC4_040 Pin No.

C Machine select 1 Machine select 2 Machine select 3 STEERING HOIST OIL TANK LEVEL SWITCH (OPTION) COOLANT LEVEL SWITCH TRANSMISSION FILTER SWITCH ENG OIL LEVEL SWITCH (OPTION) ENG OIL FILTER SWITCH (OPTION) STEERING HOIST FILTER SWITCH (OPTION) FILL SIGNAL "LOW" FILL SIGNAL "4TH" FILL SIGNAL "HIGH" FILL SIGNAL "1ST" FILL SIGNAL "2ND" FILL SIGNAL "3RD" FILL SIGNAL "REV" FILL SIGNAL "L/U" KEY SWITCH C EMERGENCY STEERING RELAY 1 HEATER SIGNAL SHIFT LEVER "R" SHIFT LEVER "N" SHIFT LEVER "D" SHIFT LEVER "6" SHIFT LEVER "5" SHIFT LEVER "4" SHIFT LEVER "3" SHIFT LEVER "2" SHIFT LEVER "L" MACHINE SELECT 1 MACHINE SELECT 2 MACHINE SELECT 3 HD465-7.STRUCTURE.C N.C Transmission filter clogging switch Engine oil level switch (option) Engine oil filter clogging switch (option) Hydraulic oil filter clogging switch (option) Fill switch signal "Low clutch" Fill switch signal "4th clutch" Fill switch signal "High clutch" Fill switch signal "1st clutch" Fill switch signal "2nd clutch" Fill switch signal "3rd clutch" Fill switch signal "Rev clutch" Fill switch signal "lockup clutch" Key C signal Emergency steering operation signal 1 Heater signal N.C Shift lever signal "R" Shift lever signal "N" Shift lever signal "D" Shift lever signal "6" Shift lever signal "5" Shift lever signal "4" Shift lever signal "3" Shift lever signal "2" Shift lever signal "1" N. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM CN5 (040 20+16-POLE) Machine Connector Number : ATC5A_040 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CN_CHKI ON/OFF INPUT 0 ON/OFF INPUT 1 ON/OFF INPUT 2 ON/OFF INPUT 3 ON/OFF INPUT 4 ON/OFF INPUT 5 ON/OFF INPUT 6 ON/OFF INPUT 7 ON/OFF INPUT 8 ON/OFF INPUT 9 ON/OFF INPUT 10 ON/OFF INPUT 11 ON/OFF INPUT 12 ON/OFF INPUT 13 ON/OFF INPUT 14 ON/OFF INPUT 15 ON/OFF INPUT 16 ON/OFF INPUT 17 ON/OFF INPUT 18 ON/OFF INPUT 19 ON/OFF INPUT 20 ON/OFF INPUT 21 ON/OFF INPUT 22 ON/OFF INPUT 23 ON/OFF INPUT 24 ON/OFF INPUT 25 ON/OFF INPUT 26 ON/OFF INPUT 27 ON/OFF INPUT 28 ON/OFF INPUT 29 ON/OFF INPUT 30 ON/OFF INPUT 31 ON/OFF INPUT 32 ON/OFF INPUT 33 ON/OFF INPUT 34 Specification GND Signal name INPUT GND Remarks Hydraulic tank level switch (option) Coolant level N.C N. HD605-7 10-143 (10) .C N.

depending on the condition of the input signals. retarder brake operated) When the following three conditions are fulfilled 1. Accelerator pedal released When the following three conditions are fulfilled 1. Economy mode 10-144 (12) HD465-7. and transmission shock are improved. Accelerator pedal depressed 3.: 7484 and up HD605-7 Serial No. Brake signal ON (footbrake. Brake signal OFF (footbrake. retarder brake not operated) 2.: 7001 – 7483 HD605-7 Serial No. the engine speed is maintained at a higher level. HD465-7 Serial No. retarder brake operated) 2. HD605-7 . High power mode: The high power mode uses the power of the machine to the maximum to provide the maximum payload. such as when traveling unloaded or on flat ground. Power mode selector switch is at economy High power mode Economy mode Braking mode High power mode Braking mode: The shift-down point and the shift-up point are both raised. Brake signal OFF (footbrake. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE • The relationship between each gearshift position and the automatic gearshifting range is as shown in the table below. Brake signal ON (footbrake. retarder brake not operated) 2. Accelerator pedal depressed 3. the engine speed is maintained at a lower level.: 7182 and up Mode Braking mode Set conditions 1. Gearshifting characteristics • Shifting the transmission up and down is carried out according to the shift map saved in the controller memory. The settings for each mode are as shown in the table below.: 7001 – 7181 Mode Set conditions When either of the following conditions is fulfilled 1. and the fuel consumption. retarder brake not operated) 2. and the amount of cooling oil for the retarder is ensured to provide greater effect when the engine is used as a brake. Power mode selector switch is at high power When the following two conditions are fulfilled 1. Economy mode: When the machine is being used under light load. Brake signal OFF (footbrake. Power mode selector switch is at high power When the following three conditions are fulfilled 1. the shift-up point and shift-down point are both lowered. noise.STRUCTURE. Power mode selector switch is at economy HD465-7 Serial No. Brake signal OFF (footbrake. Accelerator pedal depressed 3. There are three types of shift map. retarder brake not operated) 2.

HD605-7 10-145 (12) . the torque converter lock-up ON/OFF points. the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.: 7001 – 7181 • The shift-up/shift-down points.500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below. F2 with the accelerator pedal released. • When the machine moves off downhill F1. Lock-up • For the lock-up ON point.STRUCTURE.300 and 1. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM AUTOMATIC GEARSHIFTING GRAPH HD465-7 Serial No. HD465-7.: 7001 – 7483 HD605-7 Serial No. the optimum point between 1.

the torque converter lock-up ON/OFF points. Lock-up • For the lock-up ON point. the optimum point between 1. • When the machine moves off downhill F1.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM HD465-7 Serial No. and the automatic braking (for overrun prevention) ON/OFF points of each mode are as shown in the figure below.: 7484 and up HD605-7 Serial No.: 7182 and up • The shift-up/shift-down points. the lock-up is not engaged until the accelerator pedal is depressed or the footbrake is applied.300 and 1. 10-145-1 (12) HD465-7.500 rpm is selected according to the torque converter input speed (engine speed) and output speed (transmission input shaft speed). HD605-7 . F2 with the accelerator pedal released.

the lock-up clutch is engaged. but as the machine accelerates. When the transmission input shaft speed reaches 1. The gearshifting time delay is controlled precisely by each gearshifting pattern through the use of the all-range electronic modulation system. the engine speed is also raised (a command is output to the engine controller) in order to reduce the shock when shifting gear. 4) Gearshift lever position N At the neutral position. The safety functions related to travel in reverse are the directional inhibitor and reverse safety.500 rpm. For details. 3. the transmission is set to F2 torque converter range. F4. and the engine speed is reduced at a time. so the torque converter is directly engaged and the transmission is set to direct travel. While the transmission is shifting up. none of the transmission clutches are actuated.400 rpm. So. 2) Gearshift lever positions 6. the transmission shifts down one speed. the engine speed rises and accelerates. iv) Immediately after shifting up.300 – 1. the torque converter lock-up clutch is disengaged and the transmission enters the torque converter drive. the lockup does not work. 5. 10-146 (12) HD465-7. 3) Gearshift lever positions R This is the shift lever position for REVERSE travel. 2. a time delay is used to prevent the gears from being shifted within the set time. the engine speed is also lowered (a command is output to the engine controller) in order to reduce the shock when shifting gear. when traveling in F6. see the automatic gearshifting graph. • In the above explanation. to prevent mistaken operation caused by excessive variation in the speed when shifting gear. the transmission shifts down to F5. it rises again and the transmission shifts up in turn to F4 to F7 in the same way as in iii) above. HD605-7 . F2) is the same as for gearshift lever position D above. the engine speed momentarily goes down. ii) As the engine speed goes down further and the transmission shifts down in turn to F2. Gearshifting load time • In the automatic shift range. If the operation is not correct. the set speed or actuation may differ according to the travel conditions. The approximate values for the gearshifting pattern and gearshifting time delay are shown in the diagram below. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM Gearshift lever positions and method of shifting 1) Gearshift lever position D When shifting up (in high power mode) i) When the gearshift lever is set at position D.100 rpm. When shifting down (in high power mode) i) When the load increases and the engine speed drops to 1. 4. L The method of shifting automatically from F1 to F6 (F5. ii) When the accelerator pedal is depressed. (For example. iii) As the engine speed rises further and reaches 2. gearshifting is restricted.STRUCTURE. F3. the transmission shifts up to F3.) While the transmission is shifting down.

It shifts down F6 → F5 → F4 in turn according to the travel speed. the transmission is shifted to REVERSE. to improve durability and reliability) Condition in which high speed mode can be selected: Any of coditions below is sattisfied (1) Shifting up is possible (2) Gear shift is placed in any of F7. and transmission. to improve durability and reliability) 4) Power train overrun prevention rear brake function When the engine speed exceeds 2. even if the gearshift lever is operated to positions R. (This is a safety circuit to prevent the machine from moving unexpectedly when the engine is started. the transmission will not be shifted immediately to travel in reverse. 4 → 3-L. When the travel speed goes below 4 km/h. 3 → 2-L. the machine starts in F2. HD465-7. This is to prevent the engine from overrunning.) 3) Directional inhibition function When traveling forward at a speed of more than 4 km/h. the transmission does not shift directly F6 → F4. shifting up is limited. or alarm buzzer may also be actuated. when traveling in D (F6). If any abnormality is detected by the self-diagnosis function. torque converter. HD605-7 10-147 . 2 → L For example. The transmission system caution. The transmission does not shift up until the body is completely lowered.600 rpm in high-speed mode or 2. if the body is not completely lowered. The speed range is shifted to N and the engine speed is lowered to reduce the travel speed. If the gearshift lever is at D.STRUCTURE. Self-diagnostic function The controller carries out self-diagnosis of the system and displays any abnormalities.) 2) Neutral safety function This circuit prevents the engine from starting if the gearshift lever is not at the N position. After dumping the load. and if it is at positions 6 to L. the machine starts in F1. When the engine speed exceeds 2. (The transmission does not jump two speed ranges if the operator makes a mistake when operating the gearshift lever. the rear brake is activated automatically. even if the starting switch is turned to the START position. (Turnover prevention function) 6) Speed range limit function when dump body is raised. the central warning lamp flashes and the warning buzzer sounds. N. 5 → 4-L. warning lamp.400 rpm in low-speed mode. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM Safety functions 1) Down-shift inhibition function If gearshift lever is operated D → 6-L. and R positions Condition in which low speed mode can be seleced: In the condition other than high speed mode 5) REVERSE safety The machine will not travel in reverse if the dump control lever is not at FLOAT and the dump body is not completely lowered. even if the gearshift lever is operated to 4.500 rpm in high-speed mode or 2. (To prevent overload on power train.450 rpm in low-speed mode. the abnormality data is transmitted to the network and is displayed as an action code on the machine monitor. 6 → 5-L. (To prevent overrun of engine.

It also has an estimation display function: when loading the next load. 15. HD605-7 10-151 (6) .STRUCTURE. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the external display lamps. it is possible to know the mass on the springs of the dump truck. The load mass. 12. distance. Shift lever neutral detection switch (relay) Body FLOAT signal (reterder controller) Clinometer Pressure sensor (for front left) Pressure sensor (for front right) Pressure sensor (for rear left) Pressure sensor (for rear right) Suspension cylinder Payload meter Lamp drive relay External display lamp Battery Fuse (for external display lamp) Fuse (for controller) Memory card Travel signal sensor RS232C output (PC cable communication) socket Battery charge signal (alternator terminal R) Outline • A dump truck is supported by 4 suspension cylinders. 10. time of occurrence/cancellation of abnormalities or warnings. the new total load mass is estimated and the appropriate lamp flashes. 11. The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. 7. 17. time when engine was turned ON/OFF. 18. HD465-7. 3. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) PAYLOAD METER STRUCTURE OF SYSTEM (CARD TYPE) 1. and other data of each transportation cycle are automatically saved in memory. This prevents overloading. 2. 4. 8. 13. By measuring the total of the loads on each cylinder. time. 16. 14. 9. These data can be later transmitted to a PC or written in a memory card. 5. 6.

FUNCTION. "Initial Setting of Payload Meter". 10-151-1 (10) HD465-7. HD605-7 . replaced. the payload meter (card type) cannot be mounted. or removed on a dump truck having the VHMS controller. "Initial Setting of Payload Meter" and TESTING AND ADJUSTING. perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)". and [Items related to VHMS controller] "VHMS Initial Setting Manual (Tool)". and MAINTENANCE STANDARD. see STRUCTURE. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) BLOCK DIAGRAM OF PAYLOAD METER • • If a dump truck having the VHMS controller is equipped with the payload meter (having VHMS) optionally. When the payload meter (card type) is installed for the first time. For setting procedure.STRUCTURE.

The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. it is possible to know the load mass on the springs of the dump truck. The load on each cylinder can be calculated from the internal pressure and sectional area of the suspension cylinder.STRUCTURE. By measuring the total of the loads on each cylinder. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) PRINCIPLE OF CALCULATION 1. HD605-7 . Outline A dump truck is supported by 4 suspension cylinders. PB PT Therefore. the load can be calculated as follows. W = PBST 10-152 (6) HD465-7. [Load bearing on suspension cylinder] W = PB SB – PT (SB – ST) Where W = Load bearing on suspension cylinder PB = Bottom pressure PT = Top pressure SB = Cross-sectional area of cylinder ST = Cross-sectional area of rod Because of the structure of the suspension cylinder.

Measurement of mass when full Load the dump truck and measure the mass at that time. When loading for this purpose. 3. 4. set the gearshift lever in the "N" position and set the dump control lever in the "FLOAT" position on a ground where the longitudinal inclination of the dump truck is ± 5°. The reason why the mass is measured while the dump truck is traveling is that the sliding resistance of the suspension cylinders must be averaged by extracting and retracting the cylinders by changing the condition of the dump truck. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) 2. and then measure the average load and use it as the mass when empty. Detecting distance. travel speed The travel speed and distance are detected from the travel signal sensor on the truck. the measured mass is different from the mass measured on a level ground. the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. Measurement of mass when empty (Calibration) Drive the empty dump truck at a speed of about 10 km/h for about 30 seconds. HD605-7 10-153 (10) . To solve this problem.STRUCTURE. Correction on slope If the dump truck is loaded on a slope. a Travel signal sensor: Transmission output speed sensor HD465-7. The measured mass when empty is saved as a calibration data in the memory in the controller. (Correction range of inclination angle: ± 5°) 5.

Memory card 10. gearshift lever (neutral sensor switch on Payload meter ). Mode switch 6. Communication "transmitting" lamp (Tx busy) 4. Communication "receiving" lamp (Rx busy) 3. Display 2. clinometer. calculates the load mass with the microcomputer in it. Memory card access lamp (CARD busy) 5.. 1) General locations of payload 1. Total/shift switch 8. HD605-7 . a When not inserting or removing memory card (9). 10-154 (10) HD465-7. Light/increment switch 9. Cover a Communication "transmitting" lamp (3) lights up even when the communication cable is not connected to a PC or when there is defective connection. and indicates the load level on the external indicator lamps. etc. always keep cover (10) closed. Payload meter Payload meter receives signals from the pressure sensors. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) FEATURES OF EACH DEVICE 1.STRUCTURE. Calibration/clear switch 7. displays the calculation result on the panel. body float sensor.

Rotatory volume a The switches are adjusted before the machine is shipped. do not touch any other switch. Down: US ton (Short ton) Up : Permitted Down : Prohibited According to Permitted/prohibited setting table for switches Turn CLOCKWISE to DECREASE volume Turn COUNTERCLOCKWISE to INCREASE volume B. Name Load mass compensation trimmer Speed compensation trimmer Distance compensation trimmer Model selector switch Memory card use switch Clinometer use switch Mass unit setting switch Switch forcible prohibition setting switch Buzzer volume adjustment Type Rotary volume 0 – F rotary selector switch 0 – F rotary selector switch 0 – F rotary selector switch 2-stage selector switch 2-stage selector switch 2-stage selector switch 2-stage selector switch Remarks –20% – (Counterclockwise) +20% (Clockwise) 0 : 107% –7 : 107% – F : 92% 0 : 107% –7 : 107% – F : 92% According to model selector code table Up : Not used Down : Used Up : Not used Down : Used Up: t (Metric ton).STRUCTURE. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) LEFT FACE • Details of switches on left face No. 7. 6. 4. 5. 7 and No. 8. 3. 2. 1. For this reason. HD465-7. B can be adjusted. HD605-7 10-155 (10) . Only No.

7 STD Large-tire Komatsu engine HD405-6 STD Large-tire Komatsu engine HD985-3 STD 30:00-51 Komatsu engine HD605-5. 8 Top (permitted) Left side switch No. data all clear. 10-156 (10) HD465-7. 8 (top) All switches can be operated. 8 (top) All switches can be operated. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) • Table of model selector code No. (3) Left side switch No. time. No. No. The PLM on HD1200-1 has a different part No. No. (4) Left side switch No. HD605-7 . 8 (bottom) Calibration. time. 5 (bottom). 8 (bottom) Calibration.STRUCTURE. 5 (top). • Permitted/prohibited setting table for switches Left side switch No. date setting operations only are possible. of model selector switches 0 (*1) 1 2 3 4 5 6 7 8 9 A B C D E HD785-3 STD Small-tire Komatsu engine HD465-5. 5 Top (memory card not used) Bottom (memory card used) (1) Bottom (prohibited) (2) (3) (4) (1) Left side switch No.7 STD Large-tire Komatsu engine HD785-5 STD Large-tire Komatsu engine Model HD1200-1 STD Large-tire Cummins engine HD785-3 STD Large-tire Komatsu engine HD465-5 STD Small-tire Komatsu engine HD325-6 STD Large-tire Komatsu engine *1. date setting operations only are possible. data all clear. No. (2) Left side switch No. card dump. 5 (top). 5 (bottom).

i) Power ON (reset) When the power is turned ON. even there are items left to display.STRUCTURE. a If the engine is started during the flow for this display. the display will switch after several seconds to iii) Normal operation display. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) Payload meter has the following basic functions. all functions are checked and displayed. HD605-7 10-157 (10) . HD465-7.

warning generated N N FLOAT FLOAT o RAISE o LOWER o FLOAT Shift lever position N Except N N Except N N Except N Except N Dump lever position FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT Payload meter display Mass display (*1) Time display Mass display Mass display Mass display Travel distance displayed in units of m from 0 – 160 m (each 5 m) after completion. before reaching 50% of correct mass During loading. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) Normal operation display Condition of the machine Stopped Empty Traveling During loading. (*3) The aggregate mass display is shown in units of 100 t. display shows 0 t. HD605-7 . see v) Content of memory (1). The applicable lamp flashes to prevent overload. after reaching 50% of correct mass Stopped Traveling Stopped Traveling Traveling Loaded Stopped When dumping (*2) Abnormality. These data are retained even when the power is turned OFF. see the Operation and Maintenance Manual) See the Normal operation display. changes to time display Mass display Aggregate mass display (*3) (Error code displayed in order of priority) External display lamps Mass display OFF Mass display and estimated display OFF Mass display and estimated display OFF OFF Mass display OFF See Operation and Maintenance Manual — — (*1) When load is less than 50% of correct mass. iv) External display lamp drive (estimated display) The chart on the right shows the mass display level for the external display lamps during the normal operation display. (*2) For details of conditions taken as dumping. The estimated display shows the estimation of the total mass when one more load is added. iii) Normal operation display (for details. 10-158 (10) HD465-7.STRUCTURE. (Rounded to the nearest 100) ii) Measuring empty mass (calibration) The mass of the machine when empty is measured and this is used as the calibration data.

HD465-7.0 0-4.0 0-4. a The cycle data are recorded when the dumping conditions are fulfilled (see right).5 0-99 0-99 0-6553. HD605-7 10-159 (10) .5 0-25.5 0-99 Displays set value at time of dumping V V V V V V Times Times 0-4.5 0-6553. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) V) Content of memory (for details.0 0-4.5 0-6553. a The maximum limit for cycle data in memory is 2900 cycles.0 0-4.5 0-6553. see Operation and Maintenance Manual) a) Cycle data a The period between one dumping operation and the next dumping operation is taken as one cycle and the data are recorded.5 0-99 0-99 0-6553.0 0-255 0-255 Data processing on PC Data inside cycle are handled separately as spare signal input data.0 0-4. Item Engine operation number Month Day Time Hour Time Minute Machine ID Open ID Load mass Empty travel time Empty travel distance Empty max.5 0-25.5 0-25.STRUCTURE. travel speed Loaded average travel speed Loaded stopped time Dumping time Limit speed Warning items/cycle Analog spare 1 MAX electric potential MIN electric potential Average electric potential Analog spare 2 MAX electric potential MIN electric potential Average electric potential Digital spare 1 Lo frequency Digital spare 2 Lo frequency Unit Integer Month Day Hour Minute Integer Integer t (Metric ton) or US ton (Short ton) min km km/h km/h min min min km km/h km/h min min km/h Range 1-65535 1-12 1-31 Displayed as 0-23 Displays value and set value at time of 0-59 dumping 0-200 0-200 0-6553. travel speed Empty average travel speed Empty stopped time Loading stopped time Loaded travel time Loaded travel distance Loaded max.

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) b) Engine ON/OFF data a Each time the engine was stopped and started is recorded. Item Engine operation number Year (last 2 digits) Month Day Time Hour Time Minute Year (last 2 digits) Month Day Time Hour Time Minute Aggregate load mass Total number of cycles Unit Integer Year Month Day Hour Minute Year Month Day Hour Minute t (Metric ton) or US ton (Short ton) Times Range 1-65535 Consecutive number for operation of engine 0-99 1-12 1-31 Shows when engine was switched ON Displayed as 0-23 0-59 0-99 1-12 1-31 Shows when engine was switched OFF Displayed as 0-23 0-59 0-9999000 0-9999 Total value between engine ON and engine OFF c) Abnormality. warning data a Each time a payload meter abnormality or warning is generated or cancelled is recorded. HD605-7 .STRUCTURE. a The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets. a The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets Item Unit Range 0-65535 1-255 Engine operation number when According to 5 error code was generated Integer Frequency of generation Times after engine is switched ON Year (last 2 digits) Month Day Time Hour Time Minute Engine operation number when cancelled Year (last 2 digits) Month Day Time Hour Time Minute Year Month Day Hour (0 – 23) Minute Integer 0-99 1-12 Shows when error code was generated 1-31 Displayed as 0-23 0-59 0-65535 Year Month Day Hour (0 – 23) Minute 0-99 1-12 Shows when error code was cancelled 1-31 Displayed as 0-23 0-59 10-160 (10) HD465-7.

(For details. a The calculation is started again for both values when the data for aggregate load mass and total number of cycles are cleared. see software manual. total number of cycles a It is possible to calculate and record again from any desired time the aggregate load mass and total number of cycles for each time that the dumping conditions are fulfilled. HD605-7 10-161 (10) .) HD465-7.STRUCTURE. Item Aggregate load mass Total number of cycles Year (last 2 digits) Month Day Time Hour Time Minute Unit t (Metric ton) or US ton (Short ton) Times Year Month Day Hour Minute Range 0-999900.0 t (Metric ton) or US ton (Short ton) and 9999 cycles respectively. a The maximum limit in memory for aggregate load mass and total number of cycles is 999900.0 0-9999 Shows aggregate from time when data were cleared 0-99 1-12 1-31 Shows date and time when data were cleared Displayed as 0-23 0-59 e) Other data Content Operator check mode set data Item Machine ID Open ID Limit speed Option code Year (last 2 digits) Month Day Time Hour Time Minute Data 1 Data 2 Data 3 Data 4 Unit Integer Integer km/h Integer Year Month Day Hour Minute Range 0-200 0-200 0-99 0-11 0-99 1-12 1-31 Displayed as 0-23 0-59 20 Characters 20 Characters 20 Characters 20 Characters Operator check mode set in input operation Calibration performance data Date and time when calibration was performed User write data Comments that can be written freely into payload meter. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) d) Data for aggregate load mass. Note: Input and settings are possible only from PC through cable communications.

5 0-6553.5 0-6553.99999 0-9. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) f) Calibration data a These are saved in RAM each time calibration is performed.99999 0-9.5 –9.7500 –1.5 0-6553.99 0-9.99999 0-6553.5 0.5 0-6553.5 0-6553. a The maximum limit in memory for calibration data is 15 sets. Item Year Month Day Time Hour Time Minute Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear) Tilt angle Front wheel tilt compensation factor Rear wheel tilt compensation factor Front wheel link factor Rear wheel link factor Mass on spring (empty) (Calibration value) Trimmer gain value Load mass Backup battery voltage Unit Year (last 2 digits) Month Day Hour Minute x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton) x 180 rad Integer Integer Integer Integer t (Metric ton) Integer t (Metric ton) V Range 00-99 1-12 1-31 0-23 0-59 0-6553.99999 0-6553.99999 0-9.5 0-25.5 0-6553.2500 0-6553.5 0-6553.5 0-6553.5 The above data items a) – g) are retained even when the power is switched OFF.STRUCTURE.99 – +9. HD605-7 .99 – +9.5 –9.99999 0-9.5 0-6553. 10-162 (10) HD465-7. a The maximum limit in memory for load mass calculation data is 180 sets.5 0-6553.99999 0-9.5 Shows values and settings when calibration was performed Shows values before compensation factor was calculated x 180 rad Front wheel tilt compensation factor Integer Rear wheel tilt compensation factor Integer Integer Front wheel link factor Integer Rear wheel link factor t (Metric ton) Mass on spring (empty) g) Load mass calculation data (analog data) a These are saved in RAM when the load mass calculation data are required.99999 0-9. Item Year Month Day Time Hour Time Minute Model selection code Suspension pressure (front left) Suspension pressure (front right) Suspension pressure (rear left) Suspension pressure (rear right) Mass on spring (front) Mass on spring (rear) Tilt angle Unit Year (last 2 digits) Month Day Hour Minute Integer x 98 kPa x 98 kPa x 98 kPa x 98 kPa t (Metric ton) t (Metric ton) Range 00-99 1-12 1-31 0-23 0-59 0-F 0-6553.99 0-9.

when the latest calibration was carried out. x) Service check mode By operating the switches of payload meter . vii) Operator check mode By operating the switch of payload meter . a) Memory card dump b) Data all clear c) Abnormality. check the time and date. c) Memory card dump (service area) This writes all the data displayed for Items 66 and 6-7 to the memory card inserted in the machine. warning exists/cancelled. a) Detailed calibration data display The display shows the date. ix) Downloading saved data It is possible to download any data recorded in payload meter to a PC through a cable (ANSI/ E1A RS-232C). a Before clearing the data. Always carry out the operation with the machine unloaded. 5 switch on the left side of the controller (memory card use switches) is set for "Use" d) Data all clear (service area) This forcibly deletes all the calibration data and analog data. etc.STRUCTURE. it is possible to carry out forcible display of these items. HD605-7 10-163 (10) . setting. total number of cycles Forced display of existing abnormalities and warnings By operating the TOTAL/SFT switch of payload meter II. and correction of the following items. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) vi) Forced display of aggregate load mass. a This function is available only when the No. For details. e) Input signal condition display This displays some of the signal conditions for the sensors input to payload meter and the present recognition condition of the payload meter. Do not carry out the operation unless necessary. For details. always download the data to a PC or carry out a) Card dump. Available range for setting: –9 – +9 (%) HD465-7. see the Operation and Maintenance Manual. input signal condition display d) Machine ID setting e) Open ID setting f) Limit speed setting g) Option code setting h) Time. For details. f) Forced initialization This forcibly deletes all the data in payload meter . b) Detailed load mass calculation data display (analog data) The display shows the suspension pressure and machine angle used when calculating the present load mass. except for the latest calibration data. suspension pressure. date correction viii) Dimming of display portion It is possible to adjust the brightness of the payload meter II display portion to 10 levels with the LIGHT/INC switch. it is possible to carry out the following items. see the PC software manual provided by Komatsu. g) Extra load mass setting when loading The extra load can be forcibly input or corrected to set the load mass when loading. it is possible to forcibly carry out display. see the Operation and Maintenance Manual. a Before carrying out this operation.

STRUCTURE.000 [ x 1 100 t] 10-164 (10) HD465-7. it is possible to input and correct to set the display for the load mass when loading is completed (when loading at least 50% of set load mass and traveling 160 m and starting to dump). 01. HD605-7 .000 – 2. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) h) Load mass fixed display and cycle data recording.480 [ x 100 t] HD405-6 HD465-7 HD605-7 HD785-5 HD985-3 690 – 1. load mass value setting (1) Load mass fixed display When displaying the load mass in the range shown in the table below. Possible set range: 0 – 255 (m) Loading start recognition load mass setting This is used to input and correct the values to set the load mass recognized as the start of loading by payload meter .690 [ x 1 100 j) t] 1. not the real-time load mass. 10. 10 Possible set value table Display 00 01 10 Load mass fixed display Yes Yes No Recorded load mass value Load mass fixed display value Value when dumping load Value when dumping load i) Loading completion recognition travel distance setting This is used to input and correct the values to set the travel distance recognized as completion of loading by payload meter . Setting TALKS not set (option codes 0 – 3. 11 set) When there is permission to start TALKS set option codes 4 – 9 set Range The time that machine is stopped when loading at least 50% of set load mass and traveling 160 m and starting to dump The time that machine is stopped from permission to move off to starting to dump The time that machine is stopped from disconnection of line to starting to dump Payload fixed display Load mass when stopped in previous cycle Load mass last displayed in previous cycle (Final radio transmission value) Load mass last displayed in previous cycle When disconnection of line from payload meter is requested (2) Switching load mass fixed display in cycle data recording If the load mass fixed display in Item (1) above is applicable. Possible set range: 00. it is possible to input and correct the data to set the load mass inside the cycle data in Item 6-1 to the fixed display load mass value. Possible set range: HD325-6 1 480 – 1.

HD465-7.STRUCTURE. on the HD1200-1. but in this case. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) k) Zero ton display range setting This is used to input and correct the values to set the range of the zero display on the load mass display. c) and d) are actuated on the HD1200-1 when the parking brake is ON or when the brake lock is ON. Possible set range: 5 – 10 [%: ratio of correct load mass] l) External display lamp display range setting This is used to input and correct the values to set the lamp display load mass range when displaying the load mass. set the parking brake to ON or the brake lock to ON. see the software manual. the payload meter will return to the normal operation display. set the shift lever to the N position and the dump lever to FLOAT. f) is actuated only when the power is ON. and on machines other than the HD1200-1. Possible set range: Lamp 1 (green) Lamp 2 (yellow) Lamp 3 (red) A : 510 – 255 B : A – 255 C : B – 255 The set value is displayed as a proportion (%) of the correct load mass. If they are operated to other positions. (1) Method of operation ALways actuate the service check mode Note. a When the service mode is working. t Of the service check mode functions. • Calibration data • Load mass calculation data (analog data) For details. the data set and input in the service check mode may not be processed correctly. the following functions can be downloaded to a PC using the PC downloading software provided by Komatsu. HD605-7 10-165 (10) . and on machines other than the HD1200-1 when the shift lever is at the N position and when the dump lever is at FLOAT.

HD605-7 . FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) 10-166 (6) HD465-7.STRUCTURE.

If MODE switch (2) is pressed at any time during the display in Steps 1.XXX Spring-up mass calculated All displayed values are rounded to 16 according to calibration the value given. and repeats sequence Same number of digits as 9. CALO flashes 17 Returns to 1. and 10.XX Angle of tilt when CAL was 11 x 180 rad carried out 12 13 14 15 Front axle tilt coefficient Rear axle tilt coefficient Front axle link coefficient Rear axle link coefficient X.STRUCTURE. Set to CHEC display.X Appears when value is negative O (–) X. (End) From CALO flashing 1 2 3 4 5 6 7 8 9 10 Last 2 digits of year for date when CAL was carried out Month and day for date when CAL was carried out Hour and minute for date when CAL was carried out Model selection switch (decimal value) when CAL was carried out Remarks x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left) x 98kPa P'RR (Rear right) t t Mass on front axle x 2 (P'FL+P'RL)) (= – DF – 4 Mass on rear axle x 2 (= – DR – (P'RL+P'RR)) 4 Suspension pressure less than 100 x 98 kPa: XX. the display will return to CHEC. 3. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (a) Operation for calibration data display 1. or 2. HD465-7.. then press CAL/CLE switch (1) for at least 2 seconds. Every time the CAL/CLE switch (1) is pressed.X Less than 100 t: XX.X More than 100 x 98 kPa: XXX.X More than 100 t: XXX. HD605-7 10-167 (10) . Display: CALO 2. the display changes in the order shown on the right.

X Appears when value is negative Remarks 8 x 180 O (–) X.X More than 100 x 98 kPa: XXX. Display: ALLO (when data in memory is less than 170 cycles) A. (End) From ALLO flashing or A. the display will return to CHEC. If MODE switch (2) is pressed at any time during the display in Steps 1.XXX Suspension pressure less than 100 x 98 kPa: XX.FUL (when data in memory is more than 180 cycles) 2. o Gain trimmer Same as 7..XX 9 10 11 12 13 14 15 16 10-168 (10) HD465-7. the display changes in the order shown on the right. or 2. and 8. X. then press LIGHT/INC switch (1) for at least 2 seconds.X More than 100 x 98 kPa: XXX. X.FUL (when data in memory is more than 170 cycles) A. HD605-7 . FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (b) Operation for payload calculation data (analog data) display 1.X Same as 7. and 8.FUL flashing 1 2 3 4 5 6 7 Hour. 3. minute x 98kPa P'FL (Front left) x 98kPa P'FR (Front right) x 98kPa P'RL (Rear left) x 98kPa P'RR (Rear right) t t Mass on front axle x 2 (= – D– (P'FL+P'RL)) 4 F Mass on rear axle x 2 (= – D– (P'RL+P'RR)) 4 R Angle of tilt when CAL was rad carried out Front axle tilt coefficient Rear axle tilt coefficient Front axle link coefficient Rear axle link coefficient t — t V Spring-up mass calculated according to calibration GT Present load mass Backup battery Voltage 17 ALLO flashing Returns to (1) and repeats sequence All displayed values are rounded to the value given. Set to CHEC display.X Suspension pressure less than 100 x 98 kPa: XX.STRUCTURE. Every time the LIGHT/INC switch (1) is pressed.

press MODE switch (2). FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (c) Operation for memory card dump (service area) (d) Operation for data all clear (service area) 1. 1. Press CAL/CLE switch (2). then press LIGHT/INC switch (1) and CAL/CLEswitch (2) at the same time for at least 2 seconds.CLE (lighted up). HD465-7. presss MODE witch (3). 5 switch (memory card use switch) on the left side of the controller is set to "Use". it will return automatically to the CHEC display. Set to CHEC display. Set to CHEC display. it will return automatically to the CHEC display. (End) If it is desired to stop the data all clear operation when the display is A : CLE. The main display will go out and memory card access lamp (3) will light up. and the display will return to CHEC without performing the data all clear operation. The memory card dump function can be used only when the No. When the memory card dump operation is completed. a Before clearing the data. and the display will return to CHEC without performing the memory card dump operation. The display will become A. HD605-7 10-169 (10) .STRUCTURE. (End) If it is desired to stop the memory card dump operation when the display is Cd : dP. Display: A : CLE 2. download the necessary data to a PC or carry out the card dump operation in Item (c). then press TOTAL/SFT switch (1) Display: Cd : dP 2. and when the data all clear operation is completed. Press TOTAL/SFT switch (1) again.

Display: S : CHE 2. Input signal (V) O (2-f) Analog spare input 2 signal condition Display: C6:XX (lights up for 3 seconds) X.... Set to CHEC display. FLOAT:C2 : oo Except FLOAT:C2 : — — O (2-c) Engine oil pressure signal condition Display: C3:XX (lights up for 3 seconds) Engine running:C3 : oo Engine stopped:C3 : — — O O (2-h) Digital spare input 2 signal condition Display: C8 : XX (lights up for 3 seconds) X. then press TOTAL/SFT switch (1) and CAL/CLR switch (2) at the same time for at least 2 seconds. O Go to next page 10-170 (10) HD465-7. Same as C5 O (2-g) Digital spare input 1 signal condition Display: C7:XX (lights up for 3 seconds) Hi:C7 : oo Lo: C7 : — — 1.. the display changes in the order shown below. Every time CAL/CLR switch (1) is pressed. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (e) Operation for input signal condition display (2-d) Battery charge signal condition Display: C4:XX (lights up for 3 seconds) Engine running: C4 : oo Engine stopped: C4 : — — O (2-e) Analog spare input 1 signal condition Display: C5:XX (lights up for 3 seconds) X. Travel speed (km/h) O (2-j) Travel distance display Travel distance with machine in present condition (empty or loaded) for that cycle XXXX ..STRUCTURE... brake lock switch signal condition [HD1200-1] Display: C1:XX (lights up for 3 seconds) Either one ON:CL : oo Both OFF:CL : — — O (2-a’) Shift lever position signal condition [except HD1200-1] Display: C1: XX (lights up for 3 seconds) "N":CL : oo Except "N":CL : — — O (2-b) Dump lever position signal condition Display: C2:XX (lights up for 3 seconds) F.. Same as C7 O (2-i) Travel speed display Display: C9 : XX X.. (2-a) Parking brake. the display starts again from 0.X . HD605-7 ... (m) * If the value goes above 9999m..X ..X ...X .

3..... then press CAL/CLR switche (11)........ 02... or 2... and the display will return to CHEC without performing the forced initialization operation.... it carries out the process from 10........ 04....04 Loaded stopped... the display will return to CHEC..CAL. The display becomes : (lighted up) (2 seconds).STRUCTURE.05 Dumping ...... * The value for the present machine recognition condition increases in minutes in real time.... 06...06 Invariable May change according to N signal when dumping O (2-l) Machine condition time display shown below 1......... and when all the data is completely cleared. If it is desired to stop the forced initialization operation when the display is : ..01 Empty traveling... the display advances one place in order from a) to f).. HD605-7 10-171 (10) . Press CAL/CLR switch (1) for at least 2 seconds.... TOTAL/SFT switch (2) and LIGHT/ INC switch (3) at the same time for at least 2 seconds... Set to CHEC display. 05.... (End) After that........ it automatically displays F...... If MODE switch (3) is pressed at any time during the display in Steps 1...03 Loaded traveling . a b c d e f Empty traveling Empty stopped Loaded traveling Loaded stopped Dumping Loading S1 : S2 : S3 : S4 : S5 : S6 : 2. Display: : Every time CAL/CLR switch (1) is pressed. 01....02 Loading. press MODE switch (4)..3.... (End) HD465-7.. 03.. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) ( f ) Operation for performing forced initialization From previous page O (2-k) Payload meter present recognition display Counter display Empty stopped .........

STRUCTURE.5EL 2. (End) 1. HD605-7 . When the correction operation is completed. press MODE switch (4) at any time to return to the CHEC display. then press TOTAL/SFT switch (1) and LIGHT/INC switch (2) at the same time for at least 2 seconds. Display: S. 3. press LIGHT/INC switch (2) and correct. (End) 10-172 (10) HD465-7. Set to CHEC display. press LIGHT/INC switch (2) and correct. press MODE switch (1) at any time to return to the CHEC display. Set to UP : XX display. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (g) Operation for setting extra load mass when loading (h) Operation for setting load mass fixed display and cycle data record value 1. then press CAL/CLR switch (4) Display: PL : XX (present set value) If it is necessary to correct the setting. When the correction operation from Step 1. Press CAL/CLR switch (3). Display UP : XX present set value:for + : X for – : – X If it is necessary to correct the setting. is completed.

If CAL/CLR switch (4) is pressed again. 5. When the correction operation from Step 1. 3. press MODE switch (1) at any time to return to the CHEC display. Press CAL/CLR switch (4) again. then press CAL/CLRswitch (4) Display: P. Press CAL/CLR switch (4). Display: XXXX If it is necessary to correct the setting for the thousands. HD605-7 10-173 (10) . is completed. press LIGHT/INC switch (2) and correct.STRUCTURE. Press CAL/CLR switch (4).SEL 2. press LIGHT/INC switch (2) and correct. Display: XXX If it is necessary to correct the setting for the tens. then press CAL/CLR switch (4) Display: O. (End) If it is impossible to set the input values even when MODE switch (1) is pressed.SEL 2. the display will return to Step 3.SEL display. 4. so it is possible to correct the units again. is completed. the display will return to XXX. HD465-7. 4. press LIGHT/INC switch (2) and correct. Display: XXXX If it is necessary to correct the setting for the hundreds. Display: XXX If it is necessary to correct the setting for the units. pressMODE switch (1) at any time to return to the CHEC display after displaying O. press LIGHT/INC switch (2) and correct. press LIGHT/INC switch (2) and correct. Set to PL : XX display. (End) If it is impossible to set the input values even when MODE switch (1) is pressed. it displays O. so it is possible to correct again.. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) ( i) Operation for setting loading completion recognition travel distance ( j ) Operation for setting loading start recognition load mass 1. 1. Display: XXX If it is necessary to correct the setting for the hundreds. 6. Press TOTAL/SFT switch (2). 6. it returns to Step 1.XXX (input value) and returns to Step 2. Press TOTAL/SFT switch (3). Set to O.XXX (input value). Display: XXXX If it is necessary to correct the setting for the tens. 5. press LIGHT/INC switch (2) and correct. If CAL/CLR switch (4) is pressed again. Press CAL/CLR switch (4) again. 3. When the correction operation from Step 1.

press LIGHT/INC switch (2) and correct.SEL display. (End) 10-174 (10) HD465-7. When the correction operation from Step 1. HD605-7 .SEL 2. Display: – – XX (present value) If it is necessary to correct the setting. press MODE switch (1) at any time to return to the CHEC display. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) (k) Operation for setting 0 ton display range 1. Press TOTAL/SFT switch (3). Set to P. then press CAL/CLR switch (4) Display: H.STRUCTURE. 3. is completed.

press LIGHT/INC switch (2) and correct. press LIGHT/INC switch (2) and correct.SEL 2. (End) If it is impossible to set the input values even when MODE switch (1) is pressed. then press CAL/CLR switch (4) Display: E. press MODE switch (1) at any time to return to the CHEC display.SEL display.XXX (present value of lamp 2) If it is necessary to correct the display range for lamp 2. 7. Display: C. 5.XXX (present value of lamp 4) If it is necessary to correct the display range for lamp 4. it displays d. Press CAL/CLR switch (4) again.STRUCTURE. Press TOTAL/SFT switch (3). Press CAL/CLR switch (4).XXX (present value of lamp 1) If it is necessary to correct the display range for lamp 1. HD465-7.FAL (input value) and returns to Step 2. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) ( l) Operation for setting display range of external display lamps 6.XXX (present value of lamp 5) If it is necessary to correct the display range for lamp 5. Set to H. press LIGHT/INC switch (2) and correct. Press CAL/CLR switch (4) again. 3. is completed. 1. press LIGHT/INC switch (2) and correct. When the correction operation from Step 1. Display: d. Display: E. HD605-7 10-175 (10) . Press CAL/CLR switch (4) again. press LIGHT/INC switch (2) and correct. Display: b. Display: A.XXX (present value of lamp 3) If it is necessary to correct the display range for lamp 3. 4.

The output characteristics of the sensor are as shown in the diagram on the right. the action of valve core (3) prevents the suspension pressure from going down. Connector 10-178 (6) HD465-7. be careful not to let valve (2) rotate. Tube 3. When replacing pressure sensor (1). leave the valve (2) installed to the suspension and remove only pressure sensor (1). Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom. Voltage between pin (1) (GND) and pin (3) (output) of each pressure sensor connector or voltage of output (pins (4). (6). Sensor 2. When removing pressure sensor (1). (7)) of each sensor when pin (3) of payload meter controller connector (PM6) is grounded Pressure sensor 1. (5). FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) 2. HD605-7 . When removing or installing pressure sensor (1).STRUCTURE.

HD605-7 10-179 . the clinometer measures the tilt angle of the chassis in the front-to-rear direction. HD465-7. Lamp drive relay The external display lamps are driven by a signal from the payload meter. Clinometer To carry out compensation on slopes. ! Voltage between clinometer connector pin 1 " # (GND) and pin 2 (output) or voltage of out.# # put (pin (8)) of clinometer when pin (3) of # # payload meter controller connector (PH6 # $ pin) is grounded % 4. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) 3.STRUCTURE. The output characteristics of the clinometer are as shown in the diagram on the right.

disconnection in front right suspension pressure sensor system Short circuit with ground. Self-diagnostic function The controller always observes the condition of the sensors and outputs. it displays an error message.7 V See (*1) F-09 flashes — 4 See (*1) — 5 Disconnection in terminal R Abnormality in sensor power source (18 V) Output below 2 V when engine is running Output is less than 15 V and power source voltage is more than 20 V Suspension pressure sensor input signal is 0 kg/cm2 or below F-18 flashes All flash When removed When removed When engine is running Any time 6 F-20 flashes All flash 7 Short circuit with ground. number of cycles data memory FULL — Cd flashes — When removed When removed See (*1) 3 Defective contact or voltage below 2. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) 5. Error message display Order of display priority 1 Content Dump lever at position other than FLOAT (except when dumping) Judgement standard — Error code display Controller display b-FL ON External lamp display All flash Cancellation of display When removed Timing for display [for HD1200-1] When parking brake or brake lock is ON [for HD1200-1] When parking brake or brake lock is OFF Removal detection only for card dump Except during loading Except during loading b-FL ON — When removed 2 Memory card removed Drop in backup battery voltage Cycle data memory FULL Engine ON/OFF data memory FULL Abnormality. and if any abnormality occurs. disconnection in rear left suspension pressure sensor system Short circuit with ground. disconnection in rear right suspension pressure sensor system F-21 flashes All flash When removed Any time 8 F-22 flashes 9 F-23 flashes 10 F-24 flashes 10-180 HD465-7. HD605-7 . disconnection in front left suspension pressure sensor system Short circuit with ground.STRUCTURE. warning data memory FULL Aggregate payload.

6 V — — Records (000-009) Records (000-011) (000-012) (000-013) (000-014) Records (000-018) Records (000-020) — Calibration cannot be performed when there is abnormality Calibration cannot be performed when there is abnormality Records (000-021) (000-022) (000-023) (000-024) HD465-7.STRUCTURE. warning data (PC software display code) — Remarks Display timing for other than HD1200-1: Shift lever position N Display timing for other than HD1200-1: Shift lever position other than N Detected only when performing card dump Rated voltage: 3. HD605-7 10-181 . FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) Saving abnormality.

relay coil short circuits with power source F-31 flashes All flash When removed Any time 16 F-32 flashes 17 F • CAL flashes F-41 flashes F-42 flashes F-43 flashes F-44 flashes F-45 flashes All flash When removed When removed Any time 18 19 20 21 22 23 See Remarks column Except when loading (for external display lamps. 4 relay Short circuit in external display lamp No.6 MPa {200 kg/cm2} or more Error code display Controller display F-25 flashes External lamp display All flash Cancellation of display When removed Timing for display Any time 12 F-26 flashes 13 F-27 flashes 14 F-28 flashes 15 Clinometer input signal above +100 Clinometer input signal above – 100 EG Calibration data in memory damaged When coil is conducting electricity. 1 relay Short circuit in external display lamp No. 2 relay Short circuit in external display lamp No.bad flashes SP:SP flashes F-71 F-73 F-80 F-81 F-91 F-92 F-93 F-94 F-95 F-96 F-97 F-98 F-99 — Start of empty travel Set value – 2km/h When removed Start of dumping start of empty travel When problem occurs — 24 Travel speed is over set speed limit — 25 Defective communications or defective setting of option code — 10-182 HD465-7. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) Order of display priority 11 Content Short circuit with power source in front left suspension pressure sensor system Short circuit with power source in front right suspension pressure sensor system Short circuit with power source in rear left suspension pressure sensor system Short circuit with power source in rear right suspension pressure sensor system Short circuit with ground. HD605-7 . 5 relay Defective cycle data payload (*2) Over speed limit Judgement standard Suspension pressure sensor input signal is 19. disconnection in clinometer system Short circuit with power source in clinometer system Calibration not performed or abnormality in RAM Short circuit in external display lamp No. 3 relay Short circuit in external display lamp No.STRUCTURE. see Remarks column) See (*2) L.

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE) Saving abnormality. warning data (PC software display code) Records (000-025) Remarks Calibration cannot be performed when there is abnormality (000-026) (000-027) (000-028) Records (000-031) (000-032) Applicable only when clinometer "use" switch is at "use" Calibration cannot be performed when there is abnormality Payload calculation stopped while problem occurs External display lamps actuated as follows Applicable lamp Machine stopped: Always ON Machine traveling: OFF Other lamps during loading: Specified actuation Other than loading Machine stopped: Flashes Machine traveling: OFF Records (000-019) Records (000-041) (000-042) (000-043) (000-044) (000-045) — — Records (000-071) (000-073) (000-080) (000-081) (000-091) (000-092) (000-093) (000-094) (000-095) (000-096) (000-097) (000-098) (000-099) — HD465-7. HD605-7 10-183 .STRUCTURE.

Flow switch 4. Demand valve Outline If the engine should stop when the machie is traveling. thereby making it possible to use the steering.: 7001 – 7059 1. Emergency steering pump 6.: 7001 – 7151 HD605-7 Serial No. Timer 2. 10-184 (12) HD465-7. Emergency steering motor 5. Batter 3. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM AUTOMATIC EMERGENCY STEERING SYSTEM HD465-7 Serial No. HD605-7 . This system can also be operated manually.STRUCTURE. the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering. or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit.

Magnet 4. HD605-7 10-185 .STRUCTURE. Spring 7. the flow switch detects this and actuates the lead switch. If the flow of oil inside the hydraulic piping drops below the specified level or stops. Wire cable 2. Lead switch Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. Pivot pin 5. HD465-7. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM FLOW SWITCH 1. Disc 6. Housing 3.

When this happens. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM Operation • When oil flow is above specified level Plate (5) is pushed in the direction of the oil flow a by the oil in the piping. When this pushing force overcomes spring (6). the contact with the lead switch is closed and the circuit is switched ON. the contact with the lead switch is opened and the circuit is switched OFF. • When oil flow is below specified level or stops. HD605-7 . The force of the oil in the piping pushing plate (5) is weaker than spring (6). When this happens. so magnet (3) returns to the left.STRUCTURE. magnet (3) is moved to the right (pivot pin (4) is taken as the center of rotation). 10-186 HD465-7.

the relay points are switched after electric current is passed through the coil for the time set by the timer. Dial 2. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM RELAY TIMER 1. HD605-7 10-187 (9) .STRUCTURE. HD465-7. With this relay timer. Pin Set time: 1 seconds Outline The relay timer is a delay timer to prevent the emergency steering system from being actuated when the flow switch is acuated mistakenly by the pulse of the oil or fluttering of the flow switch. Lock 3.

: 7152 and up HD605-7 Serial No. Batter 3. thereby making it possible to use the steering. or there is any abnormality in the hydraulic pump and the specified amount of oil does not flow to the steering circuit. This system can also be operated manually. Steering oil pressure switch 4. Timer 2.: 7060 and up 1. HD605-7 . the emergency system automatically actuates an electric pump to ensure the hydraulic pressure for the steering. Emergency steering motor 5.STRUCTURE. 10-187-1 (12) HD465-7. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM HD465-7 Serial No. Emergency steering pump 6. Demand valve Outline If the engine should stop when the machie is traveling.

If the flow of oil inside the hydraulic piping drops below the specified level or stops. Disc 6.STRUCTURE. the flow switch detects this and actuates the lead switch. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM FLOW SWITCH 1. Spring 7. Magnet 4. Wire cable 2. Housing 3. Pivot pin 5. HD465-7. Lead switch Outline The flow switch is a switch for the auto emergency steering and is installed in the piping of the steering hydraulic circuit. HD605-7 10-187-2 (12) .

the contact with the lead switch is closed and the circuit is switched ON. so magnet (3) returns to the left. the contact with the lead switch is opened and the circuit is switched OFF. 10-187-3 (12) HD465-7. When this happens. The force of the oil in the piping pushing plate (5) is weaker than spring (6). When this happens. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM Operation • When oil flow is above specified level Plate (5) is pushed in the direction of the oil flow a by the oil in the piping. HD605-7 .STRUCTURE. • When oil flow is below specified level or stops. When this pushing force overcomes spring (6). magnet (3) is moved to the right (pivot pin (4) is taken as the center of rotation).

After the current flows in the coil for the time set by the timer. Pin Set time: 1 seconds Outline The relay timer is a delay timer to prevent emergency steering system from malfunctioning. HD605-7 10-187-4 (12) . Dial 2.STRUCTURE. Lock 3. HD465-7. the relay contacts are switched. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC EMERGENCY STEERING SYSTEM RELAY TIMER 1.

Dump control lever 2. Suspension cylinder 4. Solenoid valve 5. see SUSPENSION 10-188 (6) HD465-7. Hydraulic cylinder Outline The front suspension mode (damper force) is automatically switched according to the travel condition and load condition to give a more comfortable ride to the operator and to improve the travel stability. Retarder controller 3. For details of the internal mechanism of the suspension. HD605-7 . FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM AUTOMATIC SUSPENSION SYSTEM 1.STRUCTURE.

(No control when traveling empty) (Brake (Brake ON) OFF) (Brake (Brake ON) OFF) Anti-lift (Float) (Other than Float) (Float) (Other than Flot) High speed stability HD465-7. S:Soft M:Medium H:Heard Set mode Control pattern Function Content of control S Distinguishing empty/loaded Anti-roll To set damping force according to load on machine To prevent the chassis from rolling when turning at high speed Internal pressure of front suspension cylinder is measured and compared with standard valve This detects the travel speed and steering angle. Detects travel speed and selects damping force. In this case. select the machine model HD605 by the switch for the transmission control system. the increased load on the springs will affect the loaded/unloaded judgement in the table below. When a liner has been installed to the body for HD465 to make it equivalent to the rock body.STRUCTURE. The damping force is made stronger when the dump body control lever is at any position except FLOAT. (Not controlled when traveling empty) Empty M H S Loaded M H (When turning) Anti-dive To prevent nose-diving when braking To prevent the front from lifting up when dumping To improve stability when traveling at high speed The damping force is made stronger when the brakes are applied. HD605-7 10-189 (10) . FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM AUTOMATIC SUSPENSION MODE SELECTION CONTROL With the front suspension. The control patterns and functions of the modes (damping force) are as shown in the table below. and switches the mode according to certain conditions. the mode (damping force) is automatically changed according to the travel conditions and load conditions to ensure a comfortable ride and to improve the travel stability of the machine.

Connector 2. Medium and Hard. Two solenoid valves are combined to select three modes of Soft. HD605-7 . The valve switches oil pressure of the hydraulic cylinder which is installed to the front suspension. 10-190 (6) HD465-7. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM AUTO SUSPENSION SOLENOID VALVE 1. according to signal from the retarder controller. Solenoid A : To hydraulic cylinder head B : To hydraulic cylinder bottom P : From pump T : To transmission oil pan Function • The automatic suspension solenoid valve is installed in the circuit between the hydraulic pump and the suspension cylinder.STRUCTURE.

The suspension controller can obtain the steering speed from the number of pulses per time. If pressure is applied through the pressure receiving part to the diaphragm of the pressure sensing unit. The change of the resistance of the strain gauges is sent as a change of the voltage to the amplifier. Sensor 2. A bridge of strain gauges is formed in front of the diaphragm so that the resistance of the strain gauges will change when the diaphragm is deformed. Tube 3. Connector Principle of operation: Magnetic contactless proximity switch Form of output: Turning ON when object of sensing approaches. HD605-7 10-191 (10) . the diaphragm is deformed. FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM STEERING ANGLE SENSOR (If equipped) 1. Tube 3. HD465-7. As this disc passes through the slit in the sensor. PRESSURE SENSOR 1. A constant voltage is applied to the strain gauges.STRUCTURE. The amplifier amplifies the change of the voltage and outputs it to the controller. Connector Function • The pressure sensor is installed to the suspension cylinder. the sensor outputs a pulse signal. Function • A round disc with teeth like a comb is installed to the steering column. Body 2.

STRUCTURE. HD605-7 . FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM RETARDER CONTROL SYSTEM 10-192 (6) HD465-7.

braking. etc. Automatic retarder speed control (ARSC) This device controls retarder braking force by movement of electromagnetic proportional control valve to maintain the machine speed set by the automatic retarder machine speed setting switch when driving down hills. Automatic Suspension Control The controller switches output to the automatic suspension solenoid valve according to the travel conditions and loading conditions such as unloading or loading. 4. retarder control when there is transmission abuse The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount. Overrun prevention. Self-diagnostic display window Rotary switch Motherboard Case Connector 4. 1. 5. and the controller switches damping force of front suspension in three stages of Soft. 2. Hoist control This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) according to the position of the dump control lever and actuates the dump body.STRUCTURE. HD605-7 10-193 (10) . HD465-7. 6. The brake torque is transmitted to the lower speed wheel by braking the higher speed slipping wheel. Outline The retarder controller has the following functions. 2. turning. Medium and Hard. Retarder control The electromagnetic proportional valve is controlled according to the operating angle of the retarder control lever and actuates the retarder. 5. 3. ASR Control (if equipped) The controller detects slips of the drive wheels according to machine speed and steering angle of the right and left drive wheels. so the traveling ability is improved. according to the signal sent from various sensors. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM RETARDER CONTROLLER 1. and the controller controls the ASR proportional valve so that the speed difference between the both wheels become constant. 3.

2) The overrun prevention. Transmission of network data 1) Retarder actuation. accumulator oil pressure drop warning. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM 7. 10-194 (6) HD465-7. parking brake actuation.STRUCTURE. float caution. 3) The reverse inhibit. HD605-7 . and other data are transmitted to the transmission controller. retarder command when there is abuse. and other data sent from the transmission controller are received. and other data are transmitted to the monitor panel.

FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM CN1 Pin No. steering angle potentio power +5V A_OUT_4A. 5B– Retarder lever. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 D_OUT_1 D_OUT_3 D_OUT_5 D_OUT_6L D_OUT_7L D_OUT_9 Specification D_OUT_0 D_OUT_2 D_OUT_4 D_OUT_6H D_OUT_7H D_OUT_8 Signal name Automatic suspension solenoid 1 Automatic suspension solenoid 2 Function H side (1A) H side (1A) H side (1A) 24V/L side 24V/L side Remarks AUTO SUS SOL A AUTO SUS SOL B Push button retarder switch Battery direct Power GND Power supply +24V Front brake cut solenoid Kick out solenoid Hoist changeover valve Brake cut relay output Sensor power supply Body float signal Power GND Power supply +24V L side (150mA) Battery direct IN GND Power supply +24V H side (1A) H side (1A) H side (1A) H side/GND H side/GND L side (150mA) GND Power supply +24V P/B RETARD SW (FOR E/G Controller) FRONT BRAKE CUT SOLENOID KICK OUT SOLENOID DUMP CHANGE CONTROL VALVE BRAKE CUT RELAY SENSOR POWER BODY FLOAT SIG (FOR PLM) CN2 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 A_OUT_0– A_OUT_1– A_OUT_2– A_OUT_3– A_OUT_5A. steering speed sensor power +12V A_OUT_4A+ A_OUT_4B+ A_OUT_5A+ A_OUT_5B+ V_OUT A_OUT_0+ A_OUT_1+ A_OUT_2+ A_OUT_3+ V_OUT Power supply +24V Rear wheel retarder EPC output EPC output for ASR (left rear wheel) EPC output for ASR (right rear wheel) Hoist EPC valve Specification Signal name Solenoid power supply +24V Shut off valve — — — Function Solenoid power supply 0 – 1A 0 – 1A 0 – 1A 0 – 1A Interlocked with A_OUT0 (0 – 5V) 0 – 1A 0 – 1A 0 – 1A 0 – 1A Interlocked with A_OUT1 (0 – 5V) Solenoid power supply A_OUT4AB (COM) Sensor power supply A_OUT5AB (COM) Sensor power supply +5V (400mA) A_OUT0 (COM) A_OUT1 (COM) A_OUT2 (COM) A_OUT3 (COM) Power GND Remarks SHUT OFF VALVE (+) (FOR ASR) — — — RETARD BRAKE VALVE (L) (+) (MANU AND AUTO) RL BRAKE VALVE (+) (FOR ASR) RR BRAKE VALVE (+) (FOR ASR) DUMP CONTROL PCV (+) Shut off valve (–) (option) (option) RETARD BRAKE VALVE (–) RL BRAKE VALVE (–) (OPTION) RR BRAKE VALVE (–) (OPTION) DUMP CONTROL VALVE (–) HD465-7. HD605-7 10-195 (6) . 4B– Suspress.STRUCTURE.

7K) Pull up (4. body potentio ARSC set switch power +5V Steering angle potentiometer — Accumulator oil pressure sensor (front) Potentio power +5V (20mA) A_IN0 (+) A_IN1 (+) Pull down/(up) S/T ANGLE POTENTIO (+) (FOR ASR) — ACC OLL PRESS (FRONT) ACC OLL PRESS (REAR) — S/T SPEED SENSOR (FOR AUTO SUS) T/M OUTPUT SPEED (+) Specification D_IN PLS_AC_IN_0 PLS_AC_IN_1 PWM_IN Signal name Function Connector check 0 (pull up) Remarks CONNECTOR CHECK 1 WHEEL SPEED (RL) (FOR ASR) WHEEL SPEED (RR) (FOR ASR) Wheel speed sensor (left rear wheel) — Wheel speed sensor (right rear wheel) — Accumulator oil pressure sensor (rear) Pull down/(up) — Steering angle speed Transmission output shaft speed sensor Speed GND Pull up/down4 — — GND 10-196 (6) HD465-7.7K) Pull up (4. HD605-7 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 A_IN_0(–) A_IN_1(–) A_IN_4 A_IN_5 A_IN_6 A_IN_7 A_IN_8 A_IN_9 A_IN_10 A_IN_11 A_IN_12 A_IN_13 A_IN_14 A_IN_15 A_IN_16 A_IN_17 A_IN_18 A_IN_19 A_IN_20 A_IN_21 Accelerator signal Hoist lever potentiometer 1 Body potentio Hoist lever potentiometer 2 ARSC set switch Manual retarder lever signal — Suspension pressure sensor (left front wheel) Suspension pressure sensor (right front wheel) — — Retarder oil temperature sensor — PWM_OUT Analog sensor GND GND(Analog) A_IN0 (–) A_IN1 (–) Pull down/(up) Pull down/(up) Pull down Pull up (1K) Pull up (4.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM CN3 Pin No.7K) Pull up (150) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull up (4.7K) Pull down Pull down Pull down Pull down Pull down Pull down ACCEL SIGNAL (T/M) (FOR ARSC/ASR) DUMP LEVER POTENTIO1 BODY POSITION SENSOR DUMP LEVER POTENTIO2 ASRC SET SW (FOR ARSC) MANUAL RETARD LEVER — SUS PRESS (FL) SUS PRESS (FR) — — RETARD OIL TEMP — S/T ANGLE POTENTIO (–) A_IN_0 A_IN_1 A_IN_2 A_IN_3 A_IN_35 PLS_AC_IN_2 PLS_AC_IN_3 Hoist lever.

HD605-7 10-197 (6) .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM CN4 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Specification Signal name RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX (–) Flash switch (ON/OFF) RS422 RX (–) GND (serial) RS485 (–) S-NET (+) Function RS422 TX (+) RS422 RX (+) RS232C TXD RS232C RXD RS485 (+) S-NET (+) RS422 TX (–) Flash switch (ON/OFF) RS422 RX (–) GND (serial) RS485 (–) S-NET (+) Remarks HD465-7.

STRUCTURE. HD605-7 . EMERG BRAKE PRESS SW LEVER VALIDATION SW 1 LEVER VALIDATION SW 2 SYSTEM FILTER RETARD COOLING FILTER — — INCLINATION SW — — — — MEMORY CLEAR SW KEY SW (E/G START SIGNAL) COMMAND FROM ABS — — BRAKE WEAR RL BRAKE WEAR RR EXHAUST BRAKE COMMAND (FROM T/M) OVERRUN COMMAND (FROM T/M) RL BRAKE PRESS SW (FOR ASR) RR BRAKE PRESS SW (FOR ASR) — — — — — — — — — 10-198 (9) HD465-7. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM CN5 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 D_IN_0 D_IN_1 D_IN_2 D_IN_3 D_IN_4 D_IN_5 D_IN_6 D_IN_7 D_IN_8 D_IN_9 D_IN_10 D_IN_11 D_IN_12 D_IN_13 D_IN_14 D_IN_15 D_IN_16 D_IN_17 D_IN_18 D_IN_19 D_IN_20 D_IN_21 D_IN_22 D_IN_23 D_IN_24 D_IN_25 D_IN_26 D_IN_27 D_IN_28 D_IN_29 D_IN_30 D_IN_31 D_IN_32 D_IN_33 D_IN_34 Service brake switch Retarder switch Parking brake switch Lever validation 1 switch Lever validation 2 switch — Retarder cooling filter switch — — Inclination switch — — — — Memory clear switch Engine starting signal ABS signal — — Brake wear sensor (left rear wheel) Brake wear sensor (right rear wheel) Exhaust brake command (from transmission controller) Overrun prevention command (from transmission controller) ASR actuating pressure switch (left rear wheel) ASR actuating pressure switch (right rear wheel) — — — — — — — — — Specification Signal name Function Connector check 1 (to GND) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (5mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull up (8mA) Pull down Pull down Pull down Pull down/potentio power +5V Pull up/down 1 Pull up/down 1 Pull up/down 1 Pull up/down 1 Pull up/down 2 Pull up/down 2 Pull up/down 2 Pull up/down 2 Pull up/down 3 Pull up/down 3 Pull up/down 3 Pull up/down 3 Pull up/down 4 Pull up/down 4 Pull up/down 4 Remarks CONNECTOR CHECK 2 SERVICE BRAKE PRESS SW RETARD BRAKE PRESS SW P/B.

retarder control when there is transmission abuse • The electromagnetic proportional valve is controlled based on the command (ON/OFF command) from the transmission controller and actuates the retarder by a fixed amount. HD605-7 10-199 (6) . FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM RETARDER CONTROL FUNCTION RETARDER CONTROL SYSTEM DIAGRAM Retarder lever control • The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this is output to the electromagnetic proportional valve to actuate the retarder. Overrun prevention.STRUCTURE. HD465-7.

10-200 (10) HD465-7. the output is proportional to the angle of the lever. D: To make the opening of the hydraulic pressure smooth in the low pressure range. HD605-7 . C: In the range where the retarder is normally used. the output is set to a high value. the output is set to a low value.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM Relationship between retarder lever potentiometer and output to electromagnetic proportional valve A: To improve the initial response of the electromagnetic proportional reducing valve. B: To make the actuation of the hydraulic pressure smooth in the low pressure range. the output (trigger output) is set to a high value.

OFF. and when the top of the dump body reaches the set position of the body position sensor. HOLD. the area of opening of the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the dump body comes into contact with the chassis. HD465-7. If the engine is not started.STRUCTURE. it becomes possible to carry out normal operations. the RAISE output continues to be given. regardless of the position of the lever. 2. 10-201 (6) . Lever positioner function The dump control lever has four positions: RAISE. 3. Engine started: Immediately after the engine is started. Control when starting switch is turned to ON. If the dump control lever is operated to the RAISE position. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM HOIST CONTROL FUNCTION HOIST CONTROL SYSTEM DIAGRAM 1. the lever is returned to the HOLD position. After the lever is moved to the HOLD position. the condition remains at HOLD. If the lever is kept at the RAISE position. and LOWER. regardless of the position of the lever. HD605-7 4. the output is set to HOLD. Body seating speed control When the dump body is lowered and reaches the position just before it is seated. or START Starting switch at ON: The output is set to HOLD. even if the hoist lever is operated. Hoist control function When the engine is running. the dump body is raised. Starting switch at OFF: The dump body is held in position regardless of the position of the lever. the EPC and valve (electromagnetic proportional valve) and selector valve are controlled according to the operation of the dump control lever and operate the dump body. FLOAT.

Keep the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds. Repeat this operation 10 times. then lower the dump body completely. 4) Run the engine at low idling and operate RAISE o FLOAT with the dump body raised to the maximum height. HD605-7 . "FLOAT OUTPUT" and "SEATED" o Reverse travel permitted "NO FLOAT OUTPUT" or "NOT SEATED" o Reverse travel not permitted 6. Calibration function To absorb any inherent error in the dump body potentiometer. then lower the dump body completely. Reverse inhibit function The retarder controller judges if it is permissible to travel in reverse or not. 5) Run the engine at high idling and operate RAISE o FLOAT with the dump body raised to the maximum height. Repeat this operation 10 times. and transmits the result of the judgment through the network to the transmission controller. 3) Lower the body to the seat. (Check that the float caution has gone out. and then keep the lever at the FLOAT position for at least 5 seconds. Order of dump control calibration (hydraulic oil temperature: 80 – 90°C) 1) Lower the dump body completely. and keep the lever at FLOAT for at least 5 seconds. After adjusting the installation of the body potentiometer or after replacing the retarder controller. carry out calibration in the following order. calibration is carried out to recognize the dump body seating and the body cylinder stopper condition. FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM 5.) 2) Operate the lever to the RAISE position until and raise the dump body until it contacts the stopper. 10-202 (10) HD465-7.STRUCTURE. run the engine.

Connector Function • The engine speed sensor is installed to the ring gear of the flywheel housing. HD605-7 . SWITCHES SENSORS. FUNCTION AND MAINTENANCE STANDARD SENSORS. It uses the rotation of the gear teeth to generate a pulse voltage and transmits a signal to the transmission controller.STRUCTURE. SWITCHES ENGINE SPEED SENSOR 1. Magnet 2. Wiring harness 4. 10-204 (6) HD465-7. Locknut 3.

When the accelerator pedal is depressed.STRUCTURE. A fixed voltage is impressed between the No. 6 pin) is connected to the ground. SWITCHES ACCELERATOR SENSOR 1. HD465-7. HD605-7 10-205 (6) . 2 pin to the engine and transmission controllers. the movement rotates the shaft of the potentiometer inside the accelerator sensors. A voltage signal corresponding to the angle of the accelerator pedal is sent from the No. As a result. the resistance changes. The accelerator pedal has two accelerator sensors for engine controller and transmission controller. signal 2 (No. Pedal Outline Accelerator signal • This is installed under the operator's cab. Connector 2. Connector 3. 1 – 3 pins of both potentiometers. The engine controller then detects the condition. FUNCTION AND MAINTENANCE STANDARD SENSORS. When the accelerator pedal is released. when the accelerator pedal is depressed. signal 3 (No. Idling validation signal • This is installed under the operator's cab. 5 pin) is connected to the ground.

The maintenance caution lamp lights up and the character display shows message to warn of abnormality. COOLANT LEVEL SENSOR 1. 10-206 (10) HD465-7. 2. The signal is sent from the retarder controller through the network to the machine monitor panel to display the temperature level. HD605-7 . It take the change in resistance of the thermistor as the change in the temperature and transmit a signal to the retarder controller. and when the coolant level goes below the specified level. the lamp lights up and the buzzer sounds to warn of an abnormality. Float 2. When the display on the monitor panel reaches the specified position. Sensor 3.STRUCTURE. SWITCHES RETARDER OIL TEMPERATURE SENSOR 1. Thermistor Plug Wiring harness Connector Function • The sensor is installed to the retarder piping. FUNCTION AND MAINTENANCE STANDARD SENSORS. the float goes down and the switch goes OFF. 3. Connector Function • This sensor is installed to the top of the radiator. 4.

If the oil pressure in the steering circuit lowers below the set level while the engine is running. Switch 4. HD465-7. and when the filter becomes clogged. Tube 3. Connector Function • The steering pressure switch is installed to the steering and hoist piping. Connector A : Low pressure pickup port B : High pressure pickup port Function • This sensor are installed to each filter. Piston 2. SWITCHES TRANSMISSION OIL FILTER CLOGGING SENSOR 1.STRUCTURE. and the difference in pressure between the low-pressure side and high-pressure side reaches the specified pressure.8 kg/cm2} Principle of switch: Pressure difference sliding piston type STEERING OIL PRESSURE SWITCH (FOR AUTOMATIC EMERGENCY STEERING SYSTEM) 1. Actuating pressure: 275 kPa {2. the switch goes OFF. the steering pressure switch starts the electric pump to secure the oil pressure for steering. The maintenance caution lamp lights up and the character display shown message to warn of abnormality. Body 3. Body 2. FUNCTION AND MAINTENANCE STANDARD SENSORS. HD605-7 10-207 (12) .

Connector 2. This sends a signal to the monitor panel to indicate the remaining fuel level. Arm 4. a warning lamp flashes. SWITCHES FUEL LEVEL SENSOR 1. Spacer Function • The fuel sensor is installed to the side face of the fuel tank.STRUCTURE. Contact 7. 10-208 (6) HD465-7. This movement of the float is transmitted by the arm and actuates a variable resistance. Float 3. When the display of the monitor panel reaches a certain level. Body 5. The float moves up and down according to the fuel level. HD605-7 . FUNCTION AND MAINTENANCE STANDARD SENSORS. Spring 6.

HD605-7 10-209 (6) . Indicator 2. the maintenance caution lamp lights up and character display shows message to warn of the abnormality. FUNCTION AND MAINTENANCE STANDARD SENSORS. SWITCHES AIR CLEANER CLOGGING SENSOR 1. Adapter Function • The air cleaner clogging sensor is installed to the outward port of the air cleaner. HD465-7.STRUCTURE. If the air cleaner becomes clogged and reaches the set pressure (negative pressure). Spring 3.

Connector Function • The body position sensor is installed to the rear of the chassis. Bearing 2. SWITCHES BODY POSITIONER SENSOR 1. When the angle of the dump body changes. FUNCTION AND MAINTENANCE STANDARD SENSORS. the shaft receives sliding resistance through the link installed to the dump body. HD605-7 .STRUCTURE. and the dump body angle is detected. Rotor 3. 10-210 (6) HD465-7.

SWITCHES TILT SWITCH 1. If the dump lever is operated to the RAISE position in this condition. Connector Function • If the chassis tilts to the left or right. Plate 3. Plate 7. the disc magnet moves to the left or right. HD465-7. Print card 5.STRUCTURE. Gasket 4. Magnet 2. either the left or right switch is turned OFF. Plate 9. Bracket 6. If the chassis tilts into the roll-over danger range. the lamp lights up and the buzzer sounds to warn of the danger. Plate 8. FUNCTION AND MAINTENANCE STANDARD SENSORS. HD605-7 10-211 (6) .

HD605-7 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD DUMP LEVER DUMP LEVER 10-212 (10) HD465-7.

Rod 19. Bushing 9. Potentiometer 17. Rod 3. Detent spring 13. Body 7. HD605-7 10-213 (10) . Spring 4. Ball 15. Solenoid 10. Seat 16. Rod 12. Spring 5. Retainer 14. Lever 2. FUNCTION AND MAINTENANCE STANDARD DUMP LEVER 1. Detent spring HD465-7. Rod 20. Body 8.STRUCTURE. Retainer 6. Nut 11. Lever 18.

Ball (14) is moved to the small diameter side of protrusion b of rod (19) by retainer (13) that is being held by detent spring (20). (Before start of actuation of mechanical detent) • When rods (2) and (11) are pushed in further. so the lever is held at the FLOAT position. and this is sent as a signal voltage to the controller. Operation 1. rod (18) on the opposite side is pushed up by spring (4). rod (18) is held in position by the pushing force of the ball and protrusion b of rod (19). Dump lever operated to FLOAT • When LOWER rod (2) is pushed by lever (1) and moves down. FUNCTION AND MAINTENANCE STANDARD DUMP LEVER Function • When lever (1) is operated. • When this happens. rod (18) moves up or down according to the amount the lever is operated. • Even if the lever is released. 10-214 (10) HD465-7. HD605-7 . • The amount the control lever is operated (travels) is detected by the potentiometer. and rotates potentiometer (16). • One potentiometer is installed and outputs two related signal voltages as shown in the "Output voltage characteristics" graph. While pushing retainer (13) up. ball (14) contacts protrusion a of rod (11) during the stroke. ball (14) is being held by detent spring (12). and rod (11) passes over protrusion a.STRUCTURE. it escapes to the outside.

Dump lever operated to RAISE • When RAISE rod (18) is pushed by lever (1) and moves down. (Before start of actuation of mechanical detent) • When rods (18) and (19) are pushed in further. • When an electric current is flowing to solenoid (19). are interconnected. ball (14) contacts protrusion a of rod (19) during the stroke. so even if the lever is released. if rod (2) is pushed up. rod (2) is held at the pushed up position. nut (10) is held in contact with bushing (8). ball (14) is being held by detent spring (20). While pushing retainer (13) up. 5. and rod (19) passes over protrusion a. FUNCTION AND MAINTENANCE STANDARD DUMP LEVER 2. • Rod (18) is pushed up by the spring (4) in accordance with the amount lever (1) is operated. and ball (14). • As a result. the RAISE position is canceled and the lever returns to the N position. Dump lever operated to LOWER • When lever (1) is operated further from the FLOAT position. HD605-7 10-215 (10) .STRUCTURE. it moves to the LOWER position. so a voltage matching the up or down movement of the rod is output from potentiometer (16). 3. when the solenoid power source is turned OFF. it is pushed down by a force greater than the holding force of rod (19). Dump lever RAISE canceled • When lever (1) is returned from the RAISE position. • When this happens. Or. it is pushed down by a force greater than the attraction force of the solenoid. • Lever (17) and rod (19). rod (2) on the opposite side is pushed up by spring (4). detent spring (20). which are installed to the rotating shaft of potentiometer (16). Dump lever FLOAT canceled • When lever (1) is returned from the FLOAT position. 4. it escapes to the outside. retainer (13). HD465-7. it is held at the RAISE position.

Voltage of power supply : DC20V . method of sending and receiving data. and the procedure for the initial setup.5V (engine stopped) or more 3. It also gives commands for transmitting the accumulated data through the communications satellite. HD605-7 . Size (mm) : W272 x D169 x H72 Function The VHMS controller collects and stores signals from each sensor and signals from the machine controller. 10-216 (10) HD465-7. Voltage of power supply : DC5V 2. Size: Mount (portion a) : R 1/4 : Outside diameter of seat receiving pressure : 37 mm : Length of cable: 1. outlines.STRUCTURE. Specifications 1.110 mm Function The blow-by sensor converts the pressure inside the engine crankcase into a voltage and inputs this into the VHMS controller as the blow-by pressure.DC30V 2. see TESTING AND ADJUSTING. Output voltage : 0. BLOW-BY PRESSURE SENSOR Specifications 1. FUNCTION AND MAINTENANCE STANDARD VHMS CONTROLLER BLOW-BY PRESSURE SENSOR VHMS CONTROLLER For details of the basic precautions.

It inputs the change in temperature to the VHMS controller as a change in the resistance of the thermistor.STRUCTURE. outside diameter of mount R 1/4 Function The engine oil temperature sensor is installed to the engine oil filter.5 mW 4.Resis. Temperature range : --30 to 140 °C 6.20 8.28 17.9 MPa {50 kg/cm2} 5.27 24.Tempera.992 1.769 a : Heat sensing portion of sensor.571 5. Pressure resistance : 4. Type of sensor : Thermistor 2. HD465-7. power consumption: 0. FUNCTION AND MAINTENANCE STANDARD ENGINE OIL TEMPERATURE SENSOR ENGINE OIL TEMPERATURE SENSOR Specifications 1.293 3.Resisture tance ture tance ture tance (°C) (kz) (°C) (kz) (°C) (kz) 30 40 50 60 70 35. Max.884 80 85 90 95 100 6.887 2.750 110 115 120 125 130 2.682 4. HD605-7 10-217 (10) .544 2.Tempera. Range of measurement : 40 – 130 °C : 80 – 130 °C (guaranteed precision ± 2 °C) 3.Resis.248 1.931 4. Performance table Tempera.05 12.

Retention temperature range: --30 to 140°C 5. Rated voltage : DC24V 2. HD605-7 . Electricity consumption 2. Consumption current : Max. Detected temperature range (surrounding) : --30 to 120°C 4. Performance table below Detection temperature (°C) Resistance (kz) --20 --10 0 10 20 50 30. outside diameter of mount R 1/8 b : Amp c : Connector (power source end) d : Connector (sensor end) Output voltage characteristics (ambient temperature: 20 °C) ••• Reference value Detection temperature (°C) Output voltage (V) 50 100 400 700 800 1. It is installed to the turbocharger inlet port and outputs the exhaust temperature data to the VHMS controller.58 11.5 mW : 0.623 5.000 °C : 300 – 800 °C (guaranteed accuracy ± 10 °C) 3. Output voltage characteristics: See table below 4.899 4.397 2.626 3. 10-218 (10) HD465-7.316 Function The exhaust temperature sensor is a thermoelectric type temperature sensor.5 Function The ambient temperature sensor inputs the ambient temperature to the VHMS controller as a change in the resistance of the thermistor.74 7. 30 mA a : Heat sensing portion of sensor. FUNCTION AND MAINTENANCE STANDARD EXHAUST TEMPERATURE SENSOR/AMP AMBIENT TEMPERATURE SENSOR EXHAUST TEMPERATURE SENSOR/AMP Specifications 1.STRUCTURE.98 MPa {10 kg/cm2} 3. Pressure resistance : Max. diameter of mount 16 x 1. Detection temperature range : 100 – 1.191 1.077 1. Actuation temperature range : --40 to 110 °C 5. 0. AMBIENT TEMPERATURE SENSOR Specifications 1.32 18.712 a : Heat sensing portion of sensor.

HD605-7 10-219 (6) . Connector portion CN1A (ORB-A) : AMP070-14 CN1B (ORB-B) : AMP070-10 CN2 : Communications antenna cable connector ANTENNA Specifications 1. Size : W306 x D152 x H52 (mm) Installation location Install under assistant's seat. Input terminal : M-P type 4. Length : 165 ± 20 mm a : Communications antenna mount Installation location Install pole at right front of machine and set antenna on top of it. FUNCTION AND MAINTENANCE STANDARD COMMUNIVSTIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA COMMUNICATIONS (ORB• • • ORBCOMM) CONTROLLER/ANTENNA CONTROLLER Specifications 1. Power supply voltage : DC12V – DC30V 2. Function The antenna transmits the data collected and accumulated by the VHMS controller through the communications satellite to the computer center. Impedance : 50 Ω 3.STRUCTURE. HD465-7. Type : Helical whip antenna (1) 2.

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER PAYLOAD METER (HAVING VHMS) SYSTEM CONFIGURATION 10-220 (6) HD465-7.STRUCTURE. HD605-7 .

The measurement of the load mass is obtained by calculating the difference between the mass when empty and the mass when full. It displays. by using rotary switch 2 of the transmission controller and VHMS initial setting tool. (2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area (New method). sets. the download software for Payload meter (card type) set for HD465/ 605-5 can be used as it is. can be saved in the internal memory and downloaded with special software (if equipped). FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER Outline • A dump truck is supported by 4 suspension cylinders. see TESTING AND ADJUSTING. HD605-7 10-221 (10) . (1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). The hauled load mass can be input by the following alternative 2 methods. As the special software. For setting procedure. including the load mass of each transportation cycle. and operates various items through the machine monitor and network. Payload meter (card type) set for HD465/6055 can be installed for a user who needs a memory card. If it is installed. the new total load mass is estimated and the appropriate lamp flashes. This prevents overloading. "Initial Setting of Payload Meter". • The payload meter (having VHMS) cannot be installed to a dump truck which is not equipped with the VHMS controller or which is equipped with the VHMS controller and payload meter (card type). however. the necessary items of the VHMS controller must be set again. • The operation data. By measuring the total of the loads on each cylinder. have the machine monitor and VHMS controller recognize that it will execute the functions of the payload meter. It also has an estimation display function: when loading the next load. When the payload meter is installed for the first time or the VHMS controller is replaced. it is possible to know the mass on the springs of the dump truck. and "Replacing Parts". The VHMS controller executes the functions of the payload meter and saves the data of each transportation cycle. Payload meter displays the load mass calculated as above on the monitor screen and displays the load level on the outside indicator lamps. • HD465-7.STRUCTURE.

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER ELECTRIC CIRCUIT DIAGRAM See TROUBLESHOOTING. Troubleshooting of VHMS controller system (VHMS mode). a Travel signal sensor: Transmission output shaft speed sensor 10-222 (10) HD465-7. When loading for this purpose. and release the retarder brake and foot brake on a ground where the longitudinal inclination of the dump truck is ± 5° and the lateral inclination is ± 2°. Principle of measurement 1. 4. 3. HD605-7 . the measured mass is different from the mass measured on a level ground. (Correction range of inclination angle: ± 5°) 5. see Payload meter II (card type). Outline 2. To solve this problem.STRUCTURE. set the dump control lever in the "FLOAT" position. the longitudinal inclination of the dump truck is measured and the measured mass is corrected according to the inclination angle. Correction on slope If the dump truck is loaded on a slope. Measurement of mass when empty (Calibration) • For measurement of mass when empty. turn the parking brake ON. Sensing of distance and travel speed The distance and travel speed are obtained from the signals of the travel signal sensor of the dump truck and the travel speed correction information. Measurement of mass when full Load the dump truck and measure the mass at that time. set the gearshift lever in the "N" position.

6. Items related to the payload meter are not displayed on the machine monitor. there are the menus related to the payload meter on the machine monitor. While the payload meter (having VHMS) is not set. (*2) See "TESTING AND ADJUSTING. the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. Wrong setting of the model and serial No. etc. Wrong setting of the model and serial No. HD465-7. with the VHMS initial setting tool. When there is not a problem in installation and wiring of the payload meter but there are the following problems. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER INITIAL SETTING OF PAYLOAD METER In the following cases. Adjusting transmission controller". When the payload meter (having VHMS) or payload meter II (card type) is installed for the first time 2. When the VHMS controller or transmission controller is replaced 4. perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to the following table. Wrong setting of the date and time with the VHMS initial setting tool.. with the VHMS initial setting tool. While the payload meter (having VHMS) is set. 10-223 (10) . Date and time of the downloaded data are wrong. The storage place of the data file made by the download software is not found. HD605-7 4. 5. When the payload meter (having VHMS) or payload meter II (card type) is removed 3. Wrong setting of the model. 1. and variation code with the VHMS initial setting tool. Setting up VHMS controller. "The payload is not displayed when the machine is loaded and stopped". serial No. Wrong setting of rotary switch 2 (SW2) of transmission controller 2.STRUCTURE. When setting of VHMS controller is changed Set position of rotary switch 2 (SW2) of transmission controller (*1) F B 9 B F – – HD465 or HD605 –7 Setting with VHMS initial setting tool (*2) Date Time Time difference Summer time – Setting of payload meter VHMS controller PLM-II (card type) Model Serial No. Data cannot be downloaded. Variation code Payload meter function is not installed Payload meter function is installed VHMS PLM PLM (Without VHMS) Not installed Installed Installed Installed Not installed Not installed Not installed Installed Installed – – – ST PV P2 – Payload meter function is installed Set properly – (*1) See "TESTING AND ADJUSTING. check the above setting again. "There are not the manus related to the payload meter on the match marks". 1. Wrong setting of rotary switch 2 (SW2) of transmission controller 3.

2. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER BASIC FUNCTIONS OF PAYLOAD METER For details. This function is used to change that amount. 4. 1) Save the load mass when the dump lever is moved from the FLOAT position to another position in a dump area (This method is set when shipped). 7. verify the machine condition thoroughly when changing. Setting of criterion of maximum travel speed This function is used to set a criterion of the maximum travel speed for the machine control system. then correct the relation table of the suspension pressure and load mass forcibly with the measured masses and this function. the red lamp cannot warn of overloading. 10-224 (10) HD465-7. Since an easy change can cause wrong recognition of loading. 8. This function is used to change the travel distance to recognize completion of loading when the distance between the loading area and dump area is very short. measure the operating mass (when the truck is empty) and gross truck mass (when the truck is loaded with the rated load mass) with the user's load meter. If it is changed. Setting of indication range of outside indicator lamp This function is used to change the indication range of the outside indicator lamp. 2) Input and save the hauled load mass by statistically processing the data sampled during the travel from the loading area to the dump area. Correction of calculation of load mass If the load mass indicated by the payload meter is different from that indicated by the user's load meter. Correction of level of inclination sensor This function is used to correct the level of the inclination sensor. Setting of travel distance to recognize completion of loading When the dump truck travels 160 m from the loading area. the payload meter judges that the loading operation is finished. see Operation and Maintenance Manual.STRUCTURE. VARIOUS SETTING FUNCTIONS (SERVICE FUNCTIONS) 1. Setting of OFFSET range This function is used to adjust the calculated load mass by a set amount. the payload meter does not judge that the dump truck is unloaded and the cycle data is not completed at this time. 5. 6. The condition for turning on the red lamp cannot be changed. If the dump truck is unloaded before it travels 160 m. HD605-7 . Setting of load mass to recognize start of loading The payload meter recognizes that loading is completed when the load mass changes by certain amount. 3. Selection of method of entering saved load mass This function is used to select either of the following methods of entering the hauled load mass.

HD465-7. see TESTING AND ADJUSTING. For method of selection. "Special functions of machine monitor (EMMS)".STRUCTURE. HD605-7 10-225 (10) . FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER OPERATING METHOD Select "PLM" in Service Mode 1 on the machine monitor.

The unit is indicated in the ( ) on the right side of WEIGHT. Accordingly. "LOADED WEIGHT" is displayed when the menu is selected. The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. secure a road for this purpose. The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment. Accordingly.STRUCTURE. 1) Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper. Setting of travel distance to recognize completion of loading Input a travel distance to recognize completion of loading by pressing the following buttons. the system may recognize that loading is completed while the dump truck is still being loaded. • [ ] button: Enter the selection. execute the following procedure securely. • [<] button: Number at cursor moves backward. • [>] button: Number at cursor moves forward. • [ ] button: Enter number at cursor. perform the following procedure very carefully. • [>]. If the set value is too small. • [ ] button: Stop inputting number.158 miles). It does not always heighten the absolute accuracy. HD605-7 . i) Select "EMPTY WEIGHT". This function is used to match the calculation result to the indication of the load meter to be used.) 2) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. • [ ] button: Return to the previous screen. [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". Correction of calculation of payload Since this function affects the accuracy directly. Check the unit of the input value. The setting range is 0 – 255 m (0. 2.0 – 0. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER 1. (METRIC): metric ton (SHORT): short ton 10-226 (6) HD465-7. etc. If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes.

6 [t] (Operating weight ± 13%) (metric ton) HD605-7: 46. HD465-7. • [ ] button: Enter. HD605-7 10-227 (6) . • [ • [>] • • • • button: Number at cursor moves forward. [<] button: Number at cursor moves backward. press this button and start driving the dump truck. • [ ] button: Return to the screen for inputting values. [ ] button: Return to the largest position of the number to input the value again.8 [t] (Operating weight ± 13%) (metric ton) ] button: After getting ready for drive. • [ ] button: Return to the previous screen. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER ii) Check that measurement of the weight of the empty dump truck has been completed. • [<] button: Select "NO". iv) Check the input value. Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight.STRUCTURE. If this button is pressed again. Inputtable range HD465-7: 43. • [ • [>] button: Select "YES". ] button: Check that measurement has been completed and go to the next step. v) Move the dump truck to a place where you can drive it for about 3 minutes. [ ] button: Enter number at cursor. inputting of the value is stopped and the previous screen appears. iii) Input the measured weight of the empty dump truck.

"LOADED WEIGHT" is displayed when the menu is selected. If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes. • [ ] button: Enter the selection. • [ ] button: Return to the previous screen. When measurement is finished. i) Select "LOADED WEIGHT". see the steps up to the above step. ] button: Return to the previous screen.) 5) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes. 4) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper. the next screen appears automatically. go out of "Service mode 1" temporarily and return to "Display of load/integrated odometer". On this screen. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER vi) Display the progress of measurement. • [ • [>]. 3) Load the dump truck to measure the weight of the fully loaded dump truck. When indicating the current load for reference while the dump truck is being loaded. 10-228 (6) HD465-7. the number of [ ] increases. When loading is started. ] button: Return to the menu screen. ] button: Stop measurement and return to the previous screen. (METRIC): metric ton (SHORT): short ton ii) Check that measurement of the weight of the fully loaded dump truck has been completed. HD605-7 . [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". Check the unit of the input value. For the method of displaying the following screen. • [ • [ • [ ] button: Check that measurement has been completed and go to the next step.STRUCTURE. you can check the current load. The unit is indicated in the ( ) on the right side of WEIGHT. As measurement is executed. etc. the menu screen appears automatically.

• [>] ] button: After getting ready for drive. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER iii) Input the measured weight of the fully loaded dump truck. When measurement is finished. HD465-7. • [>] button: Select "NO". HD605-7 10-229 (6) . Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. v) Move the dump truck to a place where you can drive it for about 3 minutes. 9). press this button and start driving the dump truck.25) (metric ton) However. inputting of the value is stopped and the previous screen appears. A1 = {43.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 ± (A2 x 0. • [<] button: Number at cursor moves backward. • [ • [ ] button: Stop measurement and return to the previous screen. • [ ] button: Enter number at cursor. the number of [ ] increases. • [ ] button: Return to the screen for inputting values.8 [t] (Operating weight) + 63 [t] (Load capacity)} iv) Check the input value. • [ ] button: Return to the largest position of the number to input the value again. vi) Display the progress of measurement (Fig.STRUCTURE.25) (metric ton) However. If this button is pressed again. A2 = {46. Inputtable range HD465-7: A1 ± (A1 x 0. As measurement is executed. the next screen appears automatically. • [ ] button: Enter. button: Number at cursor moves forward. • [<] button: Select "YES".

The current standard level value is displayed on the upper line. the menu screen appears automatically. HD605-7 . If the load is dumped normally.STRUCTURE. Enter it when it is stabilized. • [ • [ • [ • [ ] button: Enter the flashing value. ii) Turn the dump truck 180 degrees (Stop it in the opposite direction). The current standard level value is displayed on the upper line. The clinometer value (F) at the current position flashes. • [ ] button: Return to the menu screen. ] button: Enter the flashing value. The clinometer value at the current position flashes. 3. Correction of level of inclination sensor 1) Move the dump truck to a level place. ] button: Return to the menu screen. 2) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. iii) Enter value of (R). If the load is dumped with the dump lever. i) Enter value of (F). ] button: Return to the menu screen. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER 6) Dump the load in the dump area. Enter it when it is stabilized. correction is finished. 10-230 (10) HD465-7.

Input a criterion of the maximum travel speed by pressing the following buttons. • [<] button: Number at cursor moves backward. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER iv) Enter the standard level value. 4. (Default: 99 km/h) HD465-7. Setting of criterion of maximum travel speed • [<] button: Select "YES".STRUCTURE. The setting range is 0 – 99 km/h (0 – 62 MPH). • [ ] button: Enter number at cursor. • [>] button: Number at cursor moves forward. • [ ] button: Stop inputting number. • [>] button: Select "NO". HD605-7 10-231 (6) . • [ ] button: Enter.

• [<] button: Number at cursor moves backward. start of loading may be recognized wrongly. 10-232 (6) HD465-7. • If the value is reduced. • [ ] button: Stop inputting number. Input an indication range of the outside indicator lamps by pressing the following buttons.5%.STRUCTURE. • [ ] button: Enter number at cursor. Setting of payload to recognize start of loading 6. • [>] button: Number at cursor moves forward. • [ ] button: Enter number at cursor. • [ ] button: Stop inputting number. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER 5. • [>] button: Number at cursor moves forward. The setting range is 0 – 130% of the load capacity. The setting range is 0 – 25. • If the value is increased and a loader having a small-capacity bucket is used. • [<] button: Number at cursor moves backward. HD605-7 . Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp). Setting of indication range of outside indicator lamps Input a payload to recognize start of loading by pressing the following buttons. the forecast function of the outside indicator lamps and the MMS communication may not operate normally. however.

• [>] button: Number at cursor moves forward. (METRIC): metric ton (SHORT): short ton • [>]. [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". • [ ] button: Stop inputting number. WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped.0 [t]. ii) Enter the selected method. WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. Selection of method of entering saved payload i) Select the method of entering the saved payload. HD465-7. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METEROR 7.0 – +5. • [>] button: Select "NO". Setting of OFFSET range 8. The unit is indicated in the ( ) on the right side of the input value [t].5. The setting range is . Check the unit of the input value on the previous menu screen. • [<] button: Number at cursor moves backward. Input an offset range by pressing the following buttons. • [ ] button: Enter the selected method. HD605-7 10-233 (6) . • [ ] button: Enter.STRUCTURE. • [ ] button: Return to the menu screen. • [ ] button: Enter number at cursor. • [<] button: Select "YES".

When removing pressure sensor (1).STRUCTURE. The output characteristics of the sensor are as shown in the diagram on the right. HD605-7 . Connector 10-234 (10) HD465-7. Sensor 2. be careful not to let valve (2) rotate. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER Pressure sensor The pressure sensor is installed at the bottom end of the suspension cylinder and acts to measure the pressure at the cylinder bottom. 1. the action of valve core (3) prevents the suspension pressure from going down. Tube 3. leave the valve installed to the suspension and remove only pressure sensor (1). When removing or installing pressure sensor (1). When replacing pressure sensor (1).

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER Clinometer To carry out compensation on slopes. HD605-7 10-235 (6) . the clinometer measures the tilt angle of the chassis in the front-torear direction. HD465-7. The output characteristics of the clinometer are as shown in the diagram on the right.STRUCTURE.

Upon receiving a request command. 2. automatic transmission. MMS communication If the mass of a bucketful is recognized. the data of the concerned cycle are transmitted automatically. HD605-7 . If the final load mass (hauled load mass of the concerned cycle) is entered. its value is transmitted automatically. the load mass at that time is transmitted automatically. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING The following 2 functions of communicating with external devices are installed. They use the RS232C communication port which is installed to download the data of the payload meter. 1. Automatic transmission When dumping is finished. and MMS communication. RS232C is used for only the selected one of data downloading. the load mass is transmitted in real time. The data saved in the payload meter can be made by accumulating the above cycle data with the system on the user side.STRUCTURE. • Specifications of RS232C connection Baud rate: 9600 bps Data length: 8 bits Stop bit: 2 bits Parity: Not applied Flow control: Not executed • Connection of RS232C (communication line) (3-wire method) • Selecting wiring harness for downloading/automatic transmission/MMS communication 10-236 (6) HD465-7.

1) If there is a code which is the same as STX or ETX in the data area of the communication frame. When one of 02h (STX).STRUCTURE. DLE (10h) is inserted just before that code. including inserted DLE. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER • Distinction of communication control codes The transmitting side transmits data as explained below so that the data in a communication from beginning with STX and finishing with EXT and BCC will have permeability. 03h (ETX). and 10h (DLE) is included in the data Original frame STX (02h) ••• STX (02h) ••• ETX (03h) BCC Transmitted frame STX (02h) ••• DLE (10h) STX (02h) ••• ETX (03h) BCC HD465-7. HD605-7 10-237 (6) . 3) Calculation of BCC XOR (Exclusive-or) is checked in order from STX at the head of the frame to ETX just before BCC. DLE (10h) is inserted just before that code. 2) If there is a code which is the same as DLE in the data area of the communication frame.

FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER • Automatic transmission (a) Timing of transmission The operation data of the concerned cycle are transmitted automatically when the concerned cycle data are entered (when dumping is finished).0 0 – 4. travel speed Loaded stoppage time Dumping time Limited speed Cycle warning code Unused Unused Unused Unused Unused Unused Unused Unused MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) MIN (10-time value) Time Time Unit ASCI1 Integer Month (BCD) Day (BCD) Hour (BCD) Minute (BCD) Integer Integer MIN (10-time value) km (10-time value) km/h km/h MIN (10-time value) MIN (10-time value) MIN (10-time value) km (10-time value) km/h km/h MIN (10-time value) MIN (10-time value) km/h 0 – 200 0 – 200 0 – 6553. (b) Contents of communication Format (VHMS controller External device) STX (02h) [1] ETX (03h) BCC [1]: Cycle data {39 bytes including header (ASCII L)} Item Header "L" Unused Month Day Time.5 0 – 25. the VHMS controller transmits up to 2 more times. If "NAK" is still returned.5 0 – 6553.0 0 – 4. travel speed Loaded ave.5 0 – 255 0 – 255 0 – 6553. the VHMS controller stops transmission.STRUCTURE.5 0 – 6553.5 0 – 99 0 – FFFF (HEX) 0 – 4.0 0 – 255 0 – 255 0 – 23 expression 1 – 65535 Range Number of byte 1 2 1 1 1 1 1 1 2 2 1 1 1 2 2 2 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) 0 (Fixed) Remarks L (Fixed) 0 (Fixed) Metric ton (10-time value) 0 – 6553.0 0 – 4.5 0 – 25. HD605-7 . 10-238 (6) HD465-7. travel speed Empty stoppage time Stoppage time for loading Loaded travel time Loaded travel distance Loaded max.0 0 – 4.5 0 – 255 0 – 255 0 – 6553.0 0 – 4.5 0 – 25.5 [BCC]: EX-OR of each bit from STX to ETX Answer (External device STX (02h) NAK (15h) VHMS controller) ETX (03h) BCC 31H (ASCII 1) Action that VHMS controller takes when answer is abnormal If "NAK" is returned. hour Time. minute Truck ID Open ID Load mass Empty travel time Empty travel distance Empty max. travel speed Empty ave.

HD605-7 10-239 (6) . and suspension pressure (a) Timing of transmission When mass of 1 bucketful is recognized. HD465-7. If an answer is still not returned. estimated load mass. [BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller) STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC or STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds. it transmits the unit distinction setting information automatically.STRUCTURE. the VHMS controller transmits up to 2 more times. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER • MMS communication Transmission of unit distinction setting (a) Timing of transmission After the VHMS controller is started by turning the key to the ON position. It is fixed to 02 (h) in the VHMS controller. Transmission of load mass. (b) Contents of communication Format (VHMS controller ) STX (02h) [1] [2] ETX (03h) BCC [1]: K (ASCII) fixed [2]: 02 (h) fixed (Unit classification [HEX]) The unit classification is the same as one used for PLM2. the VHMS controller stops transmission.

the VHMS controller transmits up to 2 more times.5 [10-time value] 0 – 6553.5 [10-time value] 0 – 6553.STRUCTURE. 1 decimal place) Order: Lower position upper position from the head byte of [2] [BCC]: EX-OR of each bit from STX to ETX Answer ( STX (02h) VHMS controller) ACK (06h) 31H (ASCII 1) ETX (03h) BCC or STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC 10-240 (6) HD465-7. 1 decimal place) [5]: Estimated load mass (C) [HEX] (2 BYTES) (Unit: Metric ton.5 [BCC]: EX-OR of each bit from STX to ETX Answer ( VHMS controller) STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC or STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds. Transmission of final load mass (a) Timing of transmission When the concerned cycle data are entered (When dumping is finished). 10-time value. 1 decimal place) [6]: (B) Calculated suspension pressure [HEX] [8 BYTES] From head Signal name P FL P FR P RL P RR Position (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) Name Front left suspension pressure (kg/cm2) Front right suspension pressure (kg/cm2) Rear left suspension pressure (kg/cm2) Rear right suspension pressure (kg/cm2) HEX [10-time value] 0 – 6553. 10-time value. (b) Contents of communication Format (VHMS controller) STX (02h) [1] [2] ETX (03h) BCC [1]: P (ASCII) fixed [2]: Load mass [HEX] (2 BYTES) (Unit: Metric ton. HD605-7 . FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (b) Contents of communication Format (VHMS controller) STX (02h) [1] [2] [3] [4] [5] [6] ETX (03h) BCC [1]: M (ASCII) fixed [2]: 4 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton. 10-time value. If an answer is still not returned. the final load mass (= the load mass to be saved as the hauled load mass of the concerned cycle in the memory) is transmitted automatically. the VHMS controller stops transmission.5 [10-time value] 0 – 6553.

If an answer is still not returned. HD465-7. too. Transmission of real-time data (a) Outline of communication procedure 1) The VHMS controller receives a request for the real-time data from MMS. the VHMS controller stops transmission. it finishes transmission of the real-time data.STRUCTURE. HD605-7 10-241 (6) . 3) When the VHMS controller receives a request for finishing transmission of the real-time data.2 seconds. the VHMS controller transmits up to 2 more times. transmission of the real-time data is finished. 2) After receiving the request for the real-time data. (b) Contents of communication 1) Request for real-time data ( VHMS controller) Format STX (02h) [1] [2] ETX (03h) BCC [1]: M (ASCII) fixed [2]: A (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller ) Transmission of the real-time data from the VHMS controller is used as a substitute for the answer. When the key is turned to the OFF position. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER Action that VHMS controller takes when answer is abnormal If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds. the VHMS controller transmits the real-time data at intervals of 0.

5 [10-time value] 0 – 6553. to 1 decimal place) 0 – 99 See (*1) 0 0 See (*2) (*1) Status of digital signals [HEX] bit 0: N signal1: N (OPEN) 0: Other than N (GND) bit 1: BODY FLOAT signal 1: FLOAT (OPEN) 0: Other than FLOAT N (GND) bit 2: Unused bit 3: Unused bit 4: Unused bit 5: Unused bit 6: Unused bit 7: Unused (*2) Status of dump truck [HEX] 00 (h): Engine stopped 01 (h): Empty and stopped 02 (h): Empty and traveling 03 (h): Loading 04 (h): Loaded and traveling 05 (h): Loaded and stopped 06 (h): Unloading [BCC]: EX-OR of each bit from STX to ETX 10-242 (6) HD465-7. HD605-7 .5 [Complement of 2 of 100-time value] [10-time value.5 [10-time value] 0 – 6553. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER 2) Transmission of real-time data (VHMS controller Format (VHMS controller ) STX (02h) [1] [2] [3] [4] ETX (03h) BCC ) [1]: M (ASCII) fixed [2]: 2 (ASCII) fixed [3]: 02 (h) fixed (Unit classification [HEX]) [4]: Real-time data (17 BYTES) From head Signal name P FL P FR P RL P RR INC PAYLD SP DIG STST ANA 1 ANA 2 VEH STAT Position (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) (Lower position) (Upper position) Name Front left suspension pressure (kg/cm2) Front right suspension pressure (kg/ cm2) Rear left suspension pressure (kg/cm2) Rear right suspension pressure (kg/cm2) Inclination angle (degree) Real-time load mass (Metric ton) (Current) Travel speed (km/h) Status of digital signals Unused Unused Status of dump truck HEX [10-time value] 0 – 6553.5 [10-time value] 0 – 6553.STRUCTURE.

and a request for finishing RTM is not returned in RTM transmission timing. FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER Answer ( STX (02h) VHMS controller) ACK (06h) ETX (03h) BCC or STX (02h) NAK (15h) ETX (03h) BCC Action that VHMS controller takes when answer is abnormal Even if "NAK" is returned or any of "ACK". If this condition is repeated 10 times. the VHMS controller stops transmission.2 seconds. 3) Request for finishing transmission of real-time data ( Format STX (02h) [1] [2] ETX (03h) BCC VHMS controller) [1]: Q (ASCII) fixed [2]: 2 (ASCII) fixed [BCC]: EX-OR of each bit from STX to ETX Answer (VHMS controller STX (02h) ACK (06h) ) ETX (03h) BCC or STX (02h) NAK (15h) ETX (03h) BCC HD465-7. HD605-7 10-243 (6) . "NAK". the VHMS controller transmits the real-time data normally after 0.STRUCTURE.

..... HD465-7. When carrying out work together with other workers.2 Standard value table for chassis ............ 2.. HD605-7 20-1 (1) ........... 20. 3. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference... the water will spurt out and cause burns. fan belt or other rotating parts. 20-301 a Note the following when making judgements using the standard value tables for testing....... 20-101 TROUBLESHOOTING .. or troubleshooting.... If the radiator cap is removed when the water is still hot..20 TESTING AND ADJUSTING STANDARD VALUE TABLE Standard value table for engine related parts ... It is used for reference together with the state of repair and the history of operation to judge if there is a failure........ When checking the water level...... adjusting.. adjusting....3 TESTING AND ADJUSTING.. These standard values are not the standards used in dealing with claims. and use blocks to prevent the machine from moving. It is used as a guideline for judging the progress of wear after the machine has been operated......... and as a reference value when carrying out repairs. or troubleshooting. Be careful not to get caught in the fan. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests...... 20. always wait for the water to cool down... When carrying out testing... park the machine on level ground.. inset the safety pins. 1.. always use signals and do not let unauthorized people near the machine....

5.7} 120 15 Oil temperature Belt tension (Alternator) Whole speed range (Inside oil pan) Deflection when pressed with finger force of approx. 0.0 – 5.1} Min. HD605-7 .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Model Engine Item Measurement conditions Power mode High idle Economy mode Stationary mode (*1) Engine Speed Low idle Lo Power mode Rated speed Economy mode Boost pressure • Hi power mode • Torque convertor stall • Hi power mode • Torque convertor stall At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature) Compression pressure (SAE30 oil) Blow-by pressure Intake valve mm Exhaust valve Oil temperature: 40 – 60°C (Engine speed: 210 – 250 rpm) MPa {kg/cm2} 0.098 {1. set the hoist lever in the "HOLD" position. 6 Bosch index Max.0 0.270 ± 50 2.100 +0 – 100 945 ± 50 945 ± 50 Exhaust temperature (Coolant temperature: Operating range) kPa • Power mode {mmH2O} • Torque convertor stall (Coolant temperature: Operating range) At high idle (SAE30) Oil pressure At high idle (SAE10W) At low idle (SAE30) At low idle (SAE10W) MPa {kg/cm2} 0.0 Max. 0. 3 °C # 4.8 {900} # 1. 700 Max. When measuring the high idle speed in the power mode or economy mode.206 {2.: 7001 – 7181 SAA6D170E-3 Standard value 2. 20-2 (12) HD465-7. 2.5 Max.200 ± 50 2.5} Min.96 {20} Max. 8. 700} Max. 800} Max. 0.539 {3. 5. 106.2} Min. 1. 2. 58.177 {1.539 {4. 93.0} Min. 670 Max. 1.900 ± 50 Min.069 {0.6 {Min.4 {550} — Min.200 ± 50 2.392 – 0.9 {30} Max.5} 0.8 N {6 kg} °C mm 90 – 110 15 *1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position.118 {1. 670 1.000 ± 50 750 ± 50 2. 0.8} Min. 6.62 Min.343 – 0.5 – 5. 2. 0.100 +0 – 100 Permissible value 2.8} Min.3 {Min.080 {0.: 7001 – 7483 HD605-7 Serial No. 3.32 Max.900 ± 50 Min.5 — kPa {mmHg} 1.270 ± 50 2. 700 750 ± 50 2.000 ± 50 Hi rpm Unit HD465-7 Serial No. 0.

2.450 ± 50 1. HD605-7 20-3 (12) .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS STANDARD VALUE TABLE FOR CHASSIS HD465-7 Serial No.300 rpm *2.450 ± 50 1. 1.0 ± 5 % 21.400 ± 50 F1 F2 Performance F3 Travel speed F4 F5 F6 F7 R Shift up High power mode Shift down Shift up Economy mode Shift down Shift up Shift down Automatic shift control 1.0 ± 5 % 12.5 ± 5 % 29.5 ± 5 % 29.3 % km/h Unit Standard value Standard tires 11.5 ± 5 % 16.5 ± 5 % 39.0 ± 5 % • Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C • “Braking mode” refers to when the accelerator is OFF or the rear brake is ON.0 ± 5 % 52.000 ± 50 1.325 ± 35 1.350 ± 10 2.5 ± 5 % 16. 0. F3 – F7: 1.350 ± 10 Down-shift inhibitor • Transmission oil temperature: 85 – 110°C • Hydraulic oil temperature: 45 – 55°C • Engine coolant temperature: Within operating range 1. Torque converter speed ratio is min.5 ± 5 % 39.0 ± 5 % 2.050 ± 50 F1.: 7001 – 7181 Component Item Measurement conditions • Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Machine unloaded • Travel resistance: 3.0 ± 5 % 52.250 ± 50 1.250 ± 50 (F2 o F1 only) (F2 o F1 only) 2.100 ± 50 1.0 ± 5 % 12.5 ± 5 % 70.550 ± 50 *1 *2 2.325 ± 35 (F2 o F1 only) (F2 o F1 only) 2.400 ± 50 Permissible value Standard tires 11.100 ± 50 1.100 ± 50 HD465-7.910 ± 100 Torque converter Economy mode Engine speed at torque converter stall 1.300 ± 50 2.300 ± 50 1.910 ± 100 *1.910±100 1. F2 : 1.325 ± 35 (F2 o F1 only) (F2 o F1 only) Power mode 1.325 ± 35 1.600 ± 10 2.: 7001 – 7483 HD605-7 Serial No.0 ± 5 % 21.500 rpm or min.600 ± 10 Reset 2.910±100 1.550 ± 50 *1 *2 Braking mode Auto lock-up Set Reset Engine speed rpm Overrun prevention Set 2. 1.5 ± 5 % 70.85 at min.000 ± 50 1.

5} 3.2 {36.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) H.7 ± 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.5 ± 1. 29.71 ± 0.15 ± 0.5} Permissible value 22.67 ± 0.5} 0.5} 1.8 } {4.8 N {kg} 2.000 rpm Inlet oil pressure At high idle (2.67 ± 0.17 ± 0.15 {38.8 + 0.5 ± 2} 1.5} 1.5} 0.05 {1.68 ± 0.9 ± 0. HD605-7 .5} 0.88 ± 0.0 ± 0.6 ± 3.82 ± 0.5 ± 2} 0.20 {17 ± 2} 3.2 {18 ± 2} 3.05 {7.5} 3.3 ± 0.15 {37.33 ± 0.5 ± 0.5} 0.20 {17 ± 2} 1.5 ± 2} 1.05 {8.67 ± 0.3 ± 0.3 } Travel 45 ± 5 21.2 {36.5 ± 2 At engine speed 2.1 – 7.67 ± 0.5 ± 0.5 ± 1.74 ± 0.05 {1.5 ± 2} 20-4 (10) HD465-7.15 {38.2 {17 ± 2} 1.5} 0.9 ± 0.58 ± 0.5} 0.2 {18 ± 2} 3.2 {18.33 ± 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.59 ± 0.5} 3.5} 0.15 {34 ± 1.5} + 2.0 42.2 ± 0.15 {34 ± 1.05 {1.58 ± 0.67 ± 0.2 ± 0.5 ± 1 24.5} 0.2 {17 ± 2} 1.5 ± 1.5 ± 4.5} 0.9 {2.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.5 ± 0.3 – 0.17 ± 0.5 ± 0.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Accelerator pedal Item Starting to depress Operating force Fully Starting to depress i o fully Measurement conditions • Operating effort at a point 150 mm from pedal fulcrum Unit Standard value 22.2 {34 ± 2} 3.7 ± 0.05 {8.2 {18.5} 1.0 42.68 ± 0.5 ± 1.05 {1.1 + – 7.2 ± 0.5} 0.15 ± 0.74 ± 0.4} 45 ± 5 Max.67 ± 0.9 {2.20 {17 ± 2} 1.5} 1.000 rpm Torque converter Outlet oil pressure • Oil temperature: 75 – 85°C Lock-up oil pressure At high idle (2.05 {7.20 {17 ± 2} 1.59 ± 0.2 {34 ± 2} 3.05 {6.20 {17 ± 2} 3.8 {4.5 ± 4.4{3} Operating force Transmission shift lever R–N N–D D–5 Travel 5–4 4–3 3–L mm 24.05 {7.3 – 0.67 ± 0.9 {2.15 {37.77 ± 0. 4th clutch Transmission L clutch Control valve set pressure 3rd clutch 2nd clutch 1st clutch MPa {kg/cm2} • Oil temperature: 60 – 80°C • Engine: at rated speed MPa {kg/cm2} 0.20 {17 ± 2} 1.0 ± 0.3 • Travel at a point 150 mm from pedal fulcrum • At center of lever knob mm N {kg} + 0.05 {7.67 ± 0.33 ± 0.33 ± 0.88 ± 0.77 ± 0.71 ± 0.5} 3.05 {6.77 ± 0.77 ± 0.000 rpm At high idle (2.000 rpm Main relief oil pressure At high idle (2.82 ± 0.

3.17 ± 0. of turns Turning time Turns sec.69 {7.5} 0.05 {0.17 ± 0.1 – 23.2 – 21.0} Min. 3.5} Permissible value 0.5} 0.05 {1. 25 Min.39 {39 ± 4} 2. 4 3.1 – 23. 1. Cylinder with buffer ring HD465-7.7 ± 0.1 {206 – 215} 20. until tires start to move • Lock o lock Left o right Right o left • Oil temperature: 45 – 55°C • Oil temperature: 60 – 80°C • Engine speed: Whole range • Lock o lock At high idle (2.0} Max.75} Tires (Inflation pressure) • Machine unloaded Standard tires MPa {kg/cm2} Tire (If equipped) 24.5} 0.5 – 3.0} • With 46ton payload • F2 • Torque converter stall See Brake A • On flat road surface • When empty mm 220 ± 10 % rpm MPa {kg/cm2} Min.4 {1.1 {206 – 215} *1.05 {1.5 ± 0. travel at low speed with engine at low idle) • Length at circumference of steering wheel • Engine stopped. HD605-7 20-5 (10) .9 ± 0. 35.46 {4. 1. 5 20.5 ± 0.09 ± 0.6} Play mm Max.7 ± 0.15 ± 0. 135 Max.05 {0. 135 No.00-R35 (Front and rear tires) 0.29 {23 ± 3} 3.82 ± 0.5 {205 – 240} 20.5} 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) Unit Standard value 0.5 ± 0.29 {23 ± 3} Suspension cylinder Installed length Rear B 204 ± 10 (*1) Front Pressure Rear • Oil temperature: 60 – 80°C • When machine stopped (empty) (If it is impossible when the machine stopped.540 0.2 – 21.15 ± 0.69 {7.82 ± 0.26 ± 0.00-35-36PR (Front and rear tires) Measurement conditions At engine speed 2.270 rpm) At low idle (750 rpm) (Reference value) MPa {kg/cm2} 2.000 rpm At high idle (2.5} 0.3 Max.6 Max.5 ± 0.46 {4.09 ± 0.5 {205 – 240} Steering valve Relief pressure MPa {kg/cm2} 20.540 Parking brake Braking capacity Starting test Releasing pressure Front See Brake 249 ± 10 249 ± 10 (*1) 249 ± 20 249 ± 20 (*1) 220 ± 20 204 ± 20 (*1) 3.7 – 29. 5 Max.75} Transmission Lubricating oil pressure MPa {kg/cm2} 0.26 ± 0. 4 Max.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item • Oil temperature: 60 – 80°C (When using EO10-CD) or Oil temperature: 80 – 100°C (When using EO30-CD) 24.3 {Max.39 {39 ± 4} Operating force (Turning speed for steering wheel: 30 rpm) Steering wheel N {kg} 14.05 {1. 25 Min.9 ± 0.05 {1.

17.1 17.2 ± 3} 296 ± 29. 17.7 {100 ± 7} MPa {kg/cm2} 8.7 {100 ± 7} 8.6 {88.5} + 0.8 ± 0.6 ± 1.7 ± 0.5} Brake oil pressure MPa {kg/cm2} 9.3 Max.49 10 {100.2 {180 ± 12} 9.7 ± 0.4 {30.8 ± 0.7 {0.7 ± 0.2 {180 ± 12} 9.4 + –5 Max.49 10 {100. 52. dry road surface • Engine: Stopped • When first operated Max.3 m Max.8 {0.3 – 1.5 ± 6.9 – 9.5} 0.6 ± 1.85 + – 0.0 – 14.8 ± 0.6 {88.1 17.6 ± 1. HD605-7 . 22.8 MPa {100 kg/cm2} Front: 17.2 {180 ± 12} 9.4 {23.6 ± 1. hydraulic pressure Rear: 9.2 ± 3} Service brake braking distance 46 ton payload Empty • Initial speed: 32 km/h • Distance from starting to lose speed to stopping • Max.6 – 1.5 ± 6.6 {88.7 ± 0.0} 0 – 78 0 –2 3.8 ± 3} 234 ± 29.8 ± 0.98 9.8 ± 3} Travel (Start of depressing o Full) mm 40 ± 5 40 ± 10 Retarder control lever Operating force Travel • At point 10 mm from tip of lever N {kg} deg 5.5 ± 6.0 17.6 {88.4 {30.4 {23.0 17.5} 20-6 (10) HD465-7.5 ± 6.4 + –5 } Front Brake actuating pressure Brakes Rear (service) Rear (retarder) Parking brake releasing pressure Stopping distance when emergency brake is applied • Engine: Stopped } • Carrying 46 ton payload • Initial speed: 32 km/h • On flat.85 – 0.6 MPa {180 kg/cm2} • On flat.5} 0 – 78 0 –4 • Measure at position a (Position at 150 mm from fulcrum of pedal) Emergency brake pedal Operating force (Full) N {kg} 296 ± 29. dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder m Max. 22.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item Measurement conditions • Measure at position a (Position at 150 mm from fulcrum of pedal) Unit Standard value Permissible value Operating force (Full) Brake pedal N {kg} 233 ± 29.7 {100 ± 7} 8. 52.7 {100 ± 7} 8.98 9.2 {180 ± 12} Max.

5 3.6} Max.6} Max.8 ± 1.5 + – 1. HD605-7 20-7 (11) .0 — Must be in wear gauge range Must be in wear gauge range Max.6 ± 0.670 rpm Must not move until torque converter stall speed Brakes Emergency brake Front brake (Pad thickness ) Rear brake (Disc wear gauge ) Left side Right side Left side Right side • Engine: stopped • Center of control lever knob HOLD o RAISE RAISE o HOLD HOLD o FLOAT FLOAT o HOLD FLOAT o LOWER LOWER o FLOAT Travel • Engine: stopped • Center of control lever knob • Oil temperature: 45 – 55°C RAISE o HOLD HOLD o LOWER mm N {kg} mm 19.8 ± 1.3 {Max. 29. 29. 3.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item Service brake Retarder brake Parking brake Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually.1 – 21.870 rpm Must not move at 1. 85 170 HD465-7.0} Max.6 – 19.5 ± 1.4 {Max.270 rpm) Relief pressure Dump EPC valve Relief pressure ( root pressure) At low idle (750 rpm) (Reference value) • Oil temperature: 45 – 55°C • Engine speed: 2.0} Max.0} Max.3 {Max.4 ± 0.8 ± 1.9 44.0 3.4 {Max.49 {27 ± 5} 11.6 – 22.5 sec.0 Dump valve At high idle (2. 3.4 ± 0.6 {200 – 230} 18. 10.6} Dump lever Operating force Must return smoothly when engine is running at 2. 3.0} Max. 3. 2 cylinder extended 200 mm • Hydraulic drift after 5 minutes Lifting speed Lowering speed Body Hydraulic drift mm Max. 35.5 44. 35.6 {190 – 200} MPa {kg/cm2} 3. 29.5 ± 1. 3.3 {Max.5 2.49 {27 ± 5} 11.6 ± 0.5 19.6 {190 – 200} 3.6 – 19.1 {205 – 215} 18.8 ± 1.9 20.270 rpm) At low idle (750 rpm) (Reference value) At high idle (2.6} Must return smoothly when engine is running at high idle Max. 3. 35.000 rpm 44. 3. 29. 3.9 19.3 {Max.400 rpm rpm Must not move at 1.9 44. Measure the engine speed when the truck starts moving Unit Standard value Permissible value Must not move at 1.0 10. 35.49 {35 ± 5} 2.000 rpm • Use FLOAT when lowering • Oil temperature: 45 – 55°C • Set with No.4 {Max.4 {Max.49 {35 ± 5} 2.5 ± 1.

2. 0. 700} Max.2} Min. 6. 6 Bosch index Max.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Model Engine Item Measurement conditions Power mode High idle Economy mode Stationary mode (*1) Engine Speed Low idle Lo Power mode Rated speed Economy mode Boost pressure • Hi power mode • Torque convertor stall • Hi power mode • Torque convertor stall At sudden acceleration Exhaust gas color At high idle Valve clearance (Normal temperature) Compression pressure (SAE30 oil) Blow-by pressure Intake valve mm Exhaust valve Oil temperature: 40 – 60°C (Engine speed: 210 – 250 rpm) MPa {kg/cm2} 0.0 Max.392 – 0.0 – 5. When measuring the high idle speed in the power mode or economy mode.8} Min. 2.206 {2.0 0.539 {4. 5. 106.343 – 0.5} 0.000 ± 50 1.: 7484 and up HD605-7 Serial No.270 ± 50 2.8} Min. 670 Max.539 {3. 1.5 — kPa {mmHg} 750 ± 50 2. 0.8 N {6 kg} °C mm 90 – 110 15 *1) Condition for stationary mode: Set the shift lever in the "N" position and apply the parking brake "PARKING" and set the hoist lever in the "FLOAT" position. 0.96 {20} Max.118 {1.: 7182 and up SAA6D170E-3 Standard value 2.900 ± 50 Min. 700 Max.000 ± 50 1. 20-8 (12) HD465-7.5 Max.098 {1.7} 120 15 Oil temperature Belt tension (Alternator) Whole speed range (Inside oil pan) Deflection when pressed with finger force of approx. 0. 0.8 {900} # 1.9 {30} Max.100 +0 – 50 Permissible value 2. 3.900 ± 50 (empty) 2.6 {Min. 8. 700 Hi rpm Unit HD465-7 Serial No. 1.069 {0.200 ± 50 2.270 ± 50 2. 93.0} Min.177 {1. set the hoist lever in the "HOLD" position.3 {Min. HD605-7 .100 +0 – 100 (empty) 2.100 +0 – 50 945 ± 50 945 ± 50 Exhaust temperature (Coolant temperature: Operating range) kPa • Power mode {mmH2O} • Torque convertor stall (Coolant temperature: Operating range) At high idle (SAE30) Oil pressure At high idle (SAE10W) At low idle (SAE30) At low idle (SAE10W) MPa {kg/cm2} 0. 58.5} Min.1} Min.5 – 5.270 ± 50 (loaded) 2.32 Max.62 Min. 3 °C # 4. 2.080 {0.4 {550} — Min. 0. 5. 670 750 ± 50 2.100 ± 50 (loaded) Min. 800} Max.

0 ± 5 % 52.000 ± 50 2.000 ± 50 2.000 ± 50 (F1 o F2 only) (F1 o F2 only) 1.100 ± 50 (F1 o F2 only) (F1 o F2 only) 1.325 ± 35 (F2 o F1 only) (F2 o F1 only) 1.5 ± 5 % 16.3 % • Standard tires • High power mode km/h 39.5 ± 5 % 16.5 ± 5 % Permissible value 11.450 ± 50 2.935/2.: 7484 and up HD605-7 Serial No.0 ± 5 % 21.450 ± 50 HD465-7.0 ± 5 % 2. HD605-7 20-9 (12) .325 ± 35 1.100 ± 50 (F1 o F2 only) (F1 o F2 only) 1.800 ± 50 1.450 ± 50 1.100 ± 50 Unit Standard value 11.070 ± 50 1.0 ± 5 % 2.100 ± 50 2.5 ± 5 % 1.935/2.070 ± 50 2.750 ± 50 1.800 ± 50 (F2 o F3 only) (F2 o F3 only) Engine speed Economy mode Shift up Accelerator OFF (Slow travel) Full throttle rpm 2.: 7182 and up Component Item F1 F2 F3 Performance Travel speed F4 F5 F6 F7 R High power mode Shift up Shift down • Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C Measurement conditions • Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Machine unloaded • Travel resistance: 3.100 ± 50 2.750 ± 50 Half throttle 1.750 ± 50 Full throttle Empty Automatic shift control Half throttle 2.5 ± 5 % 29.5 ± 5 % 70.800 ± 50 (F2 o F3 only) (F2 o F3 only) Accelerator OFF (Slow travel) 2.0 ± 5 % 21.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS STANDARD VALUE TABLE FOR CHASSIS HD465-7 Serial No.400 ± 50 1.5 ± 5 % 29.800 ± 50 1.750 ± 50 Loaded 2.0 ± 5 % 12.0 ± 5 % 52.935 ± 50 1.450 ± 50 2.935 ± 50 2.000 ± 50 (F1 o F2 only) (F1 o F2 only) 1.5 ± 5 % 70.100 ± 50 39.800/1.0 ± 5 % 12.400 ± 50 1.800/1.

F2oF1) (F3oF2.550 ± 35 (F2 o F1 only) (F2 o F1 only) Braking mode Shift up Shift down 2.875 ± 100 F3 – F7: 1.250 ± 35 1.325 ± 35 (F2 o F1 only) (F2 o F1 only) 1.250 ± 35 (F2 o F1 only) (F2 o F1 only) 1.500 rpm or 1.800 ± 100 1.550 ± 35 (F2 o F1 only) (F2 o F1 only) Shift down 1.250 ± 35 1. Auto lock-up Set Reset F3 – F7: 1.250 ± 35 1.550 ± 50 Torque converter speed ratio is minimum 0.350 ± 35 1.550 ± 50 Torque converter speed ratio is minimum 0.200 ± 35 Engine speed Accelerator OFF (Slow travel) rpm 1.910 ± 10 1.200 ± 35 Accelerator OFF (Slow travel) Automatic shift control Economy mode 1.350 ± 10 • Transmission oil temperature: 85 – 110°C • Hydraulic oil temperature: 45 – 55°C • Engine coolant temperature: Within operating range 1.450 ± 50 1.85 at minimum of 1.325 ± 35 1.910 ± 10 1.350 ± 35 Full throttle 1.050 ± 50 F1.450 ± 50 1.600 ± 10 2.300 rpm.250 ± 35 1.325 ± 35 (F2 o F1 only) (F2 o F1 only) 1.200 ± 35 1.250 ± 35 (F3oF2.200 ± 35 Empty Half throttle 1.200 ± 35 1.200 ± 35 1.875 ± 100 Overrun prevention Set Reset Power mode Engine speed at torque Empty conEconverter omy stall mode Loaded 20-10 (12) Torque converter HD465-7.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item Measurement conditions • Engine coolant temperature: Within operating range • Transmission oil temperature: 60 – 80°C • Hydraulic oil temperature: 45 – 55°C Unit Standard value 1.250 ± 35 1.250 ± 35 (F3 o F2 only) (F3 o F2 only) 1.85 at minimum of 1.200 ± 35 1.550 ± 35 1. F2: 1.350 ± 10 1.300 ± 35 Full throttle 1.200 ± 35 Loaded Half throttle 1. 2.100 ± 50 2. HD605-7 .600 ± 10 2.550 ± 35 1.500 rpm or 1.250 ± 35 (F3 o F2 only) (F3 o F2 only) 1.050 ± 50 F1.250 ± 35 (F3 o F2 only) (F3 o F2 only) 1.325 ± 35 1.100 ± 50 2. F2: 1.800 ± 100 1.F2oF1) 1.300 rpm.300 ± 35 Permissible value 1.

5} 1.7 ± 0.2 {34 ± 2} 3.20 {17 ± 2} 1.9 ± 0.5} 3.3 ± 0.67 ± 0.17 ± 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.33 ± 0.17 ± 0.5 ± 2} 1. 4th clutch Transmission L clutch Control valve set pressure 3rd clutch 2nd clutch 1st clutch MPa {kg/cm2} • Oil temperature: 60 – 80°C • Engine: at rated speed MPa {kg/cm2} 0. 29.4{3} Operating force Transmission shift lever R–N N–D Travel D–5 5–4 4–3 3–L mm 24.0 42.3 – 0.5 ± 0.5} 0.5} 2.77 ± 0.6 ± 3.74 ± 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) H.2 {34 ± 2} 3.8 } {4.5} 0.2 {36.5} 0.5 ± 1.5} 1.67 ± 0.0 ± 0.05 {6.5 ± 2} 0.88 ± 0.5} 0.05 {7.33 ± 0.5 ± 2 At engine speed 2.3 + 0.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Accelerator pedal Item Starting to depress Fully Starting to depress i o fully Measurement conditions • Operating effort at a point 150 mm from pedal fulcrum Unit Standard value 22.67 ± 0.4} 45 ± 5 Max.2 {17 ± 2} 1.5} 0.05 {8.15 {37.67 ± 0.2 ± 0.67 ± 0.000 rpm Inlet oil pressure At high idle (2.8 Operating force N {kg} {4.5} 3.15 {38.000 rpm At high idle (2.05 {1.5 ± 4.20 {17 ± 2} 1.5 ± 1.68 ± 0.0 42.5} 3.1 – 7.5} 0.05 {1.2 {18.71 ± 0.33 ± 0.15 {34 ± 1.05 {7.67 ± 0.33 ± 0.58 ± 0.5} 0.8 Permissible value 22.5 ± 0.67 ± 0.77 ± 0.77 ± 0.5 ± 1.2 {18 ± 2} 3.5} 0.2 {36.7 ± 0.5 ± 2} 1.3 • Travel at a point 150 mm from pedal fulcrum • At center of lever knob mm N {kg} + 0.2 {18 ± 2} 3.77 ± 0.15 ± 0.3 – 0.05 {1.2 {18.1 + – 7.71 ± 0.59 ± 0.9 ± 0.20 {17 ± 2} 3.05 {8.67 ± 0.9 {2.15 {37.3 ± 0.5 ± 0.68 ± 0.59 ± 0.5 ± 1 24.05 {7.5} 0.88 ± 0.0 ± 0.20 {17 ± 2} 1.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.9 {2.15 {38. HD605-7 20-11 (12) .15 {34 ± 1.8 } Travel 45 ± 5 21.5 ± 0.5 ± 4.5} 1.58 ± 0.82 ± 0.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) At engine speed 2.000 rpm Torque converter Outlet oil pressure • Oil temperature: 75 – 85°C Lock-up oil pressure At high idle (2.2 ± 0.5} 3.5} + 2.5} 0.05 {6.9 {2.5} 1.000 rpm Main relief oil pressure At high idle (2.82 ± 0.20 {17 ± 2} 3.2 {17 ± 2} 1.05 {7.05 {1.5 ± 1.5 ± 2} HD465-7.2 ± 0.20 {17 ± 2} 1.74 ± 0.15 ± 0.

0} Min.5 – 3.270 rpm) At low idle (750 rpm) (Reference value) MPa {kg/cm2} Operating force (Turning speed for steering wheel: 30 rpm) Steering wheel N {kg} 14.82 ± 0.5} 0. 3. 1.05 {1.39 {39 ± 4} 2.540 0.0} • With 46ton payload • F2 • Torque converter stall See Brake A • On flat road surface • When empty mm % rpm MPa {kg/cm2} Min.1 {206 – 215} 20.09 ± 0.5} Permissible value 0.9 ± 0. Cylinder with buffer ring 20-12 (12) HD465-7. 135 No. 5 20.29 {23 ± 3} Suspension cylinder Installed length Rear B Front Pressure Rear • Oil temperature: 60 – 80°C • When machine stopped (empty) (If it is impossible when the machine stopped.05 {0.05 {1. 35.29 {23 ± 3} 249 ± 20 249 ± 20 (*1) 220 ± 20 204 ± 20 (*1) 3.540 Parking brake Braking capacity Starting test Releasing pressure Front See Brake 249 ± 10 249 ± 10 (*1) 220 ± 10 204 ± 10 (*1) 3. 3.09 ± 0. 25 Min.1 {206 – 215} *1.270 rpm) (Reference value) At low idle (750 rpm) (Reference value) Unit Standard value 0.05 {1.5} 0.39 {39 ± 4} 2.69 {7.0} Max.5} 0.2 – 21.5 ± 0. 5 Max.5 {205 – 240} Steering valve Relief pressure MPa {kg/cm2} 20.5 ± 0.3 {Max.7 ± 0.1 – 23.2 – 21.15 ± 0.69 {7.75} Transmission Lubricating oil pressure MPa {kg/cm2} 0.75} Tires (Inflation pressure) Standard tires • Machine unloaded MPa {kg/cm2} Tire (If equipped) 0.000 rpm At high idle (2. 135 Max.4 {1.9 ± 0.15 ± 0. 1.05 {1. 4 Max. 4 3.00-R35 (Front and rear tires) Measurement conditions At engine speed 2.46 {4.6} Play mm Max.5 ± 0. until tires start to move • Lock o lock Left o right Right o left • Oil temperature: 45 – 55°C • Oil temperature: 60 – 80°C • Engine speed: Whole range • Lock o lock At high idle (2.5} 0.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item • Oil temperature: 60 – 80°C (When using EO10-CD) or Oil temperature: 80 – 100°C (When using EO30-CD) 24.05 {0.5} 0.00-35-36PR (Front and rear tires) 24. travel at low speed with engine at low idle) • Length at circumference of steering wheel • Engine stopped.1 – 23. of turns Turning time Turns sec.5 ± 0.6 Max. 25 Min.26 ± 0.26 ± 0.17 ± 0.5 {205 – 240} 20.3 Max. HD605-7 .46 {4.7 – 29.7 ± 0.82 ± 0.17 ± 0.

7 ± 0.85 – 0.2 {180 ± 12} 9.7 ± 0.6 ± 1.3 – 1.7 {100 ± 7} 8.4 + –5 } + 0.2 {180 ± 12} 9.2 ± 3} 296 ± 29.6 {88.5} 0 – 78 0 –4 • Measure at position a (Position at 150 mm from fulcrum of pedal) Emergency brake pedal Operating force (Full) N {kg} 296 ± 29.7 ± 0. 22.8 ± 0.6 {88. dry road surface Operating pressure at first operation after Front accumulator is charged Rear Retarder m Max.6 MPa {180 kg/cm2} • On flat.1 17.8 ± 0. HD605-7 20-13 (12) .8 ± 3} Travel (Start of depressing o Full) mm 40 ± 5 40 ± 10 Retarder control lever Operating force Travel • At point 10 mm from tip of lever N {kg} deg 5.49 Max.7 ± 0.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item Measurement conditions • Measure at position a (Position at 150 mm from fulcrum of pedal) Unit Standard value Permissible value Operating force (Full) Brake pedal N {kg} 233 ± 29.8 ± 0.7 {0.5 ± 6. hydraulic pressure Rear: 9.0} 0 – 78 0 –2 3. 52.8 MPa {100 kg/cm2} Front: 17.8 ± 3} 234 ± 29.5} } 10 {100. 17.2 {180 ± 12} Max.4 {30. 22.2 {180 ± 12} 9.6 {88.6 ± 1.5 ± 6.85 + – 0.8 ± 0.2 ± 3} Service brake braking distance 46 ton payload Empty Front • Initial speed: 32 km/h • Distance from starting to lose speed to stopping • Max.4 {23.6 ± 1.49 Brake actuating pressure Brakes Rear (service) Rear (retarder) MPa {kg/cm2} • Engine: Stopped Parking brake releasing pressure Stopping distance when emergency brake is applied • Carrying 46 ton payload • Initial speed: 32 km/h • On flat.7 {100 ± 7} 8.8 {0.0 17.7 {100 ± 7} 8. 17.1 17.0 – 14. 52.98 9.4 {23.5 ± 6.5 ± 6.4 + –5 0.3 Max.0 17.7 {100 ± 7} 8.5} Brake oil pressure MPa {kg/cm2} 9.98 9.5} 10 {100.4 {30.6 ± 1.9 – 9.3 m Max. dry road surface • Engine: Stopped • When first operated Max.6 {88.5} HD465-7.6 – 1.

HD605-7 . 3.8 ± 1. 85 170 20-14 (12) HD465-7. Measure the engine speed when the truck starts moving Unit Standard value Permissible value Must not move at 1.3 {Max.3 {Max.1 – 21.0 Dump valve At high idle (2. 3. 35.4 {Max.6 {190 – 200} MPa {kg/cm2} 3.8 ± 1. 29. 3.3 {Max.6 ± 0.1 {205 – 215} 18.5 19. 35.5 + – 1.6 – 19. 3.8 ± 1.6 {200 – 230} 18.4 {Max.0} Max.49 {27 ± 5} 11.5 ± 1.0 3.5 ± 1.4 {Max.670 rpm Must not move until torque converter stall speed Brakes Emergency brake Front brake (Pad thickness ) Rear brake (Disc wear gauge ) Left side Right side Left side Right side • Engine: stopped • Center of control lever knob HOLD o RAISE RAISE o HOLD HOLD o FLOAT FLOAT o HOLD FLOAT o LOWER LOWER o FLOAT Travel • Engine: stopped • Center of control lever knob • Oil temperature: 45 – 55°C RAISE o HOLD HOLD o LOWER mm N {kg} mm 19. 3. 35.4 {Max.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Component Item Service brake Retarder brake Parking brake Measurement conditions Apply the brake and set the gear shift lever in D and raise the engine speed gradually. 29.5 3.870 rpm Must not move at 1.49 {35 ± 5} 2.9 19. 29.6 ± 0.6 – 19. 10.4 ± 0.5 ± 1.9 20.6} Must return smoothly when engine is running at high idle Max.0} Max.000 rpm 44.9 44.270 rpm) Relief pressure Dump EPC valve Relief pressure ( root pressure) At low idle (750 rpm) (Reference value) • Oil temperature: 45 – 55°C • Engine speed: 2.6 – 22.0 — Must be in wear gauge range Must be in wear gauge range Max. 29.9 44. 2 cylinder extended 200 mm • Hydraulic drift after 5 minutes Lifting speed Lowering speed Body Hydraulic drift mm Max. 3.0 10.0} Max.49 {27 ± 5} 11.6 {190 – 200} 3.3 {Max. 3. 35.0} Max. 3.5 sec.49 {35 ± 5} 2.270 rpm) At low idle (750 rpm) (Reference value) At high idle (2.6} Max.5 44.000 rpm • Use FLOAT when lowering • Oil temperature: 45 – 55°C • Set with No.5 2.6} Max.4 ± 0.6} Dump lever Operating force Must return smoothly when engine is running at 2.8 ± 1.400 rpm rpm Must not move at 1.

...................................................................................................................... hoist circuit ............................................................... 20-203........... 20-160-2 Special functions of machine monitor (EMMS) .................. 20-133 Testing wear of front brake pad............................... 20-120 Testing and adjusting alternator belt tension............................................................................................................ 20-144 Testing and adjusting hydraulic pressure in steering.... 20-203-11 Inspection and maintenance ................................................................................................................................................................................................................................................................................20-117 Measuring exhaust color ................................................................................................................................................................................................................................................................................................................................. 20-156 Adjusting transmission controller ...... 20-203-20 Performing Pm-clinic using manual snapshot (= Quick Pm) ....... 20-136 Testing and adjusting front suspension cylinder ...................... 20-149 Procedure for raising dump body in emergency ....................................................................... 20-123 Adjusting transmission speed sensor ......20-112 Measuring fuel pump outlet port pressure .......................................................................... 20-102 Adjusting engine speed sensor ..................................................................................... 20-134 Testing wear of rear brake disc .......................... 20-122 Measuring power train oil pressure ................................................................................................. 20-121 Testing and adjusting...................................................................................................................................20-115 Bleeding air from fuel circuit........... 20-203-16 Replacing parts ......................... 20-203........................................................................20-112 Measuring fuel pump inlet port pressure................ 20-106 Measuring exhaust temperature ................................................ air conditioner compressor belt tension ........... 20-104 Measuring engine oil pressure .............. 20-137 Testing and adjusting inverted type rear suspension cylinder......................................................TESTING AND ADJUSTING Tools for testing................................................................................... 20-101-1 Measuring engine speed................................................................................................................................................... 20-148 Air bleeding from steering cylinder................... adjusting........................................................................ 20-203-16 Procedure for initial setup of VHMS .........................................................9 Collection.............................................. 20-141 Testing and adjusting front suspension cylinder (mode selector hydraulic cylnder)............................................................... 20-131 Bleeding air from brake circuit ..................................... HD605-7 20-101 (11) ......................................................................................................................................................................................................................................................................................................................................................................................................................................... 20-151 Method for emergency escape when there is failure in electrical system ..... 20-150 Adjusting body positioner sensor ...................................................................................................................................................................................................................................... transmission of data........................................................................................................................................... 20-203-17 Procedure for opening orbcomm service ........................................................................ 20-145 Testing and adjusting oil pressure in dump EPC circuit .............................. and troubleshooting .........................................................................................................................................................................................................................................................................................................................................................20-114 Visual inspection of return fuel ............................................................20-119 Adjusting valve clearance ......................................................................................................... 20-152 Adjusting machine monitor (EMMS) ............................................................................................................................................................20-111-1 Handling equipment in fuel system .......................... 20-205 HD465-7...................... 20-160-1 Setting of card-type payload meter after installation or replacement ....... 20-204 Pm-clinic service .......................................................................................................................................................................................................................................................... 20-160 Initial setting of payload meter ......................................................................................................................................... 20-161 Basic precautions.......................................................................... 20-135 Method of releasing parking brake in an emergency .......................................................20-111 Measuring compression pressure .................................................................................................................................................................................................................................................................... 20-108 Measuring blow-by pressure ....................20-110 Troubleshooting of injector................................................................................................................... 20-203...........20-114 Adjusting injector set load ...............1 Outline............ 20-105 Measuring air supply pressure (boost pressure)..........................4 Setting up VHMS controller........................................................................................................................................................................................................................................................................................................................ 20-130 Inspecting brake oil pressure ...........................

60. 58. ADJUSTING. 58. 5.9.9 MPa {0 – 70 kg/cm2} 20-101-1 (11) HD465-7.8 MPa {25.9.8 MPa {25. 400.8 MPa {600 kg/cm2} Pressure gauge: 2. 400. 600 kg/cm2} Pressure gauge: 58. 5.5. 400.5.5.9. exhaust. ADJUSTING.8 MPa {25.8 MPa {600 kg/cm2} Pressure gauge: 0. 60.2. 600 kg/cm2} Pressure gauge: 58.2. 5.9 – 1.8 MPa {600 kg/cm2} 1 790-261-1204 14 × 1.TESTING AND ADJUSTING TOOLS FOR TESTING. 400.9. 39. 39. AND TROUBLESHOOTING Measurement item Air supply pressure (boost pressure) Wear level of front brake pad Symbol A b Part No.8 MPa {25. 39.5. AND TROUBLESHOOTING TOOLS FOR TESTING.500 mmHg} Attached tool -99. 799-201-2202 566-98-41410 799-101-1502 Coolant.9. 600 kg/cm2} Pressure gauge: 58.5. 58. 58. HD605-7 . hoist oil pressure circuit 790-261-1204 799-401-2320 799-101-5002 1 790-261-1204 799-101-5002 Power train oil pressure C 799-101-5002 1 790-261-1204 Dump EPC oil pressure circuit 3 799-101-5230 799-401-3100 4 02896-11008 799-101-5002 1 Brake oil pressure J 1 799-261-1204 566-35-43561 795-502-1590 795-611-1210 6560-11-8410 6560-11-8310 2 Compression pressure D 6560-11-8210 6560-11-8510 6560-11-7310 795-799-5410 3 795-799-5420 Remover 1 O-ring (3rd) O-ring (4th) Gasket Adapter 6 6 6 1 Injector pull out O-ring Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Nipple Compression gauge Adapter O-ring (TOP) O-ring (2nd) 1 1 1 1 1 6 6 6 Pressure gauge: 2.2.8 MPa {600 kg/cm2} Part Name Boost gauge KIT Gauge Digital temperature gauge Sensor Wiring harness Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Nipple Adapter Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks -101 – 200 kPa {-760 – 1. 60. 5. 600 kg/cm2} Pressure gauge: 58. 60.5 Face seal type (# 02) (Female: PT 1/8) 18 × 1. 39.2.2. and oil temperatures B 6215-11-8170 799-201-1110 799-101-5002 1 Engine oil pressure 2 Steering.8 MPa {25.98 MPa {10 kg/cm2} Pressure gauge: 2.8 MPa {600 kg/cm2} Pressure gauge: 2. 60. 58. 600 kg/cm2} Pressure gauge: 58. 5. 400.299 °C Wire length: 490 mm Pressure gauge: 2. 39.5 (Female: PT 1/8) 0 – 6.

39. 792-610-1200 H2 – H6 Pump assembly KIT part No. 600 kg/cm2} Pressure gauge: 58. 400. ADJUSTING. 792-610-1100 10 • 792-610-1640 11 • 792-610-1400 12 • 792-610-1430 13 • 792-610-1440 HD465-7.8 MPa {25. 5.5.8 MPa {600 kg/cm2} Fuel pump outlet pressure 1 K 2 3 795-799-5460 Commercially available 795-799-5550 799-101-5002 C 1 790-261-1204 Fuel pump inlet pressure 1 M 2 Blow-by pressure E 1 Valve clearance F 2 Injector set load F1 1 Exhaust color G 2 1 2 3 4 5 6 Suspension cylinder of adjustment H 7 8 9 795-502-1350 792-610-1000 • 792-610-1130 • 792-610-1110 • 792-610-1120 • 07020-21732 • 792-610-1140 • 792-610-1250 • 792-610-1260 • 792-610-1480 795-799-5560 799-201-1504 6162-23-4500 Commercially available 6162-23-4500 799-201-9001 795-799-5550 Pressure gauge: 2.2. 400. HD605-7 20-101-2 (11) . 58. 60. 799-101-5002 790-261-1204 Part Name Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Cable Tester Adapter Oil pressure gauge KIT (Analog) Oil pressure gauge KIT (Digital) Adapter Negative pressure gauge Blow-by checker Barring device Thickness gauge Barring device Handy smoke checker Smoke meter Suspension tool • Pump assembly • Hose • Joint • Fitting • Joint • Valve assembly • Nipple • Stem • Joint • Regulator assembly • Gauge • Gauge Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Pressure gauge: 2. 39.1 MPa {0 – -1 kg/cm2} 0 – 4.5. AND TROUBLESHOOTING Measurement item Symbol C 1 Part No.5 MPa {250 kg/cm2} 9.9 kPa {0 – 500 mmH2O} Bosch index: 0 – 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24.81 MPa {100 kg/cm2} H7 – H13 Charging tool assembly KIT part No.2. 60. 600 kg/cm2} Pressure gauge: 58.8 MPa {600 kg/cm2} 0 – -0. 58.9. 5.TESTING AND ADJUSTING TOOLS FOR TESTING.9.8 MPa {25.

hydraulic drift Work equipment speed Voltage. at repair set up L 1 799-608-3211 799-608-3220 2 Commercially available 79A-264-0021 OS: Windows 98/2000 0 – 294 N {0 – 30 kg} 0 – 490 N {0 – 50 kg} Operating effort P 79A-264-0091 Commercially available Commercially available Commercially available 799-601-7400 799-601-3450 799-601-7330 799-601-7340 799-601-7360 1 799-601-7370 799-601-7510 799-601-7520 Travel. ADJUSTING. AND TROUBLESHOOTING Measurement item Troubleshooting of injector At raise of emergency dump body Symbol J K Part No. HD605-7 . wiring harnesses T 799-601-7530 799-601-7540 799-601-7550 2 3 4 5 6 799-601-9000 799-601-9300 795-799-5520 795-799-5530 795-799-5540 20-101-3 (11) HD465-7. 40 pin) For speed sensor For fuel temperature sensor For engine coolant temperature sensor For intake temperature sensor Sensor.TESTING AND ADJUSTING TOOLS FOR TESTING. 795-799-5510 792T-491-1110 799-608-3101 Part Name Heat gun Plug Service KIT • Discket • Harness Lap top type personal computer Push-pull scale Push-pull scale Scale Stopwatch Tester T-adapter assembly Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter T-adapter assembly T-adapter assembly Socket (S) Socket (C) Socket (A) Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For MS-5 Remarks Initial set up of VHMS controller and. resistance Q R S For S-16 (White) For M-8 For relay (5 pins) For relay (6 pins) For AMP070-10 For AMP070-12 For AMP070-14 For AMP070-18 For AMP070-20 For DT connector For DT connector (For 24.

795-799-5460 795-799-5470 795-799-5480 Part Name Cable (Cummins Part No. wiring harnesses T 8 9 SKETCH OF SPECIAL TOOL Note: Komatsu cannot accept any responsibility for special tools manufactured according to these drawings.: 3824774) Cable (Cummins Part No. HD605-7 20-101-4 (11) . ADJUSTING. AND TROUBLESHOOTING Measurement item Symbol 7 Part No.TESTING AND ADJUSTING TOOLS FOR TESTING.: 3824776) Q’ty 1 1 1 Remarks Atmosphere pressure sensor Fuel rail pressure sensor Timing rail actuator Fuel pump actuator Fuel rail actuator Engine oil pressure sensor Timing rail pressure sensor Boost pressure sensor Fuel pump pressure sensor Sensor.: 3824775) Cable (Cummins Part No. K Plug HD465-7.

Preparation work Turn the starting switch ON and set the machine monitor (EMMS) in the "Monitoring function of service mode 1" to prepare for measurement of the engine speed. 20-102 (10) HD465-7. 2) Start the engine and set the accelerator pedal in the low idle position and measure the engine speed. Never operate the gearshift lever with the accelerator pedal depressed. turn the parking brake switch PARKING. so never operate the gearshift lever to any position other than the D position during the stall operation. It will cause a big shock and will also lead to a reduction in the service life of the machine. run the engine at high idle and stall the torque converter to raise the torque converter oil temperature. so always measure at the D position. 01001: Engine speed (2) Code No. see SPECIAL FUNCTIONS OF MACHINE MONITOR. 30100: Torque converter oil temperature a For details of the method of operation. 5) When the torque converter oil temperature goes above 90°C. 2. There is danger of damage to the internal parts of the transmission. a For the operating method. 3.TESTING AND ADJUSTING MEASURING ENGINE SPEED MEASURING ENGINE SPEED Stop the machine on flat ground. HD605-7 . then set the gearshift lever to the D position. a Torque converter oil temperature: 60 – 80°C a Hydraulic oil temperature: 45 – 55°C 3) Depress the parking brake pedal. • Monitoring code: 01001 (Engine speed) a The unit of displayed engine speed is 1 rpm. turn the parking brake switch TRAVEL. run the engine immediately at low idle and return the gearshift lever to the N position. 4. 2) Start the engine and raise the temperature of the hydraulic oil and torque converter oil. the machine may move off even if the brake is being depressed. a Measure the engine speed under the following condition. 2) Start the engine and set the accelerator pedal in the high idle position and measure the engine speed. Measuring low idle speed 1) Set the shift lever N and dump lever in HOLD. Measuring high idle speed 1) Set the shift lever N and dump lever in HOLD. a If the gearshift lever is operated to any position other than the D position. and block the tires. Measuring torque converter stall speed 1) Switch the machine monitor display to the monitoring function of service mode 1 and display the following 2 items at the same time with the monitoring function. a Monitoring items (1) Code No. 4) Depress the accelerator pedal gradually. • Engine coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C 1. see "Special functions of machine monitor (EMMS)".

so always measure the stall speed at the time of delivery. a The stall speed may vary according to the following conditions. a Keep the gearshift lever at the N position. measure the stall speed when the torque converter oil temperature is 80°C.TESTING AND ADJUSTING MEASURING ENGINE SPEED 6) Run the engine at a mid-range speed. run at low idle. 7) Repeat Steps 3 – 6 and equalize the oil temperature in the torque converter and transmission. 80°C. and when the torque converter oil temperature goes down to approx. a Measure the stall speed 2 or 3 times. i) Variations according to the engine serial number ii) Variations in engine output due to atmospheric pressure and temperature iii) Variations due to consumption torque of accessories iv) Variations due to features of the torque converter v) Variations according to the method of measuring the stall HD465-7. HD605-7 20-103 (10) . 8) At the same time as repeating Steps 3 and 4.

Nut: 33. a For details of the method of operation. Remove engine speed sensor (1). Screw in sensor (1) until the tip of the sensor contacts the tip of the tooth of flywheel ring gear (2).TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR ADJUSTING ENGINE SPEED SENSOR a If the engine speed sensor has been removed and installed or the flywheel has been removed or installed. 5. Fix engine speed sensor (1) and tighten locknut (3). check that the tip of the sensor is not scratched and that there are no iron particles sticking to it.9 – 47. Thread: Loctite hydraulic sealant (No. a Angle to return: 1/2 – 3/4 turns a Clearance a of 0. • Monitoring code: 01001 (Engine speed) 2.8 kgm} 20-104 (10) HD465-7. 4. HD605-7 .5 – 4. and check that the engine speed is displayed normally. 21028) 3.25 mm is made between the tip of the sensor and the tip of the gear tooth. After completing the adjustment. a Before adjusting. then install it again. switch the machine monitor to the display of "Monitoring function of service mode 1".5 Nm {3. 1. remove the engine speed sensor. Return sensor (1) by the specified angle from that position. see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).75 – 1. adjust as follows.

Remove engine oil pressure measurement plug (1). a For the method of measurement. see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS). 799-101-5002 790-261-1204 799-401-2320 Part Name Hydraulic tester Digital type hydraulic tester Hydraulic tester (1. For details of the method of operation.0MPa {10kg/cm2}) (Measuring with measuring instruments) 1. and measure the oil pressure at low idle and high idle.TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE MEASURING ENGINE OIL PRESSURE Special tool list Symbol 1 C 2 Part No. HD465-7. Start the engine. a Measure the engine oil pressure under the following conditions. • Monitoring code: 37200 (Engine oil pressure) a The engine oil pressure is displayed in units of 1 kPa. see MEASURING WITH MEASURING INSTRUMENTS. After completing the measurement. 4. Fit nipple [1] of hydraulic tester C1. 3. HD605-7 20-105 (11) . then connect to hydraulic tester C2. • Engine oil temperature: Min. 2. remove the measuring equipment and set to the original condition. 80°C • Coolant temperature: Within operating range (Measuring with monitor panel) a It is also possible to check the engine oil pressure with the "Monitoring function of service mode 1" of the machine monitor (EMMS).

• Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C (Measuring with monitor panel) 1. the gauge will not work. so always bleed the oil. 36500: Boost pressure 2. HD605-7 .500mmHg} (Measuring with measuring tool) 1. a For the method of measurement. see MEASURING WITH MEASURING INSTRUMENTS.9kPa {–760 – 1. 01001: Engine speed (2) Code No. 799-201-2202 Part Name Boost gauge kit Remarks –101 – 199. the air bleed coupling (790-261-1130) inside the kit can be used. a Insert the connection of the hose and pressure gauge about half way. a If there is oil inside the hose. Remove air supply pressure measurement plug (1). then connect gauge. and bleed the oil. Run the engine at a mid-range speed or above to bleed the oil from the hose. Change the machine monitor to Service mode 1 and display the following 2 items simultaneously with the monitoring function. Be careful not to touch any hot parts when removing or installing the measuring tools. a Monitoring items (1) Code No. a Measure the air supply pressure (boost pressure) under the following conditions. 3. repeat the action to open the self-seal portion at the hose end. 20-106 (1) HD465-7. Fit nipple of boost gauge kit A. a If Pm kit (A) is available.TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) Special tool list Symbol A Part No.

After completing the measurement. Run the engine at high idle to stall the torque converter. s e e M E A S U R I N G TORQUE CONVERTER STALL SPEED. a The air supply pressure (boost pressure) should be measured with the engine running at rated output. a similar value can be obtained at torque converter stall speed. 5.TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 4. rermove the measuring equipment and set to the original condition. and measure the air supply pressure (boost pressure). when measuring in the field. HD465-7. a For details of the procedure for stalling the t o r q u e c o n v e r t e r. However. HD605-7 20-107 (9) .

run the engine at high idle and stall the torque converter. 3) Depress the parking brake pedal.TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE MEASURING EXHAUST TEMPERATURE Special tool list Symbol Part No. then stall only the torque converter and measure the temperature. 799-101-1502 B 6215-11-8170 799-201-1110 Part Name Digital temperature gauge Sensor Wiring harness Remarks –99. then connect to digital temperature gauge B.9 – 1. There is danger of damage to the internal parts of the transmission. HD605-7 . a To prevent the torque converter from overheating. use the full stall (torque converter stall + hydraulic relief) to stabilize the exhaust temperature. • Coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C Method using measuring equipment 1. At the same time. 1) Turn the power mode switch to the HIGH POWER position. so always measure at the D position. 20-108 (10) HD465-7. so never operate the gearshift lever to any position other than the D position during the stall operation. the machine may move off even if the brake is being depressed. 2) Start the engine and raise the temperature of the coolant to the operating range. Install sensor [1]. a Continue until the exhaust temperature reaches the standard value of 670°C. a Clamp the wiring harness of the temperature gauge at a suitable place to prevent it from touching any hot part. 3. 4) Depress the accelerator pedal gradually. 2. Method of periodic measurement for preventive maintenance service. operate the dump lever to the LOWER position and relieve the oil pressure (full stall). turn the parking brake switch TRAVEL. then set the gearshift lever to the D position. a Measure the exhaust temperature under the following conditions. If the gearshift lever is operated to any position other than the D position.299°C Wire length: 490 mm Wait for the temperature of the exhaust pipe to go down before removing or installing the measuring equipment. Remove exhaust temperature measurement plug (1).

HD605-7 20-109 (10) . (Set the temperature gauge to the PEAK mode.) a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). After completing the measurement. a Monitoring items (1) Code No.TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE 5) When the temperature stabilizes at near the target temperature. so measure the temperature when it stabilizes. a Use the PEAK mode of the digital temperature gauge. Accordingly. HD465-7. a After completing the measurement. return the dump lever to FLOAT and measure the temperature with only the torque converter stalled. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. 42600 : Exhaust temperature (front) (1) Code No. Method using monitoring a This method applies only to the VHMS specification machine. 42601 : Exhaust temperature (rear) a For details of the method of measuring. 4. see METHOD USING MEASURING EQUIPMENT. remove the measuring equipment and set to the original condition. Carry out actual work and record the maximum exhaust temperature during operation. 01001 : Engine speed (2) Code No. correct it by the following calculation. lower the engine speed to low idle. a The exhaust temperature will start to go down from the full stall condition. a If the exhaust temperature does not go down but rises. • Corrected value [°C] = Measured value + 2 x (20 – ambient temperature) 5. then return the gearshift lever to the N position. 1. if any abnormal value is obtained. The maximum temperature automatically recorded. When measuring the maximum value for the exhaust temperature during troubleshooting. 01001 : Engine speed (2) Code No. make the set temperature at full stall higher. do as follows.

Install nozzle and hose [1] to blow-by hose (1). so never operate the gearshift lever to any position other than the D position during the stall operation. 42800: Blow-by pressure a For details of the method of measuring. If the gearshift lever is operated to any position other than the D position. 3. 799-201-1504 Part Name Remarks Blow-by checker 0 – 4. Depress the parking brake pedal. a After completing the measurement. There is danger of damage to the internal parts of the transmission. Switch the machine monitor display to [Service mode 1] and use the monitoring function to display the following two items at the same time. Start the engine and raise the temperature of the coolant to the operating range. Method using monitoring a This method applies only to the VHMS specification machine. 4. run the engine at high idle and stall the torque converter. Depress the accelerator pedal gradually. remove the measuring equipment and set to the original condition. so always measure at the D position. turn the parking brake switch TRAVEL. 5.TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE MEASURING BLOW-BY PRESSURE Special tool list Symbol Part No.9 MPa {0 – 500 mmH2O} Method using measuring equipment 1. the machine may move off even if the brake is being depressed. see METHOD USING MEASURING EQUIPMENT. 20-110 (10) HD465-7. and measure the blow-by pressure. 2. HD605-7 . then return the gearshift lever to the N position. then set the gearshift lever to the D position. run the engine at low idle. 01001: Engine speed (2) Code No. a Monitoring items (1) Code No. then connect to blow-by checker E. 1. After completing the measurement.

1 Measured 86 value Compensa. 9. then calculate the average temperature. 1) Measurement and judgment example 1: No. Cylinder No. Cylinder No. wait for the temperature of the exhaust manifold to cool down to a temperature of "ambient temperature +20°C".6 103 123 3) Measurement and judgment example 3: No cylinder is more than 20°C lower than the average value. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point.1 Measured 85 value Compensation value 105 Average value No.2 cylinder is more than 20°C lower than the average value. 795-799-5510 Heat gun Part Name a If the engine output drops or there is any other problem. so judge that all cylinders are normal. Run the engine at low idle.5 86 91 Unit:°C No. HD605-7 20-111 (10) .3 cylinder is abnormal.5 89 94 Unit:°C No. Using the heat gun J. measure the exhaust manifold outlet temperature of each cylinder before starting the engine. a Apply the measuring beam (center) of heat gun J to part "a" of each cylinder to "prevent dispersion of the measurement results" caused by difference in the measuring point.1 Compensa.TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR TROUBLESHOOTING OF INJECTOR Special tool list Symbol J Part No.6 72 92 HD465-7. Cylinder No. Using the heat gun J. if there is the possibility of defective combustion due to defective injection by the injector.5 +5 Unit:°C No.4 112 112 No.5 94 99 Unit:°C No. 2) Measurement and judgment example 2: No. carry out troubleshooting of injector.3 79 79 93 No.2 96 101 No. a Compensation value Cylinder No.6 82 102 3. measure the exhaust manifold outlet temperature of each cylinder 3.3 cylinder is more than 20°C lower than the average value.4 91 91 No. 4. 5.4 93 93 No. a Make marks to the same points on the upper side or lower side of the exhaust manifolds of the all cylinders. 6. Make marks a for measurement to the exhaust manifolds of the all cylinders. judge that the cylinder is abnormal. Stop the engine and leave it to cool down. so judge that No.106 tion value Average value No.90 tion value Average value No. as a guideline. If the temperature of any cylinder is more than 20°C lower than the average.2 88 93 No. so judge that No.2 +5 No. Adjust the temperature of each cylinder measured 12 minutes after by the compensation value and find out the abnormal cylinder.3 88 88 91 No.1 Measured 70 value Compensa.3 0 No. 6. 2.4 0 No.3 73 73 99 No.2 cylinder is abnormal.+20 tion value No. a When cooling the engine down. 1.2 62 67 No.6 +20 a Method of judgment Add up the temperatures after compensating. and 12 minutes after starting the engine.

etc. or get caught in a rotating part.5 kgm} 20-111-1 (7) HD465-7. Remove rocker arm assemblies (1) of all the cylinders. a Secure the adapter assemblies with the injector holders. muffler. a Since adapter assemblies D2 of the all cylinders should be removed and installed simultaneously for efficiency. prepare 6 sets of them. 3 Holder mounting bolt: 24. 5. 2. F When measuring the compression pressure. 795-502-1590 795-611-1210 6560-11-8410 2 6560-11-8310 6560-11-8210 6560-11-8510 6560-11-7310 3 795-799-5410 795-799-5420 Part Name Compression gauge Adapter O-ring (Top) O-ring (2nd) O-ring (3rd) O-ring (4th) Gasket Adapter Remover 4. Remove injector push rods (2) and injectors (3). Install adapter assemblies D2 to the all cylinders and secure them with the holders. Remove all cylinder head covers.5 – 3. 1. a Install the adapter assemblies with the drain holes in the diagonal direction of the holders. take care not to burn yourself on the exhaust manifold.TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE a Special tools list Symbol 1 Part No. 3. pull out each injector (See DISASSEMBLY AND ASSEMBLY). Open the right side cover and left side cover of the engine. HD605-7 . a Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 – 60°C).5 – 34. a Using tool D3.3 Nm {2.

the fuel pump does not supply fuel to the injectors. 2 Threads and seat of rocker arm assembly mounting bolt: Engine oil (EO30CD) 3 Rocker arm assembly mounting bolt: 235. replace the bolt. 3 Cylinder head cover mounting bolt: 9. 2 Threads and seat of mounting bolt: Engine oil (EO30CD) 3 Mounting bolt: 235. see ADJUSTING SET LOAD OF INJECTOR.5 – 3. After finishing measurement.8 Nm {24 – 26 kgm} 10. Crank the engine with the starting motor and measure the compression pressure.1 kgm} 8. For details. see ADJUSTING VALVE CLEARANCE. a Read the gauge when its pointer is stabilized.8 ± 1.3Nm {2. a After this step.2 – 254. Disconnect 2 connectors (4) (POW) and (SIG) of the engine. For details.2 – 254.0 Nm {1 ± 0.5 – 34. If it is longer than 80 mm.8 Nm {24 – 26 kgm} a Adjust the valve clearance. a Measure the stem length of the injector holder mounting bolt. 3 Holder mounting bolt: 1st time: 24. Connect compression gauge D1 to adapter assembly D2 of the cylinder to be measured. HD465-7. 9.TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE 6. Install rocker arm assemblies (1) and adjust the valve clearance. a Adjust the set load of the injector. HD605-7 20-111-2 (10) .5kgm} 2nd time: Tighten by 90 – 120° 2 Threads and seat of holder mounting bolt: Engine oil (EO30CD) 7. remove the measuring instruments and return the removed parts.

2) Start the engine. use clean fuel to wash it off completely. never use such filters. If there is any dirt stuck to any part. if any filter is used as a substitute for the genuine filter. see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). MEASURING FUEL PUMP OUTLET PORT PRESSURE Special tool list Symbol C 1 1 K 2 3 Part No. HD605-7 . and prepare to measure the engine speed. To prevent this. there is danger that problems will occur with the fuel system. When carrying out inspection and maintenance of the fuel system. a Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel filter cartridge. Measuring pressure sensor signal voltage 1) Disconnect connector CN-PMPR (1) of the fuel pump pressure sensor. a For details of the method of operation. For this reason. so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. switch the machine monitor to the display of "Monitoring function of service mode 1". • Monitoring code: 01001 (Engine speed) a The engine speed is displayed in units of 1 rpm.TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL SYSTEM MEASURING FUEL PUMP OUTLET PORT PRESSURE HANDLING EQUIPMENT IN FUEL SYSTEM a Precautions for inspection and maintenance of fuel system The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle. The HPI type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle. so problems may occur if dirt or dust get in. then connect cable K1 to the male and female ends. 20-112 (11) HD465-7. pay more attention than usual to prevent dirt or dust from getting in. 799-101-5002 790-261-1204 795-799-5460 Commercially available 795-799-5550 Part Name Hydraulic tester Digital hydraulic tester Cable Tester Adapter 1.

switch the machine monitor to the display of "Monitoring function of service mode 1".25 V 4) Run the engine at each speed in the following table and check that the signal voltage of the fuel pump pressure sensor is in the corresponding range shown in the same table. a For details of the method of operation.TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE 3) Run the engine at low idle and check that the source voltage of the fuel pump pressure sensor is in the following range.68 ± 0.14 MPa {16. a Signal voltage of sensor (CN-PMPR connector between (C) – (D)): Table 1 Engine speed and signal voltage Engine speed Fuel pump outlet port Signal voltage pressure (Reference) 1.43 kg/cm2} 2.23 ± 0.300 rpm 3.43 kg/cm2} 1. • Monitoring code: 010 (Engine speed) a The engine speed is displayed in units of 1 rpm.26 ± 0. 3) Start the engine.75 – 5.0 ± 1.21 V 1. HD605-7 20-113 (10) . 2) Install nipple [1] of hydraulic tester C1 to nipple (2) and connect them to hydraulic tester H1.57 ± 0. see SPECIAL FUNCTIONS OF MACHINE MONITOR.14 MPa {12. HD465-7.15 ± 1. and prepare for measuring the engine speed. a Source voltage of sensor (CN-PMPR connector between (A) – (B)): 4.00 ± 0.000 rpm 1.21 V 1.6 ± 1.43 kg/cm2} 1.21 V {18.14 MPa 1.500 rpm 3. 4) Run the engine at the speed shown in Table 1 and check that the pump outlet port pressure is in the range shown in the table 1. Measuring with pressure gauge (directly) 1) Fit adapter K3 to nipple (2) for measuring the pump outlet port pressure.78 ± 0.

repeat the action to open the self-seal portion at the hose end to bleed the oil.1 MPa{0 – -1. HD605-7 . 2. the gauge will not work. check the return piping and fuel cooler for clogging. a Insert the connection of the negative pressure gauge and hose about halfway. etc. 2. 4.02 kg/cm2}) 3. Table 1 Fuel filter New Used Fuel pump inlet port pressure Max. Fit nipple [1] of hydraulic tester C1 and hose [2] to adapter M1 and connect them to negative pressure gauge M2. a Plug the hole of the fuel tank. so always bleed the oil. the air bleed coupling (790-261-1130) inside the kit can be used. Fit adapter M1 to pump inlet port pressure measuring nipple (1). Disconnect the fuel return hose before the fuel tank. a If Pm kit (A) is available. a Fuel spillage (Reference) At low idle: 4 – 6 /min At high idle: 10 – 12 /min a If the fuel spillage is extremely low. a If the engine does not revolve normally or fuel consumption is abnormally high. a If there is oil inside the hose. – 102 mmHg} Max. a Keep the return hose open and receive the fuel with an oil pan. – 27. VISUAL INSPECTION OF RETURN FUEL a The fuel used for control of the timing rail in the fuel circuit and the excessive fuel that is not used injected in the fuel rail are returned from the injector through the fuel cooler to the fuel tank. Run the engine at a medium speed to bleed the oil from the hose. 799-101-5002 790-261-1204 795-799-5550 795-799-5560 Part Name Hydraulic tester Digital hydraulic tester Adapter Negative pressure gauge (0 – -0.60 kPa {Max.10 kPa {Max.TESTING AND ADJUSTING MEASURING FUEL PUMP INLET PORT PRESSURE VISUAL INSPECTION OF RETURN FUEL MEASURING FUEL PUMP INLET PORT PRESSURE Special tool list Symbol C 1 1 M 2 Part No. – 13. Run the engine at full throttle and measure the pump inlet port pressure (See Table 1). 20-114 (11) HD465-7. 1. – 203 mmHg} 1. inspect the return fuel according to the following procedure. Start the engine and check that the fuel flows out of the fuel return hose smoothly.

5 kgm} a At compression top dead center.4 – 34. repeat the loosening operation. Open the engine hood cover. a Remove the flywheel housing cover and install barring device F1 to rotate the crankshaft. and set the No. Loosen locknut (2) of the injecter to be adjusted and adjustment screw (1) completely.3 Nm {3.0 – 3.1 cylinder at compression top dead center. align [1. respectively. • Cylinder at compression top dead center and cylinder where injector is inspected. Tighten adjustment screw (1). so check the chart below when carrying out the operation.5 kgm} 4th time : Loosen fully 5th time : 29. then tighten finally. HD465-7.5 kgm} 2nd time : Loosen fully 3rd time : 29. 4. it is not at compression top dead center.0 – 3. so rotate the crankshaft one more turn. the rocker arm of the No. a Check that the socket at the tip of the rocker arm and the ball of the push rod are both fitted securely into the injector and push rod. 6162-23-4500 Part Name Barring device a The cylinder where the injector is adjusted is different from the cylinder at compression top dead center.1 cylinder can be moved by hand and amount equal to the valve clearance. If the rocker arm does not move. HD605-7 20-115 (7) . and then tighten the adjustment screw with your fingers. Rotate the crankshaft in the normal direction.4 – 34.3 Nm {3. 2. 3. Compression top dead center Injector to adjustment 1 2 5 4 3 1 6 5 2 3 4 6 1. 5. Remove all cylinder head covers (1). Adjustment screw: 1st time : 29.6TOP] line a on the damper with pointer (2).TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD ADJUSTING INJECTOR SET LOAD Special tool list Symbol F1 Part No.3 Nm {3.4 – 34.0 – 3.

1 kgm} 20-116 (4) HD465-7. Cylinder head mounting bolt : 9. Locknut: 205.TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD 6. then tighten locknut (2). HD605-7 .8 ± 1.0 Nm {1 ± 0. After completing the adjustment. set to the original position. Hold adjustment screw (1) in position.8 – 245 Nm {21 – 25 kgm} 7.

TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT BLEEDING AIR FROM FUEL CIRCUIT a If the engine does not start or is difficult to start after the following operations or conditions. HD465-7. Portion b is the outlet port after filterinig (clean side). Remove fuel filter (1). 2. then install it again. Check that there is ample fuel in the fuel tank. a Add fuel from the inlet port a (8 places). so never add fuel from portion b. so do not remove the fuel filter. a If the fuel filter is not to be replaced. there is danger of dirt getting in. a Carry out this operation only if the fuel filter has been replaced. HD605-7 20-117 (1) . • When starting the engine for the first time • After cleaning the fuel tank • After adding fuel when the engine has stalled • After replacing the fuel filter (only when the air is not bled easily) 1. fill it with fuel. bleed the air from the fuel circuit as follows.

fill the fuel pump with fuel as follows. 1) Remove air bleeding valve (1). 4. HD605-7 . and bleed the air from the vent circuit. 20-118 (10) HD465-7. Air bleeding plug: 12. the engine rotation will be slightly unstable until the air remaining in the circuit is completely bled.7 Nm {1. a There is no problem with starting even if some air is in the circuit. so continue to run the engine at low idle until it stabilizes. Crank the engine with the starting motor. a The injector is an open circuit.3 kgm} 4) Crank the engine with the starting motor. push air bleed the valve (1). a After the engine is started. a If the engine will still not start after the above operation. so if the fuel flows out the bleeding operation is completed.TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT 3. 30 cc (reference) 3) Install air bleeding plug (1). 2) Fill with clean fuel through the hole in the valve until it overflows. so while the engine is running the air remaining in the circuit is released from the injector to the inside of the engine or the fuel tank. Start the engine and run at low idle. a Amount of fuel to add: Approx.

799-201-9001 795-502-1350 Part Name Handy smoke checker Smoke meter Remarks Bosch index: 0 – 9 Be careful not to touch any hot parts when removing or installing the measuring tools. When measuring with a handy smoke meter. Measuring with Handy Smoke Checker G1 1) Install filter paper to handy smoke checker G1. 3) Connect the power cord to the AC socket. a Before connecting the cord. 3) Start the engine and raise the temperature of the coolant to the operating range.5 MPa (15 kg/cm2). 4) Keep the dump body raised and set handy smoke checker G1 to the joint of the exhaust pipe and dump body. 6) Remove the filter paper and compare it with the scale supplied to judge the condition. a Keep the pressure of the air supply below 1. use smoke meter G2. 2) Connect the air hose and the socket of the probe hose and accelerator switch to smoke meter G2. and fit the filter paper. 2) Insert the exhaust gas suction port into the exhaust pipe.TESTING AND ADJUSTING MEASURING EXHAUST COLOR MEASURING EXHAUST COLOR Special tool list Symbol G 1 2 Part No. 2. 5) Accelerate the engine suddenly. 5) Turn the power switch of smoke meter G2 ON. HD465-7. HD605-7 20-119 (11) . use handy smoke checker G1 . when recording formal data. 4) Loosen the cap nut of the suction pump. and operate the handle of handy smoke checker G1 while running at high idle to collect the exhaust gas on the filter paper. avoid standing against the exhaust gas and insert the exhaust gas suction port into the exhaust pipe. Measuring with Smoke Meter G2 1) Keep the dump body raised and insert the probe of smoke meter G2 in the joint of the exhaust pipe and dump body and fix it to the exhaust pipe. check that the power switch of the smoke meter is OFF. a When measuring in the field where there is no air or electric power supply. 1.

to set the No. and adjust the valve clearance with adjustment screw (5).1 cylinder can be moved by hand an amount equal to the valve clearance. it is not at compression top dead center. a Use a barring device F1 on the flywheel housing to carry out cranking.TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE Special tool list Symbol 1 F Part No.2 mm Exhaust valve: 0.0 ± 0. a Insert the feeler gauge and turn the adjustment screw until the clearance is a sliding fit. If the rocker arm does not move.9 – 7. set to the original condition. 2. 1 cylinder is at the compression top dead center and adjust the valves marked with Q when the No. Intake valve : 0. Rotate the crankshaft in the normal direction. Insert feeler gauge F2 into clearance b between rocker arm (3) and crosshead (4). then tighten locknut (6). Rotate the crankshaft 120° each time in the normal direction and repeat the procedure in Steps 3 – 5. check the valve clearance again.4 Nm {5. 6. 1.32 ± 0. Open the engine hood. Remove all cylinder head covers (1). 6 cylinder is at the compression top dead center. HD605-7 . 5.0Nm {1.8 ± 1.8 – 77. the rocker arm of the No. Hold adjustment screw (5) in position.6TOP] line a on the damper with pointer (2). Cylinder head cover mounting bolt: 9.2 mm 7.62 ± 0. Locknut: 57. 3. After completing the adjustment. • Firing order: 1–5–3–6–2–4 a Valve clearance (at cold). You may adjust the valves marked with q when the No. and align [1.9 kgm} a After tightening the locknut.1 kgm} 20-120 (10) HD465-7.1 cylinder at compression top dead center. referring to the following valve arrangement. a At compression top dead center. so rotate the crankshaft one more turn. 6162-23-4500 Commercially available Part Name Barring device Feeler gauge 4.

adjust as follows. 3. Tighten the 2 alternator mounting bolts and 1 lock bolt for the adjustment rod. 98 N {approx. then turn adjustment nut (4) to move alternator (1) and adjust the belt tension.TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION TESTING AND ADJUSTING ALTERNATOR BELT TENSION Testing • Measure deflection a when a point midway between the alternator pulley and idler pulley is pressed with a finger.7 – 8. 10 kg} Adjusting a If the deflection is not correct. 1. HD605-7 20-121 (1) . Loosen the 2 alternator (1) mounting bolts and 1 lock bolt (2) for the adjustment rod. a Pushing force: Approx. 2.7 kgm} Alternator locknut (1): 147 – 247 Nm {15 – 25 kgm} HD465-7. Alternator mounting bolt (4): 65 – 85 Nm {6. Loosen locknut (3).

TESTING AND ADJUSTING TESTING AND ADJUSTING. tighten air conditioner compressor mounting bolts. Loosen locknut (3). adjust as follows. a Pushing force: Approx. After completing the adjustment. 10 kg} Adjusting a If the deflection is not correct. HD605-7 . AIR CONDITIONER COMPRESSOR BELT TENSION TESTING AND ADJUSTING. 20-122 (10) HD465-7. 3. Loosen the mounting bolts (2) of air conditioner compressor bracket (1). then turn adjustment nut (4) to move air conditioner compressor bracket (1) and adjust the belt tension. 98 N {approx. 1. AIR CONDITIONER COMPRESSOR BELT TENSION Testing • Measure deflection a when a point midway between the air conditioner compressor pulley and idler pulley is pressed with a finger. 2.

HD605-7 20-123 (11) .9{60} 5.2.8 MPa meter {600 kg/cm2} a Table of oil pressure measurement port positions and gauges to use No.9{60} 5.9{60} 5.TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE MEASURING POWER TRAIN OIL PRESSURE Special tool list Symbol Part No.9{60} 5.9{60} 5. 5.8 MPa {25. 600 kg/cm2} Digital hydraulic Pressure gauge 58.9. meter 58. HD465-7.9{60} 10 Transmission 4th clutch pressure 5A.5.9{60} 5.9{60} 2. 1 2 3 4 5 6 7 8 9 11 Measurement location Main relief pressure Torque converter inlet port pressure Torque converter outlet port pressure Torque converter lock-up clutch pressure Transmission Lo clutch pressure Transmission Hi clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Transmission R clutch pressure Gauge (MPa{kg/cm2}) 5. so there is no need to measure it.Each clutch pilot pressure 11A a The transmission lubrication pressure is represented by the torque converter outlet port pressure.9{60} 5. 60.45{25} 2. 39.45{25} 5.9{60} 5. 799-101-5002 C1 790-261-1204 Part Name Remarks Pressure gauge Analog hydraulic 2. 400.

stop the engine. When removing and installing a plug or an oil pressure gauge. 1) Raise the transmission oil temperature. Take care not to "get burned". Take care not to "get burned". Items related to torque converter 2. HD605-7 . Stop the engine and wait until the oil temperature lowers sufficiently before installing and removing the measuring instruments. 4) After completing the measurement. 3) Start the engine and set the gear shift lever in the "N". since the oil temperature is high. When measuring the oil pressure while the machine is traveling. [1]).88 MPa {60 kg/cm2}) (including C1. When removing and installing a plug or an oil pressure gauge. [1]). since the oil temperature is high. Measuring torque converter inlet oil pressure Raise the dump body and lock it with the safety pin. stop the engine. remove the measuring equipment and set to the original condition. remove the measuring equipment and set to the original condition. 3) Start the engine and measure the oil pressure at high idle. a Oil temperature for measurement: 60 – 80°C 2) Remove plug (1) and install tool C (5. Measuring main relief pressure Raise the dump body and lock it with the safety pin. 1) Referring to TESTING MAIN RELIEF OIL PRESSURE.TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE Stop the machine on a level ground. and then measure the oil pressure at low idle and high idle.45 MPa {25 kg/cm2}) (including C1. Whole power train 1. 4) After completing the measurement. check that there is not abnormality. turn the parking brake switch PARKING. and put chocks under the tires. 2) Remove plug (2) and install tool C (2. secure a wide travel area and take care of the safety around the machine. 20-124 (10) HD465-7.

3) Start the engine and measure the oil pressure at high idle. 4. travel at high idle. HD465-7.5 km/h is reached. 8) After completing the measurement. [1]). In F1. so check carefully that the surrounding area is safe. (4A) and install the nipple and hoses [1] for measurement. then set the gearshift lever to position L. Measuring torque converter outlet oil pressure Raise the dump body and lock it with the safety pin.45 MPa {25 kg/cm2}) (including C1. check that there is not abnormality. Take care not to "get burned". HD605-7 20-125 (10) .TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE 3. since the oil temperature is high. then lock with safety pin. 2) Remove hydraulic oil pressure measuring plug (4). Measuring torque converter lock-up clutch and pilot pressure 1) Raise the dump body. 7) Release the brake. a maximum travel speed of approx. 4) After completing the measurement. 11. 2) Remove plug (3) and install tool C (2. depress the parking brake pedal. 1) Referring to TESTING MAIN RELIEF OIL PRESSURE. remove the measuring equipment and set to the original condition. and measure the oil pressure when the lock-up pilot lamp lights up. When removing and installing a plug or an oil pressure gauge. 6) Turn the parking brake switch TRAVEL. stop the engine. 3) Lower the dump body and set to the original condition. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 4) Connect oil pressure gauge C1. remove the measuring equipment and set to the original condition.

remove the measuring equipment and set to the original condition. depress the parking brake pedal. a The mark and mark indicate the clutches that are actuated for each travel speed. 8) After completing the measurement. speed ranges.TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE Transmission related a Table of gearshift lever positions. 7) Release the brake and measure the oil pressure when traveling at high idle. a The mark indicates the speed range when measuring the oil pressure for each clutch. and clutches actuated Gearshift lever Clutches Speed R N D 6 5 4 3 2 L engine Lo Hi 1st 2nd 3rd 4th R F1 F2 F3 F4 F5 F6 F7 N R 5. a The mark indicates the speed ranges that are actuated for each position of the gearshift lever.5 km/h is reached. 6) Turn the parking brake switch TRAVEL. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 11. a maximum travel speed of approx. HD605-7 . 20-126 (10) HD465-7. so check carefully that the surrounding area is safe. (5A) and install the nipple and hoses [1] for the measurement. then set the gearshift lever to position L. In F1. then lock with safety pin. 4) Connect oil pressure gauge C1. Measuring transmission Lo clutch and pilot pressure 1) Raise the dump body. 3) Lower the dump body and set to the original condition. 2) Remove hydraulic oil pressure measuring plug (5).

4) Connect oil pressure gauge C1. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 7. 8) After completing the measurement. 8) After completing the measurement. a maximum travel speed of approx. 7) Release the brake. 3) Lower the dump body and set to the original condition.5 km/h is reached. a maximum travel speed of approx. Measuring transmission 1st clutch and pilot pressure 1) Raise the dump body. 6) Turn the parking brake switch TRAVEL. HD465-7. (7A) and install the nipple and hoses [1] for the measurement. 2) Remove hydraulic oil pressure measuring plug (7). Measuring transmission Hi clutch and pilot pressure 1) Raise the dump body. depress the parking brake pedal. 11. In F1. HD605-7 20-127 (10) .TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE 6. and measure the oil pressure when the shift indicator shows "3". 3) Lower the dump body and set to the original condition. In F3. remove the measuring equipment and set to the original condition. remove the measuring equipment and set to the original condition. so check carefully that the surrounding area is safe. 4) Connect oil pressure gauge C1. then set the gearshift lever to position L. travel at high idle. 7) Release the brake and measure the oil pressure when traveling at high idle. 6) Turn the parking brake switch TRAVEL. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. then lock with safety pin.5 km/h is reached. then lock with safety pin. depress the parking brake pedal. so check carefully that the surrounding area is safe. then set the gearshift lever to position 3. 21. 2) Remove hydraulic oil pressure measuring plug (6). (6A) and install the nipple and hoses [1] for the measurement.

7) Release the brake. (8A) and install the nipple and hoses [1] for the measurement. travel at high idle. remove the measuring equipment and set to the original condition. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. depress the parking brake pedal. 2) Remove hydraulic oil pressure measuring plug (9). and measure the oil pressure when the shift indicator shows "2". In F4. so check carefully that the surrounding area is safe.0 km/h is reached. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 9. then set the gearshift lever to position 2. 29. and measure the oil pressure when the shift indicator shows "4". 6) Turn the parking brake switch TRAVEL. 8) After completing the measurement. then lock with safety pin. 7) Release the brake.5 km/h is reached. a maximum travel speed of approx. a maximum travel speed of approx. 16. 2) Remove hydraulic oil pressure measuring plug (8). travel at high idle. 6) Turn the parking brake switch TRAVEL. 4) Connect oil pressure gauge C1. then set the gearshift lever to position 4. In F2. Measuring transmission 2nd clutch and pilot pressure 1) Raise the dump body. remove the measuring equipment and set to the original condition. (9A) and install the nipple and hoses [1] for the measurement. 3) Lower the dump body and set to the original condition. 4) Connect oil pressure gauge C1. so check carefully that the surrounding area is safe. HD605-7 . 20-128 (10) HD465-7. then lock with safety pin. 8) After completing the measurement. 3) Lower the dump body and set to the original condition. depress the parking brake pedal.TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE 8. Measuring transmission 3rd clutch and pilot pressure 1) Raise the dump body.

remove the measuring equipment and set to the original condition. 4) Connect oil pressure gauge C1. depress the parking brake pedal. (11A) and install the nipple and hoses [1] for the measurement.0 km/h is reached. and measure the oil pressure when the shift indicator shows "6". a maximum travel speed of approx. 8) After completing the measurement. (10A) and install the nipple and hoses [1] for the measurement. HD465-7. remove the measuring equipment and set to the original condition. 12. 3) Lower the dump body and set to the original condition. 2) Remove hydraulic oil pressure measuring plug (11). Measuring transmission 4th clutch and pilot pressure 1) Raise the dump body. then lock with safety pin. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 4) Connect oil pressure gauge C1. 8) After completing the measurement. a maximum travel speed of approx. depress the parking brake pedal. Measuring transmission R clutch and pilot pressure 1) Raise the dump body. 3) Lower the dump body and set to the original condition. 5) Start the engine and raise the temperature of the torque converter oil to the operating range. 6) Turn the parking brake switch TRAVEL. so check carefully that the surrounding area is safe. 7) Release the brake. then set the gearshift lever to position R. 7) Release the brake and measure the oil pressure when traveling at high idle.TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE 10. then lock with safety pin. so check carefully that the surrounding area is safe. 11.5 km/h is reached. travel at high idle. In F6. then set the gearshift lever to position 6. 52. 2) Remove hydraulic oil pressure measuring plug (10). HD605-7 20-129 (10) . In R. 6) Turn the parking brake switch TRAVEL.

After completing the adjustment.75 – 1. Screw in until the tip of sensor (1) contacts the face or tip of the tooth of gear (2). CN3: Input shaft speed sensor CN4: Intermediate shaft speed sensor CN5: Output shaft speed sensor 1.TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR ADJUSTING TRANSMISSION SPEED SENSOR a There are 3 speed sensors installed to the transmission. check that the tip of the sensor is not scratched and that there are no iron particles sticking to the sensor tip. check that the each transmission shaft speed is displayed normally by using the monitoring function of the machine monitor.0 mm. Secure nut (3) with sensor (1). a Adjust clearance a between the tip of the sensor and the tip of the gear tooth to 0. Adjust each sensor as follows.6Nm {5 – 7 kgm} 4.0 – 68. 20-130 (1) HD465-7. a For details of the method of operation. Thread portion: Gasket sealant (LG-5) 2. a Before installing. 3. Nut: 49. see SPECIAL FUNCTIONS OF MACHINE MONITOR. Turn back sensor (1) 1/2 – 1 turn from this position. HD605-7 .

799-101-5002 C1 790-261-1204 J 566-35-43561 Part Name Remarks Pressure gauge Analog hydraulic 2. see MEASURING WITH MONITOR. • Read the ACC oil pressure (front or rear) when it stops rising at the highest point (Approx. Connect nipple J and hose [1] and install oil pressure gauge C1 (Oil pressure gauge: 39. (Measuring with diagnosing devices) 1) Stop the engine and remove plug (4) (18.9.) HD465-7.2. a Monitoring items (1) Code No. a For the method of measurement. apply the parking brake. 60. 5. (Read the pointer of the oil pressure gauge.5. and set chocks under the tires securely.5). 600 kg/cm2} Pressure gauge Digital hydraulic 58. 39.8 MPa meter {600 kg/cm2} Nipple 18 × 1. 145 kg/cm2}). HD605-7 20-131 (11) . 210 kg/ cm2}) after the cut-in pressure. 3) Measure the cut-in pressure at high idle. Stop the machine on a level place. 20. Measuring ACC charge oil pressure (Measuring with monitor) 1) Set the machine monitor in service mode 1 and display the following 2 items simultaneously with the monitoring function. 35501: ACC oil pressure (Rear) 2) Start the engine.2 MPa {400 kg/cm2}). 1.8 MPa {25. meter 58.2 MPa {Approx. 14. however.TESTING AND ADJUSTING INSPECTING BRAKE OIL PRESSURE INSPECTING BRAKE OIL PRESSURE Special tool list Symbol Part No. i) Press and release the brake pedal repeatedly to lower the oil pressure in the accumulator. 2) – 4). 35500: ACC oil pressure (Front) (2) Code No.6 MPa {Approx.5 (female: PT 1/8) 4) Measure the cut-out pressure at high idle. ii) Read the lower one of the ACC oil pressures (front or rear) when it starts rising after it reaches the bottom (Approx. 400. P: 1.

Rear brake operating pressure 1) Remove air bleeder (1) and install tool C1 [Oil pressure gauge: 39. a After finishing measurement. bleed air. a After finishing measurement. r eferr ing to BLEE DING A IR FRO M BRAKE CIRCUIT on the next page. Front brake operating pressure 1) Remove air bleeder (3) and install tool C1 [Oil pressure gauge: 39. r efe rr ing to B LEEDING AIR FROM BRAKE CIRCUIT on the next page. 2) Operate the brake pedal and retarder control lever and measure the oil pressure. a After finishing measurement.2 MPa {400 kg/ cm2}]. HD605-7 . 2) Turn OFF the parking brake switch (Release the parking brake) and measure the oil pressure. Parking brake releasing pressure 1) Remove air bleeder (2) and install tool C1 [Oil pressure gauge: 39. 2) Operate the brake pedal and measure the oil pressure. 4. 3. bleed air.2 MPa {400 kg/ cm2}]. r eferr ing to BLEE DING A IR FRO M BRAKE CIRCUIT on the next page.2 MPa {400 kg/ cm2}]. 20-132 (1) HD465-7. bleed air.TESTING AND ADJUSTING INSPECTING BRAKE OIL PRESSURE 2.

Parking brake a Bleed air from the differential top block side first. 2. 1. turn OFF the parking brake switch (release the parking brake) and loosen air bleeder screw (4) by 3/ 4 turns. 3) Bleed air from bleeder (5) on the wheel side similarly to step 1) above. Keep depressing the brake pedal until bubbles do not come out of the bleeder any more. a After finishing bleeding air. Front brake a Check that the front brake cut switch is turned OFF. 1) Loosen air bleeder (6) by 3/4 turns and bleed air similarly to step 1) for the rear brake. 3) Bleed air from bleeder (3) on the wheel side similarly to step 1) above. 2) Pull the retarder control lever and loosen air bleeder screw (1) or (2) by 3/4 turns. tighten (close) the bleeder and turn ON the parking brake switch (apply the parking brake). Keep pulling the retarder control lever until bubbles do not come out of the bleeder any more. 3. When bubbles do not come out any more. Stop the machine on a level ground and set chocks under the tires securely. a After finishing bleeding air. 1) Using a vinyl tube for bleeding air. tighten (close) the bleeder and release the retarder control lever. HD605-7 20-133 (10) . HD465-7. tighten (close) the bleeder and put the cap. then bleed air from the wheel brake side. then bleed air from the wheel brake side.TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT BLEEDING AIR FROM BRAKE CIRCUIT a If any brake circuit device was removed and installed or if the transmission and brake cooling oil was replaced. Rear brake a Bleed air from the slack adjuster side first. 1) Using a vinyl tube for bleeding air. depress the brake pedal and loosen air bleeder screw (1) or (2) by 3/4 turns. tighten (close) the bleeder and release the pedal. tighten (close) the bleeder and put the cap. 2) When bubbles do not come out of the bleeder any more. When bubbles do not come out any more. bleed air from the brake circuit according to the following procedure.

2. so replace it. so check the wear of all pads.TESTING AND ADJUSTING TESTING WEAR OF FRONT BRAKE PAD TESTING WEAR OF FRONT BRAKE PAD Special tool list Symbol b Part No. 1. then insert inspection gauge b into indicator hole d of the caliper (3). replace the pad. 20-134 (10) HD465-7. and if the pad has reached the wear limit line. and put chocks under the tires. HD605-7 . 566-98-41410 Part Name Gauge Remarks Tools on truck Stop the machine on level ground. a The pad wear is not the same for both left and right sides. apply the parking brake. e: Remaining thickness up to wear limit a Replace the pads on the left and right sides at the same time. keep the pad (1) pressed against the disc (2). Visual check Check visually. the pad has reached the wear limit. Checking with gauge 1) Depress the brake pedal. 2) If the stepped part of the gauge contacts the mouth of the hole.

HD465-7. When the disk comes close to the wear limit.0 kgm} 4. HD605-7 20-135 (10) . 2. and put chocks under the tires.6 Nm {2. Install cap nut (1) of the gauge. 1. Stop the engine. so do not loosen locknut (4) of guide (3) except when replacing the disc. a Outer end b of groove D indicates the wear limit for the disc. the disc has reached the wear limit. Be sure to carry out inspection of the retarder braking performance at the same time. turn the parking brake switch PARKING. The adjustment position will move out of alignment. carry out the inspection more frequently. a With a new machine. 3.TESTING AND ADJUSTING TESTING WEAR OF REAR BRAKE DISC TESTING WEAR OF REAR BRAKE DISC Stop the machine on level ground. Push in the rod (2) of the gauge until it contacts the piston and judge the amount of wear. Carry out the inspection when the brake oil temperature is less than 60°C. If it is inside guide (3) totally [If it reaches the end face of guide (3)]. Cap nut: 19. adjust so that inner (deeper) end a of groove D on the rod (2) is aligned with the end face of guide (3). 6. Check that the brakes other than parking brake are not being actuated. Remove cap nut (1) of the gauge.

the wheel brake probably does not work normally. release it tentatively according to the following procedure.TESTING AND ADJUSTING METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY METHOD OF RELEASING PARKING BRAKE IN AN EMERGENCY a If the parking brake cannot be released because of a trouble in its electric or hydraulic system. stop the engine. Remove plugs (1) (10 pieces). When releasing the parking brake. When releasing the parking brake. stop the machine on a level place and make sure of the safety around it. Prepare 10 sets of bolt (2) (01017-51230). and nut (4) for releasing the parking brake manually and tighten the bolts alternately and evenly to release the parking brake. Accordingly. a Tighten nuts (4) to pull piston (5) and release the parking brake. HD605-7 . If it is obliged to release the parking brake on a slope in an emergency.5 – 3.3 Nm {2. be sure to tow the machine at low speed after releasing the parking brake.5 – 34. If the hydraulic system has a trouble. put chocks under the tires securely. a Prepare a container to receive the oil flowing out of the plug holes. Tightening torque for plug: 24.5 kgm} 2. 20-136 (10) HD465-7. washer (3). 1.

there is danger that releasing the gas from the valve core of feed valve (3) will damage the valve core. and hoist control lever at the FLOAT position. then loosen the valve (1) 2 – 3 turns. i) Use the retarder brake (Note 1) and drive the machine several times repeatedly forward and in reverse to set to the soft mode. loosen only the valve itself. a With the truck empty. and the resistance of the cylinder increases. starting switch ON. a When loosening the valve (1).TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER Special tool list Symbol 1 2 3 4 5 6 7 H 8 9 10 11 12 13 Part No. 2) Before adjusting the oil level. : 792-610-1200 Remarks a Stop the machine empty on level ground. a If the cylinder of the variable damper valve is not in the soft mode when checking. 2. operate as follows to switch to the soft mode. a When releasing the nitrogen gas. the automatic suspension is automatically set to the medium mode. 792-610-1000 •792-610-1130 •792-610-1110 •792-610-1120 •07020-21732 •792-610-1140 •792-610-1250 •792-610-1260 •792-610-1480 •792-610-1640 •792-610-1400 •792-610-1430 •792-610-1440 Part Name Suspension tool Pump assembly H2 – H6 : Pump assembly Hose Kit No. parking brake OFF. check that the cylinder of the variable damper valve is in the soft mode. Testing length of cylinder 1) Check that the bottom of the cylinder cover is within the range e marked by arrows for the cylinder level. check the condition of the variable damper valve. 1.81 MPa {100 kg/cm2} H7 – H13 : Charging tool assembly Kit No. HD605-7 20-137 (10) . so remove the gas at the valve (1). Note 1: If the foot brake pedal is used. Do not loosen the pressure sensor or nipple. S posision : soft mode H posision: hard mode M posision: medium mode HD465-7. Releasing nitrogen gas 1) Front suspension cylinder i) Set hydraulic jack [1] (50ton) under the main frame. so it takes time to adjust. : 792-610-1100 Joint Fitting Joint Valve assembly Nipple Stem Joint Regulator assembly Gauge Gauge 24.5 MPa {250 kg/cm2} 9. ii) Disconnect pressure sensor connector (2) of valve (1).

2) Install fitting H5 to joint H4.2 – 49. and install joint H6. then operate volume pump H2 until no more bubbles come out with the oil from the valve (1) mount. and allow time for the gas to escape slowly. remove the volume pump. Adjusting of oil level a Release the nitrogen gas before adjusting the oil level.0 Nm {4 – 5 kgm} 3.TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER a When the valve (1) is loosened. 3 Valve: 39.2 – 49. tighten the valve (1). Dimension a:79 ± 3 mm (Standard) 79 ± 3 mm (With buffer ring) 7) After completion of supplying the oil. HD605-7 . tighten air bleeding valve (4). 3) Loosen air bleeding valve (4). 3 Air bleeding valve: 39. then connect hose H3 and volume pump H2.0 Nm {4 – 5 kgm} 20-138 (10) HD465-7. 1) Remove feed vavle (3).0 Nm {4 – 5 kgm} 5) Remove valve (1). iii) Operate the hydraulic jack so that dimension a of the cylinder is the specified dimension for the oil level. then install feed valve (3). and oil and gas spurt out together.2 – 49. 4) When no more bubbles come out with the oil. 6) When no more bubbles come out with the oil. 3 Feed valve: 39. then operate volume pump H2 until no more bubbles come out with the oil from air bleed side hole b. tighten the valve slightly.

pressure inside suspension cylinder: 4.981 MPa {10 kg/cm 2 } above the internal pressure of the suspension cylinder. a Be careful not lose the O-ring of the feed valve. 5) When dimension a of the left and right cylinders reaches the standard value. a Before installing regulator H11. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). a Standard dimension a: 249 ± 10 mm 6) Turn handle H10a of H10 fully back counterclockwise. loosen air bleeding plug H7a of valve H7 .31 MPa {44 kg/cm2}). 4) Turn handle H11a of regulator H11 slowly clockwise. set the pressure reading of gauge H13 to 0. then remove tool H. release the gas inside the hose. a Fill the left and right cylinders in the same way. then operate valves H7 and H10 to fill the suspension cylinder with nitrogen gas.TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER 4. blow the connector filter with nitrogen gas at 0. (Dirt or dust in the system causes failures.981 MPa {10 kg/cm2} or more to blow out all dirt or dust.) 3) Open valve [2] of the gas cylinder [1]. HD465-7. turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas. a The pressure indicated must be at least 0. HD605-7 20-139 (10) . and check the pressure reading of gauge H12 (internal pressure of gas cylinder).981 MPa {10 kg/cm2 } higher than the pressure inside the suspension cylinder (max. 2) Set tool H as shown in the diagram.

check the installed length of the suspension and adjust the gas if the length is not within the specified value. Checking after changing oil and gas After the oil and gas have been changed. HD605-7 . 4) Repeat the above Steps 1) – 3) to adjust the cylinder to the specified length. do not make the cylinder move. Therefore. Checking for changes in installed length caused by variation in ambient temperature. so the volume of gas is reduced and the installed length of the suspension goes below the specified limit. valve (1). 20-140 (10) HD465-7. use tool [3] and remove the valve core. 5) Finally. a If there is any leakage of gas from the valve core. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine-empty and on level ground. When doing this. the installed length may be below the specified length. Use the retarder control lever to brake the machine. repeat Step 1) to check the installed length again. a Loosen the valve (1) slightly to release the nitrogen gas. Note:1. the valve core may be damaged. If the tip of the valve core is pressed. Depending on the ambient temperature when the machine is working. check that there is no leakage of gas from the valve core (6). a Do not press the tip of the valve core. and finally. so the installed length will also change. drive the machine forward approx. 2. a Use soapy water to check for leakage of gas.TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER 5. then drive in reverse to the original position and stop again suddenly. a Do not use the foot brake when braking the machine. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing). 2) If the result of the check shows that the installed length is too long. In territories where there are big differences in temperature throughout the year. 3) After releasing nitrogen gas and adjusting the installed length. 15 m and stop suddenly. a If too much nitrogen gas is released and the cylinder moves. inspect daily and adjust to keep the installed length within the specified range. operation of the machine causes the gas to dissolve in the new oil inside the cylinder until it is saturated. the gas in the suspension may expand or contract. release only a small amount of gas. allow the machine to stop slowly without depressing the brake. release nitrogen gas to adjust the length. Then measure the installed length. and piston rod gland. and check that the suspension is in the soft mode. 48 hours after changing the oil and gas. Repeat this cycle 3 – 4 times.

tighten the valve slightly. Specified value for dimension "a" : 220 ± 10 mm (Standard) : 204 ± 10 mm (With buffer ring) Thickness of frange b a For the standard dimensions. and allow time for the gas to escape slowly. there is danger that releasing the gas from the valve core of feed valve (3) w il l d am a g e t he v a lv e c o r e . Releasing nitrogen gas 1) Rear suspension cylinder i) Set block [2] between the stopper and axle housing. HD605-7 20-141 (11) . see the decal stuck to the cylinder. 2. a When releasing the nitrogen gas. gradually loosen only valve (1) itself. Thickness of block: 19 mm Dimension a : 140 ± 3 mm (Standard) : 124 ± 3 mm (With buffer ring) HD465-7. Do not loosen the pressure sensor or nipple. s o remove the gas at the valve (1). k If the nitrogen gas has not all been released. then loosen the valve 2 – 3 turns. and do not remove the valve until all the nitrogen gas has been released from the slit. so do not loosen them under any circumstances. Testing length of cylinder Check that dimension "a" of the rear suspension cylinder is within the specified value. a When loosening the valve (1). a When the valve (1) is loosened. loosen only the valve itself. pressure sensor (5) are still under high pressure. 1. and oil and gas spurt out together. Standard 49 mm With buffer ring 65 mm ii) Disconnect pressure sensor connector (2) of valve (1). k When loosening the valve (1).TESTING AND ADJUSTING TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER a Stop the machine empty on level ground.

then install feed valve (3). set the pressure reading of gauge 20-142 (10) HD465-7. then operate valves H7 and H10 to fill the cylinder with nitrogen gas. then connect hose H3 and volume pump H2. 4) When no more bubbles come out with the oil. Filling suspension cylinder with gas 1) Remove cap (5) from feed valve (3). 3) Loosen air bleeding valve (1). and install joint H6. a Standard dimension a : 220 ± 10 mm (Standard) : 204 ± 10 mm (With buffer ring) 6) Turn handle H10a of H10 fully back counterclockwise.981 MPa {10 kg/cm2} or more to blow out all dirt or dust. a Fill the left and right cylinders in the same way.TESTING AND ADJUSTING TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 3. 5) When dimension "a" of the left and right cylinders reaches the standard value. 4) Turn handle H11a of regulator H11 slowly clockwise. 1) Remove feed valve (3). 4. blow the filter in the connector with nitrogen gas at 0. Adjusting oil level a Release the nitrogen gas before adjusting the oil level. and check the pressure reading of gauge H12 (internal pressure of gas cylinder).981 MPa {10kg/cm 2 } above the internal pressure of the cylinder. 2) Install fitting H5 to joint H4. a Be careful not to lose the O-ring of the feed valve. a The pressure indicated must be at least 0. then remove tool H. release the gas inside the hose. turn handle H11a of regulator H11 counterclockwise to stop the flow of nitrogen gas.74 MPa {28 kg/ cm2}). (Dirt or dust in the system causes failures. 5) After adding oil. loosen air bleeding plug H7a of valve H7 .) 3) Open valve [2] of the gas cylinder [1]. then operate volume pump H2 until no more bubbles come out with the oil from air bleeding valve (1). H13 to 0. HD605-7 . a Before installing regulator H11. remove the volume pump. 2) Set tool H to the feed valve supply as shown in the diagram.981 MPa {10kg/cm 2 } higher than the pressure inside the cylinder (max. tighten air bleeding valve (1). pressure inside cylinder: 2.

When doing this. 2) If the result of the check shows that the installed length is too long. 2) Check that hooks (2) are not missing. Band: 6. do not make the cylinder move. repeat Step 1) to check the installed length again. a Loosen the valve slightly to release the nitrogen gas.49 Ncm {69 ± 5 kgcm} HD465-7. a If the cover is damaged. 3) After releasing nitrogen gas and adjusting the installed length. drive the machine forward approx. 1) To remove the sliding resistance of the cylinder (catching of bushing or packing). the installed length may be below the specified length. Repeat this cycle 3 – 4 times.TESTING AND ADJUSTING TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER 5. replace it with a new part. 4) Repeat the above Steps 1) – 3) to adjust the cylinder to the specified length. a Replace valve core (6) if there is any leakage of gas from the valve core. then check that the suspension is in the soft mode. HD605-7 20-143 (10) .8 ± 0. a Do not use the foot brake when braking the machine. check that there is no leakage of gas from the valve core (6). release nitrogen gas to adjust the length. allow the machine to stop slowly without depressing the brake. V a l v e c o r e : 6. release only a small amount of gas. Use the retarder control lever to brake. Then measure the installed length. a Do not press the tip of the valve core. then install hooks. a Use soapy water to check for leakage of gas. a If the band is loose or missing. then drive in reverse to the original position and stop again suddenly. tighten to the following torque. 15 m and stop suddenly. and piston rod gland. Adjusting installed length of cylinder a Carry out adjustment of the installed length of the cylinder with the machine empty and on level ground. the valve core may be damaged. remove all mud and dirt. the machine. Testing and adjusting dust cover a To protect the rear suspension from stones and other objects thrown up by the tires when the machine is traveling. and finally. then drive the machine forward approx. If the tip of the valve core is pressed. 15 m and stop suddenly. 5) Finally. valve. (3 places) a If any hooks are missing. 1) Check visually that there are no cracks or breaks in cover (1). a If the nitrogen gas is so released that the cylinder may move. 3) Check that band (3) is not loose or missing. carry out inspection of the cover and repair or replace it as necessary.

Adjusting 1) Remove mounting bolt (2) of hydraulic cylinder (1) and disconnect hydraulic cylinder (1).TESTING AND ADJUSTING TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER) TESTING AND ADJUSTING FRONT SUSPENSION CYLINDER (MODE SELECTOR HYDRAULIC CYLNDER) 1. a Specified length "a": 352 ± 1 mm 2) Shift the hoist lever from the FLOAT position to another position and check that hydraulic cylinder length "a" is not (is longer than) 352 ± 1 mm. (Reference) • "b" in hard mode : 383 ± 1 mm • "d" in medium mode : 414 ± 1 mm 5) Check that the hole of bracket (5) is in the slit (part "e") in modes S and M. HD605-7 . (3) Parking brake switch is ON. 2. (2) Starting switch is ON. 10858 20-144 (1) HD465-7. 2) Loosen locknut (3) and adjust mounting length "a" with rod end. Testing 1) Check that length "a" of hydraulic cylinder (1) is as specified under the following condition. a Specified length "a": 352 ± 1 mm 3) Install (Return) hydraulic cylinder (1) with mounting bolt (2). a Condition (Mode S) (1) Machine is empty. 4) Turn the starting switch to the ON position and shift the hoist lever from the FLOAT position to another position and check that length "a" of hydraulic cylinder (1) is not (is longer than) 352 ± 1 mm. (4) Work equipment control lever is at FLOAT.

5. Measuring hydraulic pressure in steering circuit 1) Raise the hydraulic oil temperature. a To INCREASE pressure. and put chocks under the tires. HOIST CIRCUIT a Special tool list Symbol Part No. • Steering pressure (adjust with demand valve) 1) Remove cap (2). turn CLOCKWISE To DECREASE pressure. apply the parking brake.9. turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 2. Lower the body to the frame.22 MPa {400 kg/cm2}). 600 kg/cm2} Pressure gauge: 58. 60. HOIST CIRCUIT TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING.8 MPa {600 kg/cm2} Stop the machine on level ground.45 MPa {25 kg/cm2}.8 MPa {25. adjust as follows. then loosen locknut (3) and turn adjustment screw (4) to adjust. then remove the cap from the hydraulic tank and release the pressure inside the cylinder circuit.5.2. Steering circuit 1. 799-101-5002 C1 790-261-1204 Digital hydraulic meter Part Name Analog hydraulic meter Remarks Pressure gauge: 2. 2. 58.TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING. 400. a Oil temperature when measuring : 45 – 55°C 2) Remove plug (1) and install tool C1 (39. and measure the hydraulic pressure when the circuit is relieved. Adjusting hydraulic pressure in steering circuit If the hydraulic pressure is not within the standard value. 3) Operate the steering wheel fully to the left or right. HD605-7 20-145 (11) . 10860 HD465-7. 39. stop the engine.

hold the adjustment screw with a screwdriver to prevent it from turning.22 MPa {400 kg/cm2}). and move the dump body to the maximum dump position to relieve the circuit. cap: 29. a Oil temperature when measuring : 45 – 55°C 2) Remove oil pressure measurement plug (1) and install tool C1 (39. Measuring hydraulic pressure in steering cylinder 1) Remove pressure measurement plug (7) (when turning the steering to the left) or pressure measurement plug (8) (when turning the steering to the right). then measure the hydraulic pressure with the engine at full throttle. so do not adjust the pressure. Hoist circuit 1. Measuring steering valve charge pressure 1) Remove plug (6) and install tool C1 (39. 3) Operate the hoist control lever. 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit. 2) Measure in the same way as when measuring the hydraulic pressure in the steering circuit. 4. HD605-7 .2 MPa {400 kg/cm2}). 20-146 (10) HD465-7. and install tool C1 (39. 3. then tighten the locknut and install the cap. HOIST CIRCUIT 2) After adjusting.TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING. a The pressure of crossover relief valve (5) cannot be adjusted when it is installed on the machine.4 – 39. Measuring hydraulic pressure in hoist circuit 1) Raise the hydraulic oil temperature. For details.2 MPa {400 kg/cm2}). see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT.2 Nm {3 – 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value.

22 MPa {400 kg/cm2}). Lock nut: 29.2 Nm {3 – 4 kgm} 3) Check again so that the hydraulic pressure is within the specified value.2 MPa {42.TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING. then tighten the locknut. For details.8 kg/cm2}.4 – 39. a To INCREASE pressure. 3. see MEASURING HYDRAULIC PRESSURE IN STEERING CIRCUIT. HD465-7. turn COUNTERCLOCKWISE a One turn of the adjustment screw adjusts by 4. HD605-7 20-147 (10) . turn CLOCKWISE To DECREASE pressure. HOIST CIRCUIT 2. adjust as follows. 2) After adjusting. hold the adjustment screw with a screwdriver to prevent it from turning. Adjusting hydraulic pressure in hoist circuit If the hydraulic pressure is not within the standard value. Measuring hoist cylinder pressure 1) Remove plug (4) and install tool C1 (39. 2) Measure in the same way as when measuring the hydraulic pressure in the hoist circuit. Hoist cylinder pressure (adjust with hoist valve) 1) Loosen locknut (2) and turn adjustment screw (3) to adjust.

9 MPa {60 kg/cm2}]. 60.8 MPa {600 kg/cm2} 14 × 1.TESTING AND ADJUSTING TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT a Special tool list Symbol Part No. 39. 1 790-261-1204 C 3 4 799-101-5230 799-401-3100 02896-11008 Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 58. 4) Start the engine and raise or lower the dump lever and measure the circuit oil pressure. 20-148 (11) HD465-7. 799-101-5002 Part Name Analog hydraulic meter Digital hydraulic meter Nipple Adapter O-ring Remarks Pressure gauge: 2. 600 kg/cm2} Pressure gauge: 58. (3): Dump raise side (Port PB) (4): Dump lower side (Port PA) Measuring 1.5.2.5 Face seal type (#02) (Female: PT 1/8) — 2) Install nipple C3 and hose [2] and connect oil pressure gauge C1 [5. 2) Install adapter C4 to hoist valve and connect the hose. HD605-7 .9.5) from dump EPC valve (1) inside the hydraulic tank (inside the machine). 3) Install nipple [1] and hose [2] and connect oil pressure gauge C1 [5. Measuring dump EPC valve main pressure 1) Remove oil pressure pickup plug (2) (M14 x 1. 5. 400. 3) Start the engine and measure the oil pressure when the dump lever is in neutral.8 MPa {25. 2.9 MPa {60 kg/cm2}]. Measuring dump EPC valve output pressure 1) Disconnect EPC hose (3) or (4) to be measured.

Repeat this action ten times. (This action is to prevent damage to the piston seal caused by compression and combustion of air in the steering cylinder. 4. Before operating the steering wheel. 2. Start engine. HD465-7. apply the parking brake. 50 mm from the end of the steering cylinder stroke. Turn the steering wheel as quickly as possible to the left and right to the end of the steering cylinder stroke. 1. HD605-7 20-149 (10) . When reaching the end of the stroke at the left and right. Turn the steering wheel at 30 rpm to the left and right to the end of the steering cylinder stroke. then put chocks under the tires.TESTING AND ADJUSTING AIR BLEEDING FROM STEERING CYLINDER AIR BLEEDING FROM STEERING CYLINDER Stop the machine on a level ground. a If the hydraulic cylinder was removed and installed or its hydraulic piping was removed. and carry out this action continuously. turn the steering wheel immediately in the opposite direction. be sure to check that there is no one around the front tires. Turn the steering wheel at 30 rpm (2 seconds for one turn) to the left and right to a point approx. run engine at low idle for 5 minutes. Repeat this action four times.) 3. Repeat this action ten times in both direction. breed air from the hydraulic cylinder according to the following procedure.

5 kgm} 4. remove plug (2) and tighten tool [K] slowly. turn the emergency steering switch "ON" and raise the dump body with the hydraulic pressure of the emergency steering pump. Tightening torque of plug: 44. be sure not to go under the dump body but stand on the ground. cool down the steering pump.5 – 5. 20-150 (10) HD465-7. a The dump body lowers by itself. Keep it at safe lowering speed by adjusting the tightening depth tool [K]. a Do not operate the emergency steering pump for more than 90 seconds continuously. 1. raise it to dump the load according to the following procedure. If the load cannot be dumped in 90 seconds.5 – 5. When lowering the dump body. HD605-7 .5 kgm} a If the dump body cannot be raised because of a failure in the controller or electric system. 792T-491-1110 Part Name Plug Remarks — When performing this procedure. 2) If the engine cannot be started. and the dump body rises. After the dump body lowers completely.1 – 53.9 Nm {4.9 Nm {4. Stop the engine and remove the hydraulic tank cap to release the residual pressure from the hoist circuit. Remove plug (1) and tighten tool [K] fully.TESTING AND ADJUSTING PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY a Special tool list Symbol K Part No. 5. Stop the engine and remove tool [K] and install plug (1). start the engine under this condition. a If tool [K] is tightened in fully. the spool is moved to the rising stroke end. and then operate it again. 3. 1) If the engine can be started.1 – 53. remove tool [K] and install plug (2). Tightening torque of plug: 44. 2.

35 – 0. inspect and adjust the body positioner sensor as follows. 3) Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position and RAISE position. 5) Tighten locknut (1). a Do not set installing length a less than 430 mm. HD465-7 #7057 and up HD605-7 #7021 and up 1.TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR ADJUSTING BODY POSITIONER SENSOR a If the body positioner rod has been disconnected and connected again or the body positioner sensor has been removed and installed again.40 V: HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 0. adjust the length of the link as follows. 2) Start the engine.80 – 4. Adjusting link length a If the monitoring voltage is not within the normal range. a Standard installing length a: 433 mm.44 V: HD465-7 #7057 and up HD605-7 #7021 and up a When operated fully to RAISE: 3. adjust it to the same value with following model. 6) Repeat the checking procedure above to check that the input voltage is within the normal range. see SPECIAL FUNCTIONS OF MACHINE MONITOR. 2) Remove mounting bolt (2). Checking sensor input voltage 1) Switch the machine monitor display to the monitoring function of service mode 1 and display the body positioner sensor input voltage. • INCREASE link length to DECREASE voltage • DECREASE link length to INCREASE voltage 4) Install mounting bolt (2). a HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 • If the positioner link is changed. HD465-7 #7057 and up HD605-7 #7021 and up a Adjust the input voltage as follows. a When operated fully to LOWER: 0. HD465-7 #7001 – 7056 HD605-7 #7001 – 7020 a Standard installed length "a" of link: 440 mm a Do not reduce length "a" to below 436 mm. 3) Turn rod end (3) to adjust the length of the link (4). 2.38 – 0. a Monitoring item Code No. 1) Loosen locknut (1). HD605-7 20-151 (8) .70 V HD465-7. 34400: BODY POSITION a For details of the method of operation.

Then. a Repeat the operations of 3) and 4) above 5 – 10 times.TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR 3. then put chocks under the tires securely. 20-151-1 (10) HD465-7. Then. Calibrating system Stop the machine on a level ground. a Repeat this operation 5 – 10 times. run the engine at low idle and keep the dump control lever in the RAISE position for at least 5 seconds. 2) Keep the dump control lever in the FLOAT position for at least 5 seconds. 4) Run the engine at high idle and raise the body to the stroke end. a Hydraulic oil temperature: 80 – 90°C 1) With the body seated perfectly. start the engine. 5) Run the engine at high idle and raise the body to the stroke end. a Check that the FLOAT caution lamp is turned off. lower the engine speed to low idle and set the dump control lever in the FLOAT position to lower the body to the seating position. 3) With the body raised to the cylinder stopper. apply the parking brake. HD605-7 . keep the engine speed at high idle and set the dump control lever in the LOWER position to lower the body to the seating position.

temporarily restore the engine electrical system or transmission electrical system.3 (10A) BT2 --. tow machine to safe place (see note) Does engine start when en.No. it may become impossible to start the engine or to move the machine off. When problem occurs in engine control system and engine cannot be started a Decide the escape method according to the following flowchart.15 (20A) BT4 --. For details. the parking brake cannot be released by operating the switch. see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE. move the machine to a safe place. 20-152 (11) HD465-7.No. a For details of the method of checking the failure code.10 (10A) YES Start engine and move machine (do not turn electric power ON except when absolutely necessary) YES 6 Is following service code YES displayed or recorded? C111KT C346KT (ENG) NO 8 YES 7 If there is no controller to replace. then carry out troubleshooting. see SPECIAL FUNCTIONS OF MACHINE MONITOR. If such a problem occurs. 1 Did [Engiine system caution NO lamp] on machine monitor flash when engine stopped? YES 2 NO Tow machine to safe place (see note) Is there fuel in fuel tank? 3 YES 4 5 Does engine start when folNO lowing relay is replaced? R01 (engine start relay) If there is no relay to replace or engine does not start. tow machine to safe place (see note) Is following service code YES displayed or recorded? C441KK (ENG) 442KG (ENG) NO Does engine start when following fuse is replaced? NO FUA (30A) BT2 --. HD605-7 .TESTING AND ADJUSTING METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM If any problem occurs in the electrical system of the engine control system or transmission control system.NO gine controller is replaced? 9 Does engine start when following speed sensor is replaced? NO Master speed sensor (SP1) Back-up speed sensor (SP2) YES Start engine and move machine (do not turn electric power ON except when absolutely necessary) If there is no speed sensor to replace or engine does not start. 1.No. so carry out the operation to release it temporarily. tow machine to safe place (see note) Is following service code YES displayed or recorded? C115KZ (ENG) C121LC (ENG) NO 10 Does engine start when folYES lowing relay is replaced? R02 (transmission neutral relay) NO Tow machine to safe place (see note) Note: If the engine cannot be started and the machine is towed.

see SPECIAL FUNCTIONS OF MACHINE MONITOR. Escape procedure 1 D – L : F2. the neutral condition is maintained until the lever is returned to the N position. HD605-7 20-153 (10) . R : R Escape procedure 3 D – L : F1. transmission stays in neutral even when lever is operated. R : R Escape procedure 2 — Escape procedure 3 D – L : F2 Escape procedure 1 D – L : F2. R : R Escape procedure 1 Escape procedure 1 D – L : F2 Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. when the machine is moved off again.TESTING AND ADJUSTING METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 2. transmission does not shift to any speed range. speed range does not shift. transmission shifts to neutral. a When lever is returned to N. R : R Escape procedure 1 D – L : F1 Escape procedure 1 D – L : F2 Escape procedure 1 D – L : F4 Escape procedure 1 Escape procedure 1 D – L : F6 R:R R:R HD465-7. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. when the machine is moved off again. R : R Escape procedure 1 D – L : F2. Occurrence condition 2: Transmission suddenly shifts to neutral when the machine is traveling. R : R Escape procedure 1 D – L : F2. R : R Normal travel possible if display Escape procedure 4 returns to normal (Note 1) Normal travel possible if display Escape procedure 5 returns to normal (Note 1) Normal travel possible if display Escape procedure 4 returns to normal (Note 1) Normal travel possible if display Escape procedure 9 returns to normal (Note 1) Normal travel possible if display Escape procedure 7 returns to normal (Note 1) Normal travel possible if display Escape procedure 7 returns to normal (Note 1) Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F6 Escape procedure 1 D – L : F2. Failure code 1380MW 1500L0 15G0MW 15H0MW 15J0MW 15K0MW 15L0MW 15M0MW 15N0MW 15SBL1 15SBMA 15SCL1 15SCMA 15SDL1 15SDMA 15SEL1 15SEMA 15SFL1 15SFMA 15SGL1 15SGMA 15SHL1 15SHMA 15SJL1 15SJMA D1B0KZ DAQ0KK DAQ2KK DAQ9KM DAQ9KQ DAQAKQ DAQSMA DDTGKA DDTHKA DDTJKA DDTKKA DDTLKA DDTMKA DDTNKA DDTPKA Condition when failure occurred Occurrence condition 1 Occurrence condition 2 Occurrence condition 2 Occurrence condition 3 Occurrence condition 3 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 1 Occurrence condition 1 Occurrence condition 2 Occurrence condition 2 Occurrence condition 2 Occurrence condition 4 Occurrence condition 4 Occurrence condition 4 Occurrence condition 4 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Escape method Lever position for speed range to move off after escape operation Remarks Occurrence condition 1: Speed range remains fixed. R : R Escape procedure 1 D – L : F2 Escape procedure 1 D – L : F1. and machine does not move off. R : R Escape procedure 3 D – L : F2. Occurrence condition 3: Transmission suddenly shifts to neutral. a When lever is returned to N. but after that. R : R Escape procedure 1 D – L : F2. transmission shifts to neutral. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. after machine is stopped. Occurrence condition 5: Response of lever becomes abnormal. transmission stays in neutral even when lever is operated. R : R Escape procedure 3 D – L : F2. R : R Escape procedure 1 D – L : F2. Note 1: Even when the machine condition is restored after a failure. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller. R : R Escape procedure 1 D – L : F4 Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F1 Escape procedure 1 D – L : F2. a For details of the method of checking the failure code. When problem occurs in transmission control system and machine cannot be started a Check the service code and determine the escape method from the following chart. R : R Escape procedure 3 D – L : F2. transmission shifts to neutral. speed range does not shift. and machine does not move off. Occurrence condition 4: After engine is started. Occurrence condition 6: Speed range remains fixed. lever does not work as operated When lever is operated.

R : R Escape procedure 1 D – L : F2. see METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE. R : R Escape procedure 1 D – L : F2. 2) Operate the gearshift lever again and move the machine OFF. R : R Escape procedure 1 D – L : F2. a When operating the gearshift lever. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F1. Escape procedure 3: 1) Stop traveling and return the gearshift lever to the N position. For details. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. a Connect and disconnect the connectors with the starting switch at ON or with the engine started. 3) Operate the gearshift lever again and move the machine OFF. a If the engine cannot be started and the machine is towed. R : R Escape procedure 1 D – L : F2. 2) Connect and disconnect emergency escape connectors A1 (female) and A2 (male). R : R Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. HD605-7 . 20-154 (10) HD465-7. a When operating the gearshift lever. Note 2: This phenomenon applies when there is no display on the machine monitor and there is also no display in the display window of the transmission controller. R : R Escape procedure 1 D – L : F1. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 3 D – L : F2. the parking brake cannot be released by operating the switch. Normal travel possible if display Escape procedure 8 returns to normal (Note 1) Normal travel possible if display Escape procedure 8 returns to normal (Note 1) Escape procedure 1 D – L : F2. R : R Escape procedure 1 D – L : F2. R : R Escape procedure 3 D – L : F2. a N o D – L or N o R Escape procedure 2: Tow the machine. R : R Escape procedure 1 D – L : F4 Escape procedure 1 D – L : F1 Escape procedure 1 D – L : F2. the neutral condition is maintained until the lever is returned to the N position. so carry out the operation to release it temporarily. a Connectors A1 and A2 are installed to near the fuse box. a N o D – L or N o R a The emergency escape mode is maintained until the starting switch is turned OFF. and switch to the emergency escape mode. R : R Escape procedure 1 D – L : F2. release the accelerator pedal. R : R Normal travel possible if display Escape procedure 5 returns to normal (Note 1) Escape procedure 1: 1) Stop traveling and return the gearshift lever to the N position. R : R Escape procedure 1 D – L : F2. release the accelerator pedal. R : R Escape procedure 1 D – L : F1.TESTING AND ADJUSTING METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM Failure code DF10KA DF10KB DLE2KA DLE2LC DLF1KA DLF1LC DLF2KA DLF2LC DLT3KA DLT3LC DXH1KB DXH2KA DXH2KB DXH3KA DXH3KB DXH4KA DXH4KB DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXHHKA DXHHKB – (Note 2) Condition when failure occurred Occurrence condition 5 Occurrence condition 2 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 1 Occurrence condition 6 Occurrence condition 6 Occurrence condition 1 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 3 Occurrence condition 2 Escape method Lever position for speed range to move off after escape operation Remarks Note 1: Even when the machine condition is restored after a failure. R : R Escape procedure 1 D – L : F2.

a For details of checking the model selection setting. 23 (80A) • Fuse: BT3-No. and if it is normal. Escape procedure 8: Check the fuse. HD465-7. and if they are normal. 10 (10A) Escape procedure 9: Check the transmission controller harness. • Fuse unit: Inside battery housing (30A) • Fuse: BT2-No. and if it is normal.TESTING AND ADJUSTING METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM Escape procedure 4: Replace the transmission cut relay. replace the transmission controller. 22 (10A) Escape procedure 7: Check the model selection setting. • Fuse: BT3-No. see ADJUSTING TRANSMISSION CONTROLLER. replace the transmission controller. replace the transmission controller. replace the transmission controoler. HD605-7 20-155 (1) . replace the gearshift lever. 14 (10A) Escape procedure 6: Check the fuse unit and fuse. and if it is normal. • Circuit breaker: No. • Transmission cut relay: R15 Escape procedure 5: Check the circuit breaker and fuse. and if they are normal.

SW6). HD605-7 .TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR ADJUSTING MACHINE MONITOR (EMMS) • EMMS: Equipment Management Monitoring System Machine monitor (EMMS) rotary switches (SW1. dipswitches (SW5. SW3). and option setting connectors (OP1 – OP7) 20-156 (1) HD465-7. SW2.

• When machine monitor (EMMS) have been replaced with new parts (service meter. so see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). so see TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE) for details. Unnecessary Unnecessary Unnecessary Unnecessary Open (Not connected) Connected Only in area where MPH is used as unit • • The condition of each switch and connector can be checked with the special function of the machine monitor (EMMS) (monitoring function). • When service code [DAFOKM] is displayed a There is probably mistaken connection of the option setting connector. speed when body is raised Setting of specification Unit of speed meter: km/h Unit of speed meter: MPH Exhaust brake: Not installed Connector Unnecessary Remarks Standard tire is set to position 7. • When the machine monitor has been removed and installed again. change the setting. • When the specification is changed as shown in Table 1. Table 1: Condition of switch setting functions and option setting connectors. dipswitches.TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR • In the following cases. a For details. see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS). and option setting connectors at the rear face of the machine monitor (EMMS). odometer. speed • Setting of max. it is necessary to use the special operation of the character display and mode switch. reverse travel odometer setting) a When carrying out of these settinigs. HD605-7 20-157 (10) . and change the settings as necessary. HD465-7. check the settings of the rotary switches. Connector OP7 is used for the special function of the machine monitor. Switch SW1 SW2 0–F SW3 1 ON OFF 2 SW5 3 ON OFF 4 ON OFF 1 ON OFF 2 SW6 ON OFF 3 ON OFF 4 ON Spare Spare Spare Setting of caution when body is raised: Installed Spare Connected Maintenance function: Installed Setting of caution when body is raised: Not installed Front brake cut: Installed Maintenance function: Not installed Spare Front brake cut: Not installed Open (Not connected) Connected Open (Not connected) Connected Open (Not connected) ON OFF Exhaust brake: Installed Spare 0–F OFF Position 0–F Purpose of switch Correction of travel speed (Correction of tire size) • Setting of max.

speed F7 (Default) F5 F4 F6 F5 F4 F6 F5 F4 F6 F5 F4 Setting of max. a The protruding triangular part of the rotary switch is the setting arrow. If the tire size is changed. a Be careful not to touch anything inside the grommet except for the switch.) a Travel speed compensation using SW1 Position 0 1 2 3 4 5 6 7 Speed compensation +7% +6% +5% +4% +3% +2% +1% 0% Position 8 9 A B C D E F Speed compensation 0% –1% –2% –3% –4% –5% –6% –7% 2. a When turning the rotary switch.TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR a All setting operations are carried out with the starting switch OFF and the monitor panel removed. 1. a After setting. speed when body is raised F2 (Default) F2 F2 F2 F3 F3 F3 F3 N N N N Connector OP3 • Setting is made: Connected • Setting is not made: Open (Not connected) 20-158 (10) HD465-7. use a precision flat-headed screwdriver and turn slowly. Setting rotary switch SW2 Rotary switch SW2 is used to set the maximum speed and the maximum speed when the body is raised. be sure to install grommet. Position of SW2 0 1 2 3 4 5 6 7 8 9 A B C D E F Setting of max. a Always set each switch and connector as instructed. adjust the position of the switch to compensate for the speed display. Setting rotary switch SW1 Rotary switch SW1 is used to set the travel speed compensation. a When setting. The machine monitor uses the size of the standard tire to calculate the travel speed. always avoid foreign matters or dust. Tire size 24. use a precision cross-head screwdriver and turn slowly. HD605-7 . (In the case of SW1. a When changing the dipswitch. there is no need to connect or release the connector. a Tire size and setting position.0 – 35PR SW1 7 Connector Not needed Remarks HD465-7 standard tire a The connector in the table indicates the number of the connector to be connected or released when changing the setting.

The setting must not be changed. Setting dipswitch SW5-1 Dipswitch SW5-1 is set as follows. ABS) (ASR. ARSC. ABS) (ASR. • Set position of dipswitch SW5-3: OFF • Connector operation: Not needed HD465-7.TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR 3. Setting dipswitch SW6-1 Dip switch SW6-1 is used for setting when the maintenance function is changed. a Turn ON this switch only in an area where MPH is used as the unit. AUTO SUS. When the front brake cut has been installed or removed. Setting dipswitch SW6-2 Dip switch SW6-2 is used for setting when the caution for raising the body is changed. The setting must not be changed. Maintenance function Not installed Installed SW6-1 OFF ON Connector OP5 Open Installed Remarks 9. Setting dipswitch SW5-3 Dipswitch SW5-3 is set as follows. AUTO SUS) (ARS. ABS) (AUTO SUS. etc. Exhaust brake Not installed Installed ON SW5-2 OFF ON Connector OP1 Open Connected Remarks 6. Front brake cut Not installed Installed SW5-4 OFF ON Connector OP4 Released (Not installed) Connected Remarks 8. AUTO SUS) (ASR. AUTO SUS. Setting rotary switch SW3 Rotary switch SW3 is used for setting when the functions of (ASR). ARSC) (ASR. Setting dipswitch SW6-3 Dipswitch SW6-3 is set as follows. The setting must not be changed. ARSC. • Set position of dipswitch SW6-3: OFF • Connector operation: Not needed 11. ABS) (ASR. SW5-1 OFF ON Connector Unnecessary Unnecessary Remarks Unit of speedometer: km/h Unit of speedometer: MPH 10. HD605-7 20-159 (10) . AUTO SUS) (ARSC. AUTO SUS. Setting dipswitch SW5-2 Use dipswitch SW5-2 to set the exhaust brake. set as follows. Setting caution for raising body Not installed Installed SW6-2 OFF ON Connector OP6 Open Connected Remarks Connector OP2 • Setting is made: Connected • Setting is not made: Open (Not connected) 4. (ABS). ASRC. • Set position of dipswitch SW6-4: OFF • Connector operation: Not needed 5. Position of SW3 0 1 2 3 4 5 6 7 8 9 A B C D E F Function Not set (ASR) ARSC AUTO SUS (ABS) (ASR. The setting must not be changed. ARSC. AUTO SUS. are changed. set as follows. ABS) 7. Setting dipswitch SW6-4 Dipswitch SW6-4 is set as follows. When the exhaust brake has been installed or removed. ABS) (ARSC. ABS) (ASRC. Setting dipswitch SW5-4 Use dipswitch SW5-4 to set the front brake cut.

a The e mark on the rotary switch is the guideline for setting. Setting machine body wiring harness a If the transmission controller is replaced. HD605-7 .is installed". Table 2 Switch VHMS controller Not installed Not installed SW2 Installed Installed Installed PLM function in VHMS controller Card-type payload meter (PLM. a For details of the method of operation. Adjusting transmission a After carrying out any of the following operations. 2) Align the SW1 rotary switch and SW2 rotary switch with the set position. a Set rotary switches 1 and 2 (SW1 and SW2) to only the following positions (1) Contents of setting and set position of rotary switch 1 (SW1) Table 1 Switch SW1 Contents of setting Model information Position 4 2.) Not installed Installed Not installed Installed Not installed Function of payload meter (PLM) function Not installed Installed Not installed Installed Installed Position F F B B 9 — — Not installed Not installed Installed a The transmission controller switch (SW2) is used to notify the monitor panel "whether the VHMS is installed". Setting rotary switch a If the transmission controller has been replaced. 20-160 (7) HD465-7. and "whether PLM. a Use a precision cross-head screwdriver and turn the rotary switch slowly. set the connector for selecting the model as shown below. 605-7 MS11 – MS12 MS21 – MS22 MS31 – MS32 Connected Open Connected (2) Contents of setting and set position of rotary switch 2 (SW2) (See table 2) 3. see SPECIAL FUNCTIONS OF MACHINE MONITOR. set the rotary switches for the network data and model selection as follows. HD465. "whether the PLM function in the VHMS is turned on". adjust the transmission in order to adjust the fitting between the transmission and the transmission controller. use the service function of the machine monitor.TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER ADJUSTING TRANSMISSION CONTROLLER 1. 1) Remove 2 grommets at the top of the controller. • When the transmission has been overhauled or replaced • When the transmission control valve has been repaired or replaced • When the transmission controller has been replaced • When the power train speed sensor has been repaired or replaced • When the transmission oil temperature sensor has been repaired or replaced • When the transmission oil filter has become clogged and has been cleaned a When adjusting the transmission.

. 6. Date and time of the downloaded data are wrong. While the payload meter in the VHMS is not set. HD465-7. 1. with the VHMS initial setting tool. etc. the payload does not match to the lighting condition of the red lamp of the outside indicator lamps. etc. variation code. "There are not the manus related to the payload meter on the match marks". a Wrong setting of rotary switch 2 (SW2) of transmission controller 3. see the VHMS initial setting manual (Tool) When there is not a problem in installation and wiring of the payload meter but there are the following problems. Items related to the payload meter are not displayed on the machine monitor. When the VHMS controller or transmission controller is replaced 4. 4. and variation code with the VHMS initial setting tool. (*2) For setting of the model.) Payload meter (PLM) function Set position of rotary switch 2 (SW2) of transmission controller (*1) Model Type Variation code Not installed Not installed Installed Installed Installed — — Not installed Not installed Installed Installed F F B F 9 — — HD465 or HD605 — — — — ST Not installed Not installed Not installed Not installed Installed Installed Installed Installed Installed –7 P2 PV (*1) For the set position of rotary switch 2 (SW2) of the transmission controller. perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with VHMS initial setting manual (tool)" according to Table 1. a Wrong setting of the model. there are the menus related to the payload meter on the machine monitor.. a Wrong setting of the model and serial No. with the VHMS initial setting tool. Data cannot be downloaded. The storage place of the data file made by the download software is not found. a Wrong setting of the date and time with the VHMS initial setting tool. see the section of adjustment of the transmission controller.TESTING AND ADJUSTING INITIAL SETTING OF PAYLOAD METER INITIAL SETTING OF PAYLOAD METER In the following cases. serial No. 1. While the payload meter in the VHMS is set. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed 3. check the above setting again. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time 2. 5. type. HD605-7 20-160-1 (10) . a Wrong setting of the model and serial No. "The payload is not displayed when the machine is loaded and stopped". a Wrong setting of rotary switch 2 (SW2) of transmission controller 2. When setting of VHMS controller (PLM ) is changed Table 1 Setting with VHMS initial setting manual (tool) (*2) Date Time Time difference (GMT) Summer time — — Set properly VHMS controller PLM function in VHMS controller Card-type payload meter (PLM.

• • When card-type payload meter is installed for the first time When card-type payload meter is replaced 1.) • Set the model selector switch (No. 4). (See view Z in the above figure.TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT In the following cases. 7). HD605-7 . Position of switch Upper Lower Model Metric ton American ton (Short ton) 20-160-2 (11) HD465-7. 2) Set the following switches. Position of rotary switch 7 A Model HD465-7 HD605-7 • Set weight unit setting switch (No. Setting of switches 1) Remove cover (1) from the left side of the card-type payload meter. set the rotary switches and DIP switches on the side of the card-type payload meter and set the threshold value of turning on the external indicator lamp and option code with the switches on the front.

Handling of payload meter (card type). Contents of indication. 8). When changing these switches from the initial positions. if necessary. 2). 8 ON or OFF. 5).) Execution of automatic transmission function NO YES NO YES NO YES NO YES NO NO NO NO Optional setting Setting of TALKS NO NO NO NO YES YES YES YES YES YES NO NO Setting of PMC NO NO NO NO NO NO NO NO YES YES YES YES Type of transmission of data when dumping is finished (when PMC is set) — — — — — — — — Z1 Z2 Z1 Z2 Option code Transmission baud rate (bit/sec) 0 1 2 3 4 5 6 7 8 9 10 11 9600 9600 1200 1200 9600 9600 1200 1200 9600 9600 9600 9600 HD465-7.) 2. Do not change the speed correction switch (No. Switch Speed correction switch (No. 3) Memory card using switch (No. Do not change the load weight correction trimmer (No. 5 and No. HD605-7 20-160-3 (11) . (See Operation and Maintenance Manual. (See the Operation and Maintenance Manual. memory card using switch (No. 8) Initial setting Switch position: 7 Switch position: 7 Switch position: Lower (Use) Switch position: Lower (Use) Switch position: Upper (Permission) • • a You can carry out the operations of calibration. When the power is turned ON. 6) Switch forcible prohibition switch (No. clearing all data. and setting date by turning switches No. be sure to check with the Operation and Maintenance Manual. B) and switch forcible prohibition switch (No. 2) Distance correction switch (No. Setting of option code a Required for communication with personal computer The option code is set to zero (0) initially. 3). 5) Clinometer using switch (No. dumping card. 1) from the initial position. check that the option code is zero by the following method. and clinometer using switch (No. 6) from the initial positions. distance correction switch (No. For HD465-7 and HD605-7.TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT • Set buzzer volume switch (No. "OP: 0" is indicated before the normal operation display starts.

TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT Method of changing option code 1) Set the gearshift lever in "N" and the dump lever in FLOAT. HD605-7 . Operation switches to be used • MODE (2) • LIGHT/INC (3) • TOTAL/SFT (4) • CAL/CLR (5) Screen (6) a While watching the screen. 20-160-4 (11) HD465-7. operate switches (2) – (5) to set values.

Press MODE switch (2). XX lights up and X at ones place blinks) Display XXX = Currently set machine ID O HD465-7.TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT 2) Display the option code screen according to the following procedure. XXX (0. Cd: dp (Cd lights up and dp blinks) 0. OP: XX (OP: X lights up and X at ones place blinks) Display Display F. d. HD605-7 20-160-5 (11) . CHE (F. XX lights up and X at ones place blinks) Display Display XXX = Currently set operator ID O O Press MODE switch (2). A. XXX (d. Press MODE switch (2). Press MODE switch (2). CLE (A lights up and CLE blinks) SP: XX (SP: X lights up and X at ones place blinks) Display Display XX = Current set limit speed (km/h) O O Press MODE switch (2). Press MODE switch (2) for 2 seconds. CHE blinks) XX = Current set option code O Press MODE switch (2).

o The blinking point moves to the ones place. • Changing place to be changed a Press TOTAL/SFT switch (4). o The blinking point moves to the tens place. OP: XX (OP: X lights up and X at ones place blinks) Display XX = Ones digit of currently set option code is increased by 1. 4) Finishing setting a Press MODE switch (2). HD605-7 . • Changing tens digit a Press TOTAL/SFT switch (4).TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT 3) Changing set value of option code a You can change the digit at the blinking place. OP: XX (OP: X lights up and X at tens place blinks) Display XX = Tens digit of currently set option code is increased by 1. 20-160-6 (11) HD465-7. • Changing ones digit Press LIGHT/INC switch (3). Press LIGHT/INC switch (3).

Display P. SEL lights up) O Press CAL/CLR switch (5). Display O. HD605-7). Press CAL/CLR switch (5). SEL lights up) O O HD465-7. PL: XX (PL: lights up and XX blinks) Display O Press CAL/CLR switch (5). Setting threshold value of external indicator lamp a When installing the card-type payload meter to a machine having the 3-bulb external indicator lamp (HD465-7. SEL lights up) Press CAL/CLR switch (5). Display E. O Display UP: XX (UP: lights up and XX blinks) Press CAL/CLR switch (5). see "2.TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT 3. HD605-7 20-160-7 (11) . SEL (H. SEL (P. SEL lights up) O Press TOTAL/SFT switch (4) and LIGHT/INC switch (3) simultaneously for 2 seconds. SEL (S. SEL (E. 1) Set the gearshift lever in "N" and the dump lever in FLOAT. 2) Set the threshold value of the external indicator lamp according to the following procedure. SEL lights up) O Display CHEC (CHEC blinks) Press CAL/CLR switch (5). O Display S. a For the setting switches. SEL (O. Press MODE switch (2) and LIGHT/INC switch (3) simultaneously for 3 seconds. Display H. be sure to set the threshold value of the external indicator lamp. Setting of option code". Method of changing option code.

TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT Press TOTAL/SFT switch (4). lights up and XXX blinks) O Display Press LIGHT/INC switch (3). XXX (b. XXX (d. HD605-7 . XXX (d. A. d. O 20-160-8 (11) HD465-7. c. XXX (c. lights up and XXX blinks) Display Press CAL/CLR switch (5). b. lights up and XXX blinks) Press LIGHT/INC switch (3). lights up and XXX blinks) XXX = Currently set display level of external lamp 2 Display O XXX = Currently set display level of external lamp 4 Press CAL/CLR switch (5). lights up and XXX blinks) XXX = Currently set display level of external lamp 3 Display O XXX = Set to 090. c. XXX increases to 255 and then returns to 0. a If LIGHT/INC switch (3) is held. XXX increases to 255 and then returns to 0. O a If LIGHT/INC switch (3) is held. d. lights up and XXX blinks) Display Display XXX = Currently set display level of external lamp 1 XXX = Set to 050. XXX (A. O Press CAL/CLR switch (5). XXX (c.

XXX (E. (HD605-7) a If LIGHT/INC switch (3) is held. (HD465-7) XXX = Set to 100. E. setting of weight unit setting switch. setting of switch forcible prohibition switch. XXX increases to 255 and then returns to 0. Display CHEC (CHEC blinks) O Press MODE switch (2). HD605-7 20-160-9 (11) . Press LIGHT/INC switch (3). see Operation and Maintenance Manual. E. Handling of payload meter (card type). a For contents of indication made when the power is turned ON. XXX (E. lights up and XXX blinks) Display XXX = Set to 105. lights up and XXX blinks) Display XXX = Currently set display level of external lamp 5 O 4. and setting of option code are displayed. Check of setting For 30 seconds after the card-type payload meter is turned ON.TESTING AND ADJUSTING SETTING OF CARD-TYPE PAYLOAD METER AFTER INSTALLATION OR REPLACEMENT Press CAL/CLR switch (5). setting of clinometer using switch. O Press MODE switch (2). Contents of indication. setting of memory card using switch. Check that they are correct. the model selection code. End of setting HD465-7.

The display items are divided by the internal setting of the machine monitor (EMMS). 2) Special functions: Service mode Functions which the serviceman can display and operate with the special switches to carry out inspection. odometer display function (default) (*1) Reverse travel distance display function Filter replacement. maintenance. into automatic display items and items displayed when the machine monitor switches are operated. HD605-7 20-161 (10) . oil change interval display function Telephone number input function Language selection function PLM setup function Action code display function Failure code display function 16 i o 9 10 11 12 13 14 15 Service mode Electric system fault history display function Mechanical system fault history display function Machine data monitoring function Adjustment function Filter replacement.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) • EMMS: Equipment Management Monitoring System Normal functions and the special functions of machine monitor (EMMS) The machine monitor is equipped with normal functions and special functions. Various items of data are displayed on the character display in the middle of the machine monitor. oil change interval display function Snapshot function PLM setting function Initialize function (factory use only) *1: PLM (payload meter) display function when receiving VHMS data HD465-7. Operator mode 1 2 3 4 5 6 7 8 Service meter. and troubleshooting. 1) Normal functions: Operator mode Functions for which the content is normally displayed or which can be displayed and operated by the operator operating the switches.

HD605-7 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR FLOW MODES AND FUNCTION 20-162 (10) HD465-7.

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR HD465-7. HD605-7 20-163 (2) .

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 20-163-1 (5) HD465-7. HD605-7 .

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR HD465-7. HD605-7 20-163-2 (5) .

1) : Select. ¥. if no switch is operated for more than 30 seconds. ODOMETER DISPLAY FUNCTION: If there is no failure • Goes to ACTION CODE DISPLAY FUNCTION: If there is a failure a From FAILURE CODE DISPLAY FUNCTION the screen changes to SERVICE METER.give an endless display according to the operation of the switch. 6) Special characters Control switches Control of the machine monitor display is all carried out with machine monitor mode selector switches (1) and (2). . [t]. regardless of the display screen. . [<]. a Once the ID is input and confirmed. [<]. it remains effective until the starting switch is turned OFF. c . A combination of the following characters (alphabet and numerals) and symbols is displayed according to the content. 3) Capital letters: A. . a When a failure occurs. [>]. Next. 2. 4) Katakana: Japanese display only 5) Symbols: @. . The following functions are provided for the buttons of each switch. Run 2) t: Cancel. $ . [t]. 2) Small letters: a.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Operator mode a [>]. Continue 4) <: Left. Service mode a For selection of each function. [ ]. . b. Select (YES/NO only) 3) >: Right. Release. HD605-7 . . the screen automatically changes as follows. • Goes to SERVICE METER. . B. a Regardless of the display screen. the screen changes automatically to ACTION CODE DISPLAY FUNCTION. ODOMETER DISPLAY FUNCTION with the switch operation. give an endless display according to the operation of the switch. [ ]. C . Return 20-164 (9) HD465-7. . the screen automatically changes to ACTION CODE DISPLAY FUNCTION. Previous. Character display The character display consists of a top line and bottom line with 16 characters each. 3 . 1) Numerals: 1. and if no switch is operated for more than 10 seconds.

oil replacement time display (automatic display) When the replacement interval for the filters or oil approaches. this information is automatically displayed on the machine monitor to recommend the operator to carry out maintenance (Fig. Filter. Service meter.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Operation and displays for operator mode 1. 2) a For details. HD465-7. Machine monitor system. the switches on the machine monitor can be used to reset the interval (Fig. see STRUCTURE AND FUNCTION. oil replacement interval display function 1) Filter. 1) a For details. see STRUCTURE AND FUNCTION. 2. 2) Resetting replacement time (selection menu) When the maintenance operation for the filters and oil replacement has been completed. the top line shows the service meter and the bottom line shows the odometer (Fig. 4) a For details. 3: example). Machine monitor system. Machine monitor system. a The replacement time can be set using Service mode. see STRUCTURE AND FUNCTION. Reverse travel distance display function Use the switch to display the total distance traveled in reverse of the machine monitor (Fig. odometer display function When the starting switch is turned ON. HD605-7 20-165 (10) . 3.

5). 6) a The functions of Service mode is not included in the functions for display selection. so it is always displayed in English. [CALL+ Telephone number] is not displayed. 7). see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR". 6. 10). corrected.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 4. a For details. Action code display function If any abnormality occurs on the machine. see the operation manual for the "OTHER FUNCTION OF MACHINE MONITOR". a Correspondence between action code and recommendation to operator 20-166 (10) HD465-7. the telephone number is displayed at the same time as [CALL]. 5. Language selection function The language used for the machine monitor display can be selected by operating the switches (Fig. Telephone number input function The telephone number set inside the machine monitor can be input. a When action codes [E01] and [E02] are displayed. PLM setting function a This function is applied to the "PLM in VHMS" (Only when the option is set). • Various functions of the "PLM in VHMS" are displayed and set (FIG. see the operation manual for the "PLM in VHMS". 7. a For details. or canceled by operating the switches (Fig. a For details. HD605-7 . a When action code [E03] is displayed. the degree of the abnormality is automatically displayed as a user code on the machine monitor to recommend appropriate action to the operator (Fig. a The diagram on the right shows an example of action code [E03] and [CALL+ Telephone number] being displayed in turn.

When overheat related display is shown: Stop machine and keep engine running at mid-range speed under no load. press the [>] button once more to return to the service meter/odometer display screen. a With the failure code display function and fault history display function (Service mode). press the [>] button once to display the failure codes for the existing failures (Fig. (For details. see FAILURE CODE TABLE. see Service mode.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Action code E01 CALL+ Telephone number • Not displayed • Action recommended to operator Carry out testing and adjusting after completion of operations or when changing shifts between operators When overrun related display is shown: Reduce engine speed and machine speed while continuing operations. the display automatically returns to the action code display screen. Failure code display function While the action code is being displayed on the machine monitor. 8: example). Stop engine and machine immediately and contact serviceman. If the switch is not operated for 10 seconds. the display will switch automatically to the action code screen. a With the service code display function. 9).) a If more than one failure is occurring. the following data are displayed (Fig. If the [>] button is pressed once more. A: Failure code (4 digits for location code + 2 digits for problem code) B: Controller code (MON: Machine monitor) (ENG: Engine controller) (TM: Transmission controller) (BK: Retarder controller) C: System with problem a For details of the displayed failure codes. HD465-7. press the [>] button once more to display the other failure codes. HD605-7 20-167 (10) . the failure codes will be displayed again from the beginning. a After pressing the [>] button to display all the existing failures. • [>] Button: Displays failure code a The failure codes detected in the past are divided into failures of the electrical system and the mechanical system and are recorded as fault history. a If no switch is operated on the failure code display screen for more than 30 seconds. the data that are displayed are partially different. E02 Not displayed • E03 Displayed • 8.

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR FAILURE CODES LIST Failure code 1380MW 1500LO 15B0NX 15E0KM 15E7KM 15G0MW 15H0MW 15J0MW 15K0MW 15L0MW 15M0MW 15N0MW 15SBL1 15SBMA 15SCL1 15SCMA 15SDL1 15SDMA 15SEL1 15SEMA 15SFL1 15SFMA 15SGL1 15SGMA 15SHL1 15SHMA 15SJL1 15SJMA 2F00KM 2G42ZG 2G43ZG 989AOO 989AKZ 989OO Lockup clutch Detection of double engagement Clogging of steering oil filter R o F gear shifting abuse 1 R o F gear shifting abuse 2 R clutch Hi clutch Lo clutch 1st clutch 2nd clutch 3rd clutch 4th clutch R clutch ECMV R clutch ECMV Hi clutch ECMV Hi clutch ECMV Lo clutch ECMV Lo clutch ECMV 1st clutch ECMV 1st clutch ECMV 2nd clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 3rd clutch ECMV 4th clutch ECMV 4th clutch ECMV Lockup clutch ECMV Lockup clutch ECMV Parking brake Accumulator (Front) Accumulator (Rear) Engine overrun prevention command signal Engine overrun prevention command signal Rear part tipping signal Failed section Failure phenomenon (Phenomenon/Contents of failure) Slip (MW) * See separate list (L0) Clogging (NX) Mistake in operation or setting (KM) Mistake in operation or setting (KM) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) Slip (MW) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) * See separate list (L1) Malfunction (MA) Mistake in operation or setting (KM) Lowering of oil pressure (ZG) Lowering of oil pressure (ZG) Operation (OO) Disconnection or short circuit (KZ) Operation (OO) Controller TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM TM BK BK TM TM BK Action code E03 E03 E01 — — E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 — E03 E03 E02 E01 — 20-168 (10) HD465-7. HD605-7 .

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code AA10NX AB00MA B@BCZK B@C7NS B@CENS C111KT C112LK C113KZ C115KZ C116KX C117KX C118KX C119KX C121LC C122KX C123KX C131KX C132KX C135KX C141KX C143ZG C144KX C145KX C148KX C151NS C153KX C154KX C221KX C222KX C234N1 C254KZ C259FS C261NS C263KX Failed section Air cleaner element Alternator Radiator coolant Rear brake oil Torque converter Failure in controller memory Timing actuator defective Abnormal current in timing actuator Error in engine speed sensor 2 system Abnormality in timing rail pressure sensor Abnormality in timing rail pressure sensor Abnormality in fuel pump pressure sensor Abnormality in fuel pump pressure sensor Error in engine speed sensor 1 system Abnormality in boost pressure sensor Abnormality in boost pressure sensor Abnormality in throttle sensor Abnormality in throttle sensor Abnormality in oil pressure sensor Abnormality in oil pressure sensor Lowering of oil pressure (Engine protection) Abnormality in coolant temperature sensor Abnormality in coolant temperature sensor Abnormality in FM throttle Rise of coolant temperature (Engine protection) Abnormality in intake air temperature sensor Abnormality in intake air temperature sensor Abnormality in atmospheric pressure sensor Abnormality in atmospheric pressure sensor Engine over-speed Abnormality in FSOV circuit Abnormality in FSOV circuit Rise of fuel temperature (Engine protection) Abnormality in fuel temperature sensor Failure phenomenon (Phenomenon/Contents of failure) Clogging (NX) Malfunction (MA) Lowering of level (ZK) Overheating (NS) Overheating (NS) Internal defect of controller (KT) * See separate list (LK) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Clogging (NX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) * See separate list (LC) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Disconnection or short circuit (KZ) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Overheating (NS) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Overrun (N1) Disconnection or short circuit (KZ) Fixing (FS) Overheating (NS) Out of input signal range (KX) Controller TM TM TM MON MON ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG Action code E01 E03 E01 E02 E02 E03 E03 E03 E03 E03 E03 E01 E01 E03 E03 E03 E03 E03 E01 E01 E03 E01 E01 E03 E02 E01 E01 E03 E03 E02 E03 E03 E02 E01 HD465-7. HD605-7 20-169 (10) .

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code C265KX C316KZ C318LK C346KT C423L6 C431L4 C432L5 C441KK C442KG C451KX C452KX C455KZ C467LK C468LK C514LK C554L6 D1B0KZ D1C0KZ D5ZMKZ D5ZNKZ DAF0KM DAF9KM DAFSKQ DAQ0KK DAQ1KK DAQ2KK DAQ3KK DAQ9KM DAQ9KQ DAQAKQ DAQSKR DAQSMA DASRKR DB10KK Failed section Abnormality in fuel temperature sensor Failure phenomenon (Phenomenon/Contents of failure) Out of input signal range (KX) Controller ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG TM BK TM BK MON MON MON TM TM TM TM TM TM TM MON TM MON BK Action code E01 E01 E01 E03 E03 E01 E03 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 Abnormal current in fuel injection pump actuator Disconnection or short circuit (KZ) Pump actuator defective ECM power-down error Timing rail pressure in-range error Abnormality in idle validation switch Idle validation process error Abnormality in battery voltage Abnormality in battery voltage Abnormality in fuel rail pressure sensor Abnormality in fuel rail pressure sensor Abnormality in fuel rail actuator circuit Timing actuator control error Fuel rail actuator control error Fuel rail actuator defective Fuel rail pressure sensor in-range error Transmission cut-out relay Brake cut-out relay Disconnection/Grounding fault/Short circuit in engine output mode command line Failure in front brake cut-out output system (Disconnection. grounding fault. short circuit) (OPT) * See separate list (LK) Internal defect of controller (KT) * See separate list (L6) * See separate list (L4) * See separate list (L5) Lowering of source/input voltage (KK) High source voltage (KG) Out of input signal range (KX) Out of input signal range (KX) Disconnection or short circuit (KZ) * See separate list (LK) * See separate list (LK) * See separate list (LK) * See separate list (L6) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Mistake in operation or setting (KM) Mistake in operation or setting (KM) Disagreement of model selection signals (KQ) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Monitor panel Monitor panel Monitor panel Transmission controller Transmission controller main power source line Transmission controller load power source line Transmission controller battery direct power source line Transmission controller wiring harness Transmission controller wiring harness Transmission controller rotary switch Transmission controller S-NET line Transmission controller COMMUNICATION ERROR ENG Retarder controller Mistake in operation or setting (KM) Disagreement of model selection signals (KQ) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR) Malfunction (MA) Communication defective/Abnormality in objective component (KR) Lowering of source/input voltage (KK) 20-170 (10) HD465-7. HD605-7 .

HD605-7 20-171 (10) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code DB11KK DB12KK DB13KK DB19KM DB1SKR DB1SKQ DBBSKR DDD7KX DDD8KA DDD8KB DDDAKA DDDAKB DDTGKA DDTHKA DDTJKA DDTKKA DDTLKA DDTMKA DDTNKA DDTPKA DF10KA DF10KB DGF1KX dGR2L8 DGR2L8 DGT1KX dHP4KX DhP4KX DHP4KX dHP5KX DhP5KX DHP5KX DHP6KX DHP7KX Failed section Retarder controller main power source line Retarder controller load power source line Retarder controller battery direct power source line Failure phenomenon (Phenomenon/Contents of failure) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Lowering of source/input voltage (KK) Controller BK BK BK BK MON BK MON BK BK BK BK BK TM TM TM TM TM TM TM TM TM TM TM BK BK TM BK PLM BK BK PLM BK PLM PLM Action code E03 E03 E03 E03 E03 E03 E01 E03 E03 E03 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E03 E01 E01 E03 E01 E03 E01 E01 Retarder controller wiring harness Retarder controller S-NET line Wrong information on model selection Communications error VHMS Failure in travel speed setting switch system (OP) Mistake in operation or setting (KM) Communication defective/Abnormality in objective component (KR) Disagreement of model selection signals (KQ) Communication defective/Abnormality in objective component (KR) Out of input signal range (KX) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Disconnection (KA) Short circuit (KB) Out of input signal range (KX) * See separate list (L8) * See separate list (L8) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Disconnection ARSC system switch (OP) Short circuit ARSC system switch (OP) Disconnection ASR system switch (OP) Short circuit ASR system switch (OP) Fill switch for lockup clutch Fill switch for Hi clutch Fill switch for Lo clutch Fill switch for 1st clutch Fill switch for 2nd clutch Fill switch for 3rd clutch Fill switch for R clutch Failure in flow sensor valve for 4th clutch Gear shift lever Gear shift lever Transmission valve oil temperature sensor Failure in retarder oil temperature sensor system Brake oil temperature sensor (Rear) Torque converter oil temperature sensor Failure in suspension pressure sensor (FR) system (OPT) Suspension pressure sensor (FR) Failure in suspension pressure sensor (FR) system (OPT) Failure in suspension pressure sensor (FL) system (OPT) Suspension pressure sensor (FL) Failure in suspension pressure sensor (FL) system (OPT) Suspension pressure sensor (RR) Suspension pressure sensor (RL) HD465-7.

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code DHT5KX DHT5L6 DHU2KX DHU3KX DJF1KA DK11KX dK11KX Dk11KX DK30KX DK51L5 DK52KX DK53L8 DK54KX DKD0L6 DKH1KX DLE2KA DLE2LC DLF1KA DLF1LC DLF2KA DLF2LC DLF8KA DLF8LC DLF9KA DLF9LC DLT3KA dLT3KA dLt3KA DLT3LC DLT3LC dLT3LC DV00KB DW35KZ DW36KZ Failed section Torque converter oil pressure sensor Torque converter oil pressure sensor Accumulator oil pressure sensor (Front) Accumulator oil pressure sensor (Rear) Fuel level sensor Throttle angle sensor Failure in acceleration sensor system (OPT) Failure in acceleration sensor system (OPT) Failure of steering angle potentiometer (OP) Retarder lever potentiometer Dump lever potentiometer 1 Dump lever potentiometer 2 Body positioner sensor Failure in steering speed sensor (OPT) Abnormality in angle sensor Engine speed sensor Engine speed sensor Transmission input shaft speed sensor Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission intermediate shaft speed sensor Disconnection in wheel speed sensor (RR) (OP) Failure phenomenon (Phenomenon/Contents of failure) Out of input signal range (KX) * See separate list (L6) Out of input signal range (KX) Out of input signal range (KX) Disconnection (KA) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) Out of input signal range (KX) * See separate list (L5) Out of input signal range (KX) * See separate list (L8) Out of input signal range (KX) * See separate list (L6) Out of input signal range (KX) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) * See separate list (LC) Disconnection (KA) Disconnection (KA) Disconnection (KA) * See separate list (LC) * See separate list (LC) Disconnection (LC) Short circuit (KB) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Controller TM TM BK BK TM TM BK BK BK BK BK BK BK BK PLM TM TM TM TM TM TM BK BK BK BK TM BK BK TM BK BK MON BK BK Action code E01 E01 E01 E01 E01 E03 E03 E01 E01 E03 E03 E03 E03 E01 E01 E03 E03 E03 E03 E03 E03 E01 E01 E01 E01 E03 E01 E03 E03 E01 E01 E01 E01 E01 Failure in wheel speed sensor (RR) system (OP) Disconnection in wheel speed sensor (RL) (OP) Failure in wheel speed sensor (RL) system (OP) Transmission output shaft speed sensor Disconnection in transmission output shaft speed sensor Disconnection in transmission output shaft speed sensor Transmission output shaft speed sensor Transmission output shaft speed sensor Failure in transmission output shaft speed sensor Short circuit in buzzer output Failure in auto suspension solenoid 1 output system (Disconnection. grounding fault. short circuit) (OPT) Failure in auto suspension solenoid 2 output system (Disconnection. HD605-7 . grounding fault. short circuit) (OPT) 20-172 (10) HD465-7.

grounding fault. grounding fault. short circuit) Failure phenomenon (Phenomenon/Contents of failure) Disconnection or short circuit (KZ) Disconnection or short circuit (KZ) Not control (K4) Not control (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Not control (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Not control (K4) Disconnection (KA) Short circuit (KB) Short circuit with power line (KY) Malfunction (MA) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Controller BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK TM TM TM TM TM TM TM TM Action code E01 E03 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 Shut-off valve DWNBKA Disconnection in shut-off valve system DWNBKB Grounding fauit in shut-off valve system DWNBKY Short circuit in shut-off valve system DWNBMA Shut-off valve DX11K4 DX11KA DX11KB DX11KY DX11MA DX13KA DX13KB DX13KY DX17K4 DX17KA DX17KB DX17KY DX17MA DX18K4 DX18KA DX18KB DX18KY DX18MA DXH1KA DXH1KB DXH2KA DXH2KB DXH3KA DXH3KB DXH4KA DXH4KB Electromagnetic proportional pressure reducing valve Disconnection in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Short circuit in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Grounding fault in output circuit of rear wheel electromagnetic proportional pressure reducing valve (A_OUT2) Electromagnetic proportional pressure reducing valve Disconnection in output circuit of hoist EPC valve (A_OUT3) Grounding fault in output circuit of hoist EPC valve (A_OUT3) Short circuit in output circuit of hoist EPC valve (A_OUT3) ASR proportional solenoid pressure reducing valve (Right) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Right) (OP) ASR proportional solenoid pressure reducing valve (Right) ASR proportional solenoid pressure reducing valve (Left) Disconnection in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Short circuit in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Grounding fault in output circuit of ASR proportional solenoid pressure reducing valve (Left) (OP) Disconnection in output circuit of lockup clutch solenoid Short circuit in output circuit of lockup solenoid Disconnection in output circuit of H clutch solenoid Short circuit in output circuit of H clutch solenoid Disconnection in output circuit of L clutch solenoid Short circuit in output circuit of L clutch solenoid Disconnection in output circuit of 1st clutch solenoid Short circuit in output circuit of 1st clutch solenoid HD465-7. HD605-7 20-173 (10) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code DW72KZ DW73KZ DWNBK4 Failed section Failure in kick-out solenoid output system (D_OUT3) (Disconnection. short circuit) Failure in hoist select valve output system (D_OUT5) (Disconnection.

ENG: Troubleshooting of engine controller system (ENG MODE) TM: Troubleshooting of transmission controller system (TM MODE) BK: Troubleshooting of retarder controller system (BK MODE) MON: Troubleshooting of machine monitor system (MON MODE) VHMS: Troubleshooting for VHMS controller system (including payload meter system in VHMS) (VHMS mode) 20-174 (10) HD465-7. coolant temperature switch. terminal C signal. do not match operating condition or stopped condition of machine Analog signals for 2 systems do not match Speed signals for 2 systems do not match Fill signal is OFF when command current to ECMV is ON a Failure codes with ( ) These failure codes are not recorded as fault history for either the electrical system or the mechanical system. etc. signals for oil pressure switch.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Failure code DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXHHKA DXHHKB Failed section Disconnection in output circuit of 2nd clutch solenoid Short circuit in output circuit of 2nd clutch solenoid Disconnection in output circuit of 3rd clutch solenoid Short circuit in output circuit of 3rd clutch solenoid Disconnection in output circuit of R clutch solenoid Short circuit in output circuit of R clutch solenoid Disconnection in output circuit of 4th clutch solenoid Short circuit in output circuit of 4th clutch solenoid Failure phenomenon (Phenomenon/Contents of failure) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Controller TM TM TM TM TM TM TM TM Action code E03 E03 E03 E03 E03 E03 E03 E03 a For details of the VHMS controller related failure codes not displayed on the machine monitor. HD605-7 . so check the controller code for the failure code displayed. a Controller codes and troubleshooting mode names The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting section are linked. a Separate table: Detailed phenomena of L Series phenomenon codes (L*) Problem code L0 L1 L2 L3 L4 L5 L6 L8 LC LH Nature Fill signals on 2 or more channels for clutches not forming a set are input at same time Fill signal is ON when command current to ECMV is OFF Fuel pressure is higher than maximum set pressure Corresponding component cannot be controlled ON/OFF signals for 2 systems do not match Potentiometer signal and switch signal do not match Engine speed signal. see Troubleshooting VHMS control system. then go to the applicable troubleshooting mode.

a Once the ID has been input and confirmed. 1). a ID: 6491 • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to initial screen (see Note) Note: When the cursor is at the left side. the screen returns to the normal screen (operator mode). action code. HD465-7. then release the buttons. the cursor returns to the left side. • [t] button and [<] button a If the buttons are held pressed for at least 5 sec. the whole screen will give no display. HD605-7 20-175 (9) . carry out the following special operation to switch the screen display. 3). or failure code. 1) Checking screen display With the machine monitor in the operator mode.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Procedure for switching to Service mode and screen display a When using Service mode. 4) Displaying menu initial screen After confirming all four digits of the ID. 2) Initial screen display for ID input Press the following 2 buttons at the same time for at least 5 seconds to display the initial screen display for the ID input (Fig. so check this condition. 3) Inputting ID. 2). it remains effective until the starting switch is turned OFF. confirming Operate the buttons to input the ID (Fig. a If the switch on the ID input screen is not operated for more than 60 seconds. the menu initial screen of Service mode is displayed (Fig. the screen returns automatically to the normal screen. If the cursor is not at the left side. check that the screen is one of the following displays: Service meter/odometer.

20-176 (10) HD465-7. repeat the procedure from Step 1) above (there is no need to input the ID again).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 5) Menu selection in Service mode Press the [>] or [<] buttons on the menu screen and the menus of Service mode are displayed endlessly in the following order (Fig. it is possible to finish the mode or function by using any of the following methods. a The menu is displayed in the places marked with [*]. 4). a Note that if the [t] button is pressed on the YES/NO screen. • [>] button: Goes on to next menu • [<] button: Goes back to previous menu (1) ELECTRICAL FAULT: Fault history display function for electrical system (2) MACHINE FAULT: Fault history display function for mechanical system (3) REAL-TIME MONITOR: Machine data monitoring function (4) CYLINDER CUT-OUT: Reduced cylinder mode (5) TUNING: Adjustment function (6) MAINTENANCE MONITOR: Filter. oil replacement time setting function (7) INITIALIZE: Initialize function (exclusive function for factory) 6) Completion of mode. (2) When completing all operations: Turn the starting switch OFF. function When operating at any point in any function. (1) When continuing operations in another mode or function: Press the [t] button and return to the mode screen to be used or menu screen to be used. the function will be executed. HD605-7 . a If you return to the normal screen (operator mode) by mistake.

HD465-7. and [–] is displayed on the display portion for A. • [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the electrical system. HD605-7 20-177 (10) . 3. a Note that with the fault history display function and failure code display function for the electrical system. 2: example). a If no fault history are recorded. 3). 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. Electrical system fault history display function (ELECTRIC FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. the following data can be displayed (Fig. 1: Record number (recorded up to a maximum of 20 items) A: Failure code (4-digit location code + 2-digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. They can be displayed as follows. 1). 2. a The total number of fault history items recorded in memory is displayed in the [ ] portion. press the [ ] button and display the fault history recorded in memory (Fig. 2) Fault history display With the menu selected. and 4. a For details of the failure codes displayed.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 9. see FAILURE CODE TABLE in the explanation for the failure code display function. [0] is displayed on the display portion for 1. the displayed data are partially different.

20-178 (10) HD465-7. HD605-7 . 6).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history. 6). • [ ] button: Display CLEAR screen ii) Operate the buttons according to the explanation on the screen (Fig. 6) Deleting all fault history i) Display the fault history. then press the [>] button or [<] button to display the ALL CLEAR menu (Fig. then press the [ ] button once to display the individual item CLEAR screen (Fig. • [<] button: Select YES • [>] button: Select NO • [t] button: Run a The data for an existing problem (flashing display) cannot be deleted. • [<] button: Select YES • [>] button: Select NO • [t] button: Run a The data for an existing problem (flashing display) cannot be deleted. • [ ] button: Run ALL CLEAR menu iii) Operate the buttons according to the explanation on the screen (Fig. 5). the display switches to the other recorded fault history. 4). ii) Press the [ ] button once to display the ALL CLEAR screen (Fig. • [>] button: Goes on to data for next record number • [<] button: Goes back to data for last record number 5) Deleting individual fault history i) Display the fault history to be deleted. 4).

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 10. 2) Fault history display With the menu selected. They can be displayed as follows. 1). Mechanical system fault history display function (MACHINE FAULT) The machine monitor retains the data for problems that occurred in the electrical system in the past as failure codes. 1: Record number A: Failure code (4-digit location code + 2digit problem code) 2: Number of occurrences (number of occurrences of same code in past) 3: Elapsed time 1 (time elapsed on service meter since first occurrence) 4: Elapsed time 2 (time elapsed on service meter since last occurrence) a Failure codes for problems that are still existing are shown on a flashing display. a If no fault history are recorded. HD605-7 20-179 (10) . a The total number of fault history items recorded in memory is displayed in the [**] portion. the displayed data are partially different. the following data can be displayed (Fig. • [ ] button: Runs menu 3) Displayed fault history With the display function for fault history of the mechanical system. HD465-7. 3. 2. and 4. 1) Menu selection Select the display function for fault history on the menu screen of Service mode (Fig. [0] is displayed on the display portion for 1. see FAILURE CODE TABLE in the explanation for the failure code display function. and [–] is displayed on the display portion for A. press the [ ] button and display the fault history recorded in memory (Fig. a For details of the failure codes displayed. a Note that with the fault history display function and failure code display function for the mechanical system. 3). 2: example).

• [>] button: Goes on to data for next record number • [<] button: Goes back to data for last record number 5) Deleting fault history (not permitted) a The fault history for the mechanical system cannot be deleted. HD605-7 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 4) Switching fault history display If the [>] button or [<] button is pressed during the display of fault history. 20-180 (10) HD465-7. the display switches to the other recorded fault history.

1). the sub menu displays endlessly in the following order (Fig. press the [ ] button and display the initial screen of the sub menu (Fig. • [>] button: Goes on to next menu • [<] button: Goes back to last menu (1) MONITOR PANEL: Machine monitor system (2) TRANSMISSION: Transmission controller system (3) ENGINE: Engine controller system (4) BRAKE: Retarder controller system (5) 2 ITEMS: 2-item display HD465-7. • [ ] button: Runs menu 3) Select sub menu If the [>] button or [<] button is pressed on the sub menu screen. 2).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 11. 2) Display sub menu With the menu selected. Machine data monitoring function (REALTIME MONITOR) The machine monitor can monitor the condition of the machine in real time through the signals from the sensors installed to various parts of the machine. 3). a The sub menu is displayed in the [*] portion. the following 2 types of display can be shown. • 1st item independent display (for each controller) • 2nd item simultaneous display (code input) 1) Menu selection Select the machine data monitoring function on the menu screen of Service mode (Fig. In the machine data monitoring function. HD605-7 20-181 (10) .

6).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 4) Setting 1st item individual monitoring i) Select the controller system for monitoring on the sub menu screen (Fig. HD605-7 . it becomes active again. the monitor data is held and the [ ] mark flashes. a If the button is kept pressed. a To hold or cancel monitoring data: If the [ ] button is pressed during monitoring. • [ ] button: Runs sub menu iii) Press the [>] button or [<] button to select the item for monitoring (Fig. A: Item display B: Monitoring code (5-digit) 1: Monitoring data (including unit) a For details. 5) Display data for 1st item individual monitoring On the 1st item individual monitoring screen. the following data are displayed (Fig. see MONITORING CODE TABLE. press the [ ] button and display the monitoring data initial screen. • [>] button: Goes on to next item • [<] button: Goes back to last item a Scroll the monitoring items to display in the internally set order. the items will scroll at high speed. 4: example). 20-182 (10) HD465-7. 5: example). If the [ ] button is pressed again. ii) With the menu selected.

7) Display data for 2nd item simultaneous monitoring On the 2nd item simultaneous monitoring screen. 10). press the [ ] button and display the monitoring code input screen (Fig. ii) With the menu selected. • [ ] button: Runs sub menu iii) Operate each button and input the monitoring code for the 2nd monitoring item directly. • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to code input screen iv) When both of the monitoring codes have been confirmed. see MONITORING CODE TABLE. HD605-7 20-183 (1) . a To hold or cancel monitoring data: If the [ ] button is pressed during monitoring. 6). HD465-7. the following data are displayed (Fig.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 6) Setting 2nd item simultaneous monitoring i) Select the 2nd item display on the sub menu screen (Fig. A: Monitoring code 1 1: Monitoring data 1 (including unit) B: Monitoring code 2 2: Monitoring data 2 (including unit) a For details. it becomes active again. If the [ ] button is pressed again. 9: example). the screen switches to the 2nd item display screen (Fig. the monitor data is held and the [ ] mark flashes. 7).

ON/OFF Status display 17 Setting status of option selection connector (OP1 & OP2) OPTION 1. 2 18 Setting status of option selection connector (OP3 & OP4) OPTION 3. SW3 SW5-1. ON/OFF Status display ON/OFF. 14: Setting status of dipswitch (displays 2 items at same time) • No. 12: Setting status of rotary switch (displays 3 items at same time) • No. 0 – F. 0 – F. 19: Setting status of option selection connector (displays 2 items at same time) 20-184 (10) HD465-7. 13: Setting status of dipswitch (displays 2 items at same time) • No. 17: Setting status of option selection connector (displays 2 items at same time) • No. HD605-7 . ON/OFF Status display ON/OFF. SW2. 18: Setting status of option selection connector (displays 2 items at same time) • No. ON/OFF Status display ON/OFF. SW6-2 SW6-3. SW6-4 Monitoring code Display range 0 – 65535 0 – 160 0 – 160 0 – 160 0 – 150 0. 11: Input status of connector check (displays 2 items) • No.0 – 51.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Monitoring Code Table MONITOR PANEL (Monitor panel system) No. Status display ON/OFF. ON/OFF Status display ON/OFF. SW5-2 SW5-3. SW5-4 SW6-1. • No. 6 a Note: The following monitoring items display data for 2 or 3 systems at the same time. ON/OFF Status display ON/OFF. ON/OFF Status display 0 – F.0 ON/OFF ON/OFF ON/OFF ON/OFF Unit rpm °C °C °C z V Status display Status display Status display Status display 1 2 3 4 5 6 7 8 9 01001 04104 30100 30200 04201 30300 37600 37700 37800 37900 30700 30800 30900 30901 30902 30903 31000 31001 31002 10 (Operation status of ASR switch) 11 Input status of connector check (1 & 2) 12 Setting status of rotary switch (SW1 & SW2 & SW3) 13 Setting status of dip switch (SW5-1 & SW5-2) 14 Setting status of dip switch (SW5-3 & SW5-4) 15 Setting status of dip switch (SW6-1 & SW6-2) 16 Setting status of dip switch (SW6-3 & SW6-4) ON/OFF. 15: Setting status of dipswitch (displays 2 items at same time) • No. 2 SW1. 16: Setting status of dipswitch (displays 2 items at same time) • No. Monitoring item Engine speed Engine coolant temperature (for high temperature) Torque converter oil temperature Brake oil temperature Fuel level sensor input resistance value Rheostat input voltage Operation status of front brake cut-out switch Operation status of ARSC switch (Operation status of ABS switch) Item display ENG SPEED COOLANT TEMP H T/C OIL TEMP BRAKE OIL TEMP FUEL SENSOR RHEOSTAT F BK CUT SW ARSC SW ABS SW ASR SW CONN CHK 1. 4 19 Setting status of option selection connector (OP5 & OP6) OPTION 5. ON/OFF Status display ON/OFF.

HD605-7 20-185 (10) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR TRANSMISSION (Transmission controller system) No. Monitoring item Transmission service meter Transmission input shaft speed Transmission intermediate shaft speed Transmission output shaft speed Operation status of fill switch for Lo clutch Operation status of fill switch for Hi clutch Operation status of fill switch for 1st clutch Operation status of fill switch for 2nd clutch Operation status of fill switch for 3rd clutch Item display SERVICE METER Monitoring code Display range 0 – 65535 0 – 65535 0 – 65535 0 – 65535 ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 1020 0 – 2550 0 – 2550 0 – 2550 0 – 2550 Unit h rpm rpm rpm Status display Status display Status display Status display Status display Status display Status display Status display 1 2 3 4 5 6 7 8 9 31100 31200 31300 31400 31510 31511 31512 31513 31514 31515 31516 31519 31600 31610 31601 31611 31602 31612 31603 31613 31604 31614 31605 31615 31606 31616 31609 31619 41801 41800 41806 41802 T/M SPEED: IN T/M SPEED: MID T/M SPEED: OUT FILL SW (L) FILL SW (H) FILL SW (1st) FILL SW (2nd) FILL SW (3rd) FILL SW (4th) FILL SW (R) FILL SW (L/U) ECMV H DIR ECMV H ECMV L DIR ECMV L ECMV 1 DIR ECMV 1 ECMV 2 DIR ECMV 2 ECMV 3 DIR ECMV 3 ECMV 4 DIR ECMV 4 ECMV R DIR ECMV R ECMV LU DIR ECMV LU FILL TIME H FILL TIME L FILL TIME R FILL TIME 1 10 Operation status of fill switch for 4th clutch 11 Operation status of fill switch for R clutch 12 Operation status of fill switch for lockup clutch 13 Command value of solenoid output current for Hi clutch 14 Sensed value of solenoid output current for Hi clutch 15 Command value of solenoid output current for Lo clutch 16 Sensed value of solenoid output current for Lo clutch 17 Command value of solenoid output current for 1st clutch 18 Sensed value of solenoid output current for 1st clutch 19 Command value of solenoid output current for 2nd clutch 20 Sensed value of solenoid output current for 2nd clutch 21 Command value of solenoid output current for 3rd clutch 22 Sensed value of solenoid output current for 3rd clutch 23 Command value of solenoid output current for 4th clutch 24 Sensed value of solenoid output current for 4th clutch 25 Command value of solenoid output current for R clutch 26 Sensed value of solenoid output current for R clutch value of solenoid output current for lockup 27 Command clutch mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA ms ms ms ms 28 Sensed value of solenoid output current for lockup clutch 29 Fill time of Hi clutch 30 Fill time of Lo clutch 31 Fill time of R clutch 32 Fill time of 1st clutch HD465-7.

10 Unit ms ms ms Status display Status display Status display Status display Status display Status display Status display 33 Fill time of 2nd clutch 34 Fill time of 3rd clutch 35 Fill time of 4th clutch 36 Fill status of Hi clutch 37 Fill status of Lo clutch 38 Fill status of R clutch 39 Fill status of 1st clutch 40 Fill status of 2nd clutch 41 Fill status of 3rd clutch 42 Fill status of 4th clutch 43 Input voltage of acceleration sensor 44 Operation status of emergency steering (1 & 2) 45 Input status of alternator terminal R 46 Input status of starting switch terminal C 47 Setting status of emergency escape switch 48 ECMV oil temperature 49 Torque converter oil pressure 50 Steering oil temperature 51 Output status of overrun prevention brake 52 Output status of DROOP MODE 2 (P/E) 53 Connector check input status (1 & 2) 54 Hydraulic tank level 55 Engine oil tank level 56 Transmission oil tank level 57 Electrolyte level 58 Radiator coolant level 59 Clogging status of air cleaner 60 Clogging status of transmission filter 61 Clogging status of hydraulic oil filter 62 Clogging status of engine oil filter 63 Judgment of acceleration at gear shifting point 64 Holding status of skip-shift 65 Gear shift mode status 41803 41804 41805 31501 31500 31506 31502 31503 31504 31505 31700 32100 04301 32300 32400 32500 32600 32700 35001 38100 30701 33000 38200 38300 40302 33100 33200 33300 33400 38400 38500 38600 38700 V ON/OFF.Status display MAL AIR CLEANER T/M FILTER HYD OIL FILTER ENG OIL FILTER ACCELERATON TM SKIP SHIFT TM SHIFT MODE QUICK/NRMAL Status display KEEP/NORMAL Status display 0–F Status display 20-186 (10) HD465-7.2 HYD OIL LEVEL ENG OIL LEVEL TM OIL LEVEL BATT LIQ LEVEL COOLANT LEVEL ON/OFF.02 Status display Status display Status display °C MPa OVERHEAT/NORStatus display MAL ON/OFF ON/OFF Status display Status display DROOP MODE 2 CONN CHK 1.Status display MAL CLOGGED/NOR. Monitoring item Item display FILL TIME 2 FILL TIME 3 FILL TIME 4 FILL H FILL L FILL R FILL 1 FILL 2 FILL 3 FILL 4 THROTTLE POS ENERG STRG 1.00 – 5.Status display MAL CLOGGED/NORStatus display MAL CLOGGED/NOR. ON/OFF Status display ALTERNATOR R KEY SW C ENERG TRAVEL ECMV OIL TEMP T/C OIL PRESS STRG OIL TEMP OVERRUN BK DIR ON/OFF ON/OFF ON/OFF 0 – 160 0. ON/OFF Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display LOW/NORMAL Status display CLOGGED/NOR.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR No.00 – 5.2 Monitoring code Display range 0 – 2550 0 – 2550 0 – 2550 0–2 0–2 0–2 0–2 0–2 0–2 0–2 0. HD605-7 .

3146R110 is displayed. 3146R110 is displayed. from left are displayed] Example: If part No. of software (For main CPU) TRANSM ROM 1 20204 Status display 79 Part No. from left are displayed] Example: If part No.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR No. is 7831-46R110. 66: Setting status of rotary switch (displays 2 items at same time) HD465-7. Monitoring item Item display ROTARY SW 1. 0 – F GND/OPEN GND/OPEN GND/OPEN 00 – FF Unit Status display Status display Status display Status display Status display 66 Setting status of rotary switch (SW1 & SW2) 67 Input status of model select wiring harness 1 68 Input status of model select wiring harness 2 69 Input status of model select wiring harness 3 70 1st update status for model rotary switch 71 Correction value of Hi clutch trigger 72 Correction value of Lo clutch trigger 73 Correction value of 1st clutch trigger 74 Correction value of 2nd clutch trigger 75 Correction value of 3rd clutch trigger 76 Correction value of 4th clutch trigger 77 Correction value of R clutch trigger 30801 02701 02702 02703 38800 38901 38900 38902 38903 38904 38905 38906 TRIGER MOD H TRIGER MOD L TRIGER MOD 1 TRIGER MOD 2 TRIGER MOD 3 TRIGER MOD 4 TRIGER MOD R 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display 00000000 – FFFFFFFF Status display XXXXRYYY [3rd – 10th digits of part No. is 7831-46R110. HD605-7 20-187 (10) . XXXXRYYY [3rd – 10th digits of part No. 53: Input status of connector check (displays 2 systems at same time) • No. • No. of software (For sub-CPU) TRANSM ROM 2 20205 Status display a Note: The following monitoring items display data for 2 systems at the same time. 78 Part No.2 MACHINE SEL1 MACHINE SEL2 MACHINE SEL3 TM STATE CHECK Monitoring code Display range 0 – F. 44: Actuation condition of emergency steering (displays 2 systems at same time) • No.

0 – 100 -40 – 210 0. HD605-7 .9 0.99 0 – 300 -40 – 210 0 – 1000 -273.0 0.0 – 999.00 – 9.00 – 9.0 – 125. Monitoring item Engine speed Opening rate of acceleration sensor Fuel temperature Fuel (rail) pressure Fuel consumption Timing rail pressure Boost pressure Engine coolant temperature Engine oil pressure Item display ENG SPEED THROTTLE POS FUEL TEMP METRING PRESS Monitoring code Display range 0 – 8032 0.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR ENGINE (Engine controller system) No.0 Unit rpm % °C MPa L/h MPa kPa °C kPa °C kPa 1 2 3 4 5 6 7 8 9 01002 31701 04203 37000 37300 37100 36500 04104 37200 37500 37400 FUEL RATE TIMING PRESS BOOST PRESS COOLANT TEMP ENG OIL PRESS AIR TEMP AIR PRESS 10 Temperature in intake manifold 11 Atmospheric pressure 20-188 (10) HD465-7.0 – 1735.99 0.

10 Status display Status display MPa MPa Status display V V HD465-7.26 MPa MPa CLOGGED/NORStatus display MAL ON/OFF ON/OFF 0.00 – 50. HD605-7 20-189 (10) .10 0.00 – 20.10 0.00 – 20. ON/OFF Status display WORKING/ RELEASE Operation status of retarder lever switch Input voltage of dump lever potentiometer 1 Input voltage of dump lever potentiometer 2 Input voltage of body positioner sensor Status display 0.10 0.26 0. Monitoring item Brake service meter Command value of rear retarder EPC solenoid output current Item display SERVICE METER Monitoring code Display range 0 .2 ACC OIL PRE F ACC OIL PRE R RETARD FILTER INCLINATION SW FBK CUT DIR HOIST PRESS AUTO SUS MODE ON/OFF.00 – 3.00 – 5. ON/OFF Status display 0.00 – 5.10 EMPTY/LOAD 0.00 – 3.65535 0 – 1020 0 – 1020 0.26 Status display Status display MPa MEDIUM/SOFT/ Status display HARD AUTO SUS DIR 1 AUTO SUS DIR 2 SUS PRESS (FR) SUS PRESS (FL) EMPTY OR LOAD THROTTLE POS ARSC SET SP SW ON/OFF ON/OFF 0.00 – 50.2 RETARDER DUMP LEVER 1 DUMP LEVER 2 BODY POSITION BODY SEATING KICKOUT SOL SWV FOR HOIST ON/OFF.10 (0 – 100) Unit h mA mA V (%) 1 2 3 4 5 6 7 8 9 31101 33800 33801 33900 34000 34100 34300 34301 34400 34600 34700 34800 34900 34901 35000 35100 32300 30702 35500 35501 35700 39000 39100 34501 39200 39300 39301 32802 32803 39400 31704 37701 F BK OUTP DIR Sensed value of rear retarder EPC solenoid output current F BRAKE OUTPUT Retarder lever input (Voltage & conversion quantity) Input status of retarder lever validation switch (1 & 2) RETARD LEVER RLV SW 1.10 ON/OFF ON/OFF ON/OFF 0 – 1020 0 – 1020 ON/OFF ON/OFF ON/OFF V V V Status display Status display Status display 10 Input status of body seating switch 11 Output status of dump lever kick-out solenoid 12 Output status of dump select solenoid 13 Command value of dump EPC solenoid output current EPC HOIST DIR 14 Output current detection value for dump EPC solenoid EPC HOIST 15 Input status of overran command 16 Input status of service brake oil pressure switch 17 Input status of starting switch terminal C 18 Connector check input status (1 & 2) 19 Front accumulator oil pressure 20 Rear accumulator oil pressure 21 Clogging status of brake cooling filter 22 Inclination angle switch 23 Command of front brake cut 24 Hoist lower pressure 25 Auto suspension mode 26 Auto suspension solenoid 1 output 27 Auto suspension solenoid 2 output 28 Front suspension pressure (right) 29 Front suspension pressure (left) 30 Judgment of load 31 Accelerator sensor 32 Travel speed set with ARSC switch mA mA Status display Status display Status display OVERRUN SIG SERVICE BRAKE KEY SW C CONN CHK 1.00 – 50.00 – 5.10 0.00 – 5.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR BRAKE (Retarder controller system) No.

Unit Status display 33 ARSC command 34 Travel speed set with ARSC 35 ASR command 36 (ASR output (L) (Command value)) 37 (ASR output (L) (Sensed value)) 38 (ASR output (R) (Command value)) 39 (ASR output (R) (Sensed value)) 40 (ASR switch (R)) 41 (ASR switch (L)) 42 Steering angle 43 Steering angle speed 44 Wheel speed (RL) 45 Wheel speed (RR) 39500 39501 39600 39601 39602 39603 39604 39605 39606 km/h Status display ASR STATE ASR OUTP DIR L ASR OUTPUT (L) ASR OUTP DIR R ASR OUTPUT (R) ASR SW (R) ASR SW (L) STRG ANGLE STRG ANG SPEED WHEEL SPEED RL WHEEL SPEED RR mA mA mA mA Status display Status display V 35400 35401 39700 39701 rad/s rpm rpm 46 Part No. 5: Input status of retarder lever validation switch (displays 2 systems at same time) • No. HD605-7 .99 0. does not display unit for conversion %) • No. Monitoring item Item display ARSC STATUS ARSC SET SPEED Monitoring code Display range ON/OFF 0 – 255 ON/OFF 0 – 1020 0 – 1020 0 – 1020 0 – 1020 ON/OFF ON/OFF 0. of software (For main CPU) BRAKE ROM 1 20206 Status display 47 Part No. • No. from left are displayed] Example: If part No.00 – 5.0 – 65535 [0000 – FFFF] XXXXRYYY [3rd – 10th digits of part No. from left are displayed] Example: If part No.10 0. 18: Connector check input status (displays 2 systems at same time) 20-190 (10) HD465-7. 3146R110 is displayed. 4: Retarder lever input (displays 2 types at same time. is 7831-46R110. XXXXRYYY [3rd – 10th digits of part No. 3146R110 is displayed. of software (For sub-CPU) BRAKE ROM 2 20207 Status display a Note: The following monitoring items display data for 2 systems at the same time.0 – 99.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR BRAKE [Retarder controller system] No. is 7831-46R110.0 – 65535 0.

10 – – – – (*) 0.0 – 6553.42 – +0.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR VHMS (VHMS controller system) No.0 – 20.10 – – – – (*) -0.0 – 20.10 – – – – (*) 0.0 0. HD605-7 20-190-1 (10) .44 – – – – (*) ON/OFF – – – – (*) ON/OFF – – – – (*) 0–8 – – – – (*) Unit °C °C °C °C kPa t (metric ton or short ton) 1 2 3 4 5 6 7 8 9 42600 42601 42700 37501 42800 42200 32804 32805 32806 32807 32901 42300 42500 42400 ENG OIL TEMP AIR TEMP BLOW PRESS PAYLOAD SUS PRESS (FR) SUS PRESS (FL) SUS PRESS (RR) SUS PRESS (RL) INCLINOMETER FLOAT SIG SHIFT LEVER N TRUCK STATUS MPa MPa MPa MPa rad Status display Status display Status display 10 Suspension pressure (RL) 11 Angle sensor 12 FLOAT signal 13 Gearshift lever N signal 14 Machine status a The (*) mark in the data display range column shows the case when the PLM is not set up.5 – – – – (*) 0.0 – 20.0 – 20.10 – – – – (*) 0. HD465-7.0 – 20. Monitoring item Exhaust temperature (F) Exhaust temperature (R) Engine oil temperature Ambient temperature Blow-by pressure Payload Suspension pressure (FR) Suspension pressure (FL) Suspension pressure (RR) Item display EXHAUST TEMP F EXHAUST TEMP R Monitoring code Display range 200 – 950 200 – 950 0 – +180 -30 – +100 0.

When the following operations related to the power train have been carried out. and carry out the following items in order (Fig. 2). HD605-7 20-191 (5) . see the failure code in the chart on the right) For the adjustment operation. see the failure code in the chart on the right) • When the transmission oil filter has become clogged and it has been repaired (for details. (1) Adjusting individual difference of valve (02: ECMV TUNING AUTO) (2) Resetting gearshifting feeling stabilized learning data (01: TM TRIGGER) (3) Gearshifting feeling stabilized initial learning (monitoring function) a The MANUAL menu of [02: ECMV TUNING] is a special function for the factory and is not used for service. the machine monitor can carry out the the adjustment function to correct the difference in operating feeling to a constant level caused by the the individual differences in the ECMV. perform the adjustments. It can also carry out the selfadjusting learning function so that a constant gearshifting feeling is maintained in accordance with the wear of the transmission clutch. operate the machine monitor and machine itself. see the failure code in the chart on the right) • When an abnormality has occurred in the transmission oil temperature sensor and it has been repaired (for details.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 12. a ( ) indicates the menu to use for the adjustment operation. Adjustment function (TUNING) Through the transmission controller. • When the transmission has been overhauled or replaced • When the transmission valve has been replaced • When the transmission controller has been replaced • When an abnormality has occurred in the power train speed sensor and it has been repaired (for details. Failure code DLF1KA DLF1LC DLF2KA DLF2LC DLT3KA DLT3LC DGF1KA 15B0NA Component name Transmission input shaft speed sensor Transmission intermediate shaft speed sensor Transmission output shaft R speed sensor Transmission valve oil temperature sensor Transmission oil filter HD465-7.

1) Start the engine. 20-192 (9) HD465-7. Before carrying out adjustment. 48 the 3) Raise ECMV oil temperature to 70 – 80°C by raising engine speed. 1).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Preparatory work: Adjusting ECMV oil temperature a It is necessary to carry out the adjustment operation at the specified oil temperature. so check that there is no abnormality on the machine and adjust the ECMV oil temperature as follows. 2) Display [ECMV oil temperature] with machine data monitoring function. (Fig. 4) Keep engine speed in low idle for 3 minutes. HD605-7 . be sure to check that ECMV oil temperature is kept within 70 – 80°C. • TRANSMISSION No.

then repeat from Step 1). repeat from Step 1). and start the adjustment operation (Fig. • If [NG 3] (Compensation value over] is displayed: Carry out troubleshooting for failure code [15S[ ]L1]. 6). so take action according to the display (Fig.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Adjustment operation (1): Adjusting individual difference of valve a See Preparatory work and check that the ECMV oil temperature is at the specified temperature. 1st. a For each adjustment operation. and if it is found to be normal. • If [4-4 OK] is displayed: The adjustment operation has been completed correctly. HD605-7 20-193 (10) . press the [ ] button. check the set conditions of the machine again.) • If [NG 1] (Outside compensation condition) is displayed: Adjust the ECMV oil temperature correctly. Hi. repeat from Step 1). 2nd. 3rd and 4th valves. the result is displayed as normal or abnormal. a The adjustment operation is carried out automatically four times for the Lo. • [ ] button: Runs adjustment menu a The adjustment is carried out consecutively four times for the applicable clutches and displays a screen like the one shown on the right. 5). R. 1) Set the machine to the following conditions. No. • Adjustment menu: 02: ECMV TUNING AUTO 3) Check the condition of the machine again. and if it is found to be normal. (When the starting switch is turned OFF. • If [NG 2] (No fill) is displayed: Carry out troubleshooting for failure codes [15S[ ]MA] [DDT[ ]KA]. the adjusted value is recorded in the controller. • Parking brake switch: PARKING • AISS LOW switch: LOW • Gearshift lever: N position • Engine: Low idle • Accelerator pedal: OFF (released) 2) Operate the machine monitor and display the adjustment menu screen (Fig. 4). 1 2 3 4 5 6 7 Valve Lo Hi R 1st 2nd 3rd 4th 1st time 2nd time 3rd time 4th time IP L-1 IP H-1 IP R-1 IP 1-1 IP 2-1 IP 3-1 IP 4-1 IP L-2 IP H-2 IP R-2 IP 1-2 IP 2-2 IP 3-2 IP 4-2 IP L-3 IP H-3 IP R-3 IP 1-3 IP 2-3 IP 3-3 IP 4-3 IP L-4 IP H-4 IP R-4 IP 1-4 IP 2-4 IP 3-4 IP 4-4 HD465-7.

8). 7). 20-194 (1) HD465-7.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Adjustment operation (2): Resetting gearshifting feeling stabilized learning data 1) Operate the machine monitor and display the initial menu screen (Fig. HD605-7 . check that INITIAL STATUS is displayed on the bottom line of the screen. 7). • [ ] button: Runs initialize menu 3) Operate the buttons according to the screen display (Fig. • [<] button: Select YES • [>] button: Select NO • [t] button: Run a After carrying out initializing. regardless of the present initial status. the learning data is initialized from the following operation. press the [ ] button and display the initial screen of the sub menu (Fig. 2) With the menu selected. • Initial menu: 01: TM TRIGGER a The present initial status is displayed on the bottom line of the screen. • Initializing completed: INITIAL STATUS • Initializing not performed: TUNED a With the transmission adjustment.

perform it on finished flat ground. display R CLUTCH FILL TIME with the machine monitoring function. 31 of TRANSMISSION • FILL TIME R: Fill time of R clutch (Fig. a After Step 2) is repeated 3 times. • No. and then operate the gearshift lever in the following order. a If "1" is displayed. repeat step 2) until "0" is displayed. go the next step. a When performing the adjustment work by driving the vehicle actually. HD465-7. HD605-7 20-195 (10) . (1) If the fill time is 250 msec or shorter. replace the ECMV. In this case. if "0" is still not displayed. 10). 1) Display R CLUTCH FILL STATE with the machine monitoring function (Fig. 38 of TRANSMISSION FILL R: Fill state of R clutch 2) Run the engine at low idle and hold the gearshift lever in the N position for 10 seconds. a Operation of gearshift lever: N o R o N 3) Check the fill state with the monitoring display. a If "0" is displayed.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR Adjustment work (3): Initial learning of stabilization of gear shifting feel a Referring to PREPARATION WORK. return to 1) and repeat step 2) until the fill state of the R clutch becomes "0". go to 4). check that the ECMV oil is at the specified temperature. Perform the adjustment work in a place wide sufficiently for travel. (2) If the fill time is 900 msec or longer. the ECMV may be defective. as long as possible. taking care of the safety around the machine. • No. 11) a If the above condition is still not satisfied after the steps are repeated 5 times.

13. (2) If the fill time is 550 msec or longer. • No. the ECMV may be defective. 40 of TRANSMISSION FILL 2: Fill state of 2nd clutch • No. correction is completed. go to 7). 12. (1) If the fill time is 250 msec or shorter. • No. a If "1" is displayed. 14).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 4) Set the gearshift lever in the 6 position. display 1ST CLUTCH FILL TIME with the machine monitoring function. replace the ECMV. and 1st CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. In this case. a After steps 4) and 5) are repeated 3 times. 42 of TRANSMISSION FILL 4: Fill state of 4th clutch • No. Run the engine at full throttle and shift up the gear to F6. if "0" is still not displayed as the fill state of the 1st clutch. 20-195-1 (7) HD465-7. 39 of TRANSMISSION FILL 1: Fill state of 1st clutch a If "0" is displayed. and Fig. 5) Drive the machine in F6 for 10 seconds. return to 4) and repeat steps 4) and 5) until the fill state of the 1st clutch becomes "0". 2nd CLUTCH FILL STATE. HD605-7 . 32 of TRANSMISSION FILL TIME 1 : Fill time of 1st clutch (Fig. a Shifting down: F6 o F5 o F4 o F3 o F2 o F1 a Do not operate the brake during coasting run. 15) a If the above condition is still not satisfied after the steps are repeated 6 times. Fig. repeat steps 4) and 5) until "0" is displayed for the all clutches. and then release the accelerator pedal and shift down the gear to F1 by coasting run. 6) Display 4TH CLUTCH FILL STATE.

Run the engine at full throttle and shift up the gear to F3. • No. a If "1" is displayed. correction is completed. replace the ECMV. the ECMV may be defective. go to 9). • No. HD465-7. if "0" is still not displayed as the fill state of the Hi clutch. (1) If the fill time is 200 msec or shorter.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 7) Set the gearshift lever in the 3 position. 8) Stop the machine and display HI CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 36 of TRANSMISSION FILL H: Fill state of Hi clutch a If "0" is displayed. repeat steps 7) and 8) until "0" is displayed. In this case. a After steps 7) and 8) are repeated 3 times. 17) a If the above condition is still not satisfied after the steps are repeated 5 times. (2) If the fill time is 550 msec or longer. return to 7) and repeat steps 7) and 8) until the fill state of the Hi clutch becomes "0". HD605-7 20-195-2 (7) . display HI CLUTCH FILL TIME with the machine monitoring function. 16). 29 of TRANSMISSION FILL TIME H : Fill time of Hi clutch (Fig.

Once holding is reset. 11) Drive the machine in F3 for 5 seconds. a The display keeping function of the machine monitoring function is reset automatically when any switch is operated. repeat the step from starting. a If the starting switch is turned OFF or control switch [ t] is pressed 3 times. 20-195-3 (7) HD465-7.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 9) Display LO CLUTCH FILL STATE with the machine monitoring function and check the fill state (Fig. 13) Stop the machine and display LO CLUTCH FILL STATE and 3RD CLUTCH FILL STATE with the machine monitoring function and check the fill states (Fig. If the gear has been shifted to F4. a Take care not to shift up the gear to F4. and then shift up the gear to F4 with the engine at full throttle. the value is updated. 37 of TRANSMISSION FILL L: Fill state of Lo clutch 10) Set the gearshift lever in the 4 position. a If "1" is displayed. the machine monitoring function screen disappears and the ordinary screen appears. In this case. Run the engine at full throttle and shift up the gear to F3. repeat steps 9) – 13) until "0" is displayed for both clutches. 41 of TRANSMISSION FILL 3: Fill state of 3rd clutch a If "0" is displayed. if "0" is still not displayed. correction is completed. • No. • No. replace the ECMV. 18). a After steps 9) – 13) are repeated 6 times. 12) While the machine is traveling in F4. HD605-7 . 19). a Judge the fill state of the Lo clutch by the value displayed and held during travel at F4. the ECMV may be defective. press control switch [U] to keep displaying the machine monitoring function.

2) Selecting filter. press the [ ] button and display the interval input screen (Fig. 20-196 (9) HD465-7. 3). the following content is displayed (Fig. • [ ] button: Executes change function a The presently set interval is displayed on the screen. Filter.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 13. oil replacement time setting function on the menu screen of Service mode (Fig. 1). see Table of filter and oil replacement time set items). oil replacement time setting function (MAINTENANCE MONITOR) The machine monitor can set the maintenance interval for filters and oil. • [ ] button: Runs menu ii) Press the [>] or [<] buttons to select the item to be set. 3) If the maintenance items in the display for the filter and oil replacement time set items are selected. 2). oil replacement time setting item i) With the menu selected. which form the base for the filter and oil replacement time and display. press the [ ] button and display the initial screen of the set item (Fig. 1: Code (2 digits) A: Filter and oil replacement time set items 2: Remaining time to set replacement time 3 : Number of times of replacement up to present 4) Changing replacement interval i) With the set items selected. • [>] button: Goes on to next item • [<] button: Goes back to last item a The set items are displayed endlessly in the internal set order (for details. HD605-7 . 4: example). 1) Menu selection Select Filter.

4). For numbers of less than four digits. transmission. so operate the buttons according to the screen display (Fig. input 0s at the beginning.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR i) ii) Operate the buttons to input the interval (Fig. the change confirmation screen is displayed. • [>] button: Number at cursor goes up • [<] button: Number at cursor goes down • [ ] button: Number at cursor is confirmed • [t] button: Returns to item selection screen a The time must always be input with four digits. brake oil Brake oil filter Brake cooling oil filter Hydraulic filter Differential case oil Final drive oil Hydraulic oil Item Code 03 02 01 13 06 24 14 16 04 11 08 10 Display FUEL FILT ENG FILT ENG OIL TM FILT CORR RES TC/TM/BK OIL BK OIL FIL BK C FIL HYD FILT DIFF OIL FNL OIL HYD OIL Replacement time 0500 0500 0500 0500 1000 1000 1000 1000 2000 2000 2000 4000 HD465-7. 1 2 3 4 5 6 7 8 9 10 11 12 Fuel filter Engine oil filter Engine oil Transmission oil filter Corrosion resistor Torque convertor. • [<] button: Select YES • [>] button: Select NO • [t] button: Run Table of filter and oil replacement time set items No. When all the interval times are confirmed. 5). HD605-7 20-197 (1) .

• [U] button: Enter number at cursor. 1) Setting of travel distance to recognize completion of loading Input a travel distance to recognize completion of loading by pressing the following buttons (Fig. Be sure to measure the weight of the empty dump truck and that of the fully loaded dump truck "as a set" according to the following procedure. execute the following procedure securely.0 – 0. If the set value is too small. 3). The dump truck must travel for about 3 minutes each after the weight of the empty dump truck and that of the fully loaded dump truck are measured. the system may recognize that loading is completed while the dump truck is still being loaded. PLM setting function a This function is applied to "PLM having VHMS" (only when the option is set). 1). • [<] button: Number at cursor moves backward. • [t] button: Stop inputting number. 20-197-1 (10) HD465-7. a The setting range is 0 – 255 m (0. see "Execution of PM clinic using manual snap shot (Another name: Quick PM)" (Drawing No. HD605-7 . • [>] button: Number at cursor moves forward. WJ021D060) (Fig.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 14. 15. • Various items of the "PLM having VHMS" are displayed and set with this function. secure travel distance for this purpose.158 miles). Accordingly. Snap shot function a For this function. 2) Correction of calculation of payload Since this function affects the accuracy directly.

11). Accordingly. perform the following procedure very carefully. (After selecting. (1) Select "EMPTY WEIGHT" (Fig. "LOADED WEIGHT" is displayed when the menu is selected (See Fig. go to Fig. • Check the unit of the input value.) Input the measured weight of the empty dump truck and drive the dump truck for about 3 minutes. • [U] button: Enter the selection. [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". etc. HD465-7. (METRIC) --. • [t] button: Return to the previous screen. Measure the weight of the empty dump truck with the load meter and record it (Write it on a sheet of paper. HD605-7 20-197-2 (5) .) • [t] button: Return to the previous screen.short ton (2) Check that measurement of the weight of the empty dump truck has been completed. • [>]. It does not always heighten the absolute accuracy. 5) • [U] button: Check that measurement has been completed and go to the next step. 5.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR i) ii) The relationship between the suspension pressure and payload corrected with this function cannot be returned to the condition at the time of shipment.metric ton (SHORT) ---. This function is used to match the calculation result to the indication of the load meter to be used. 4). a The unit is indicated in the ( ) on the right side of WEIGHT. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes. a Display on the screen (Fig.

• [>] button: Number at cursor moves forward. 6). 20-197-3 (5) HD465-7. • [t] button: Enter.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR (3) Input the measured weight of the empty dump truck (Fig. HD605-7 . • [t] button: Return to the screen for inputting values. • [t] button: Return to the largest position of the number to input the value again. • [>] button: Select "YES". inputting of the value is stopped and the previous screen appears. (5) Move the dump truck to a place where you can drive it. If this button is pressed again. 7). • [<] button: Number at cursor moves backward.8 [t] (Operating weight) ± 15% (metric ton) (4) Check the input value (Fig. 8) • [U] button: After getting ready for drive. • [<] button: Select "NO".6 [t] (Operating weight) ± 15% (metric ton) HD605-7: 46. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. press this button and start driving the dump truck. a Display on the screen (Fig. a Inputtable range HD465-7: 43. • [U] button: Enter number at cursor.

(1) Select "LOADED WEIGHT" (Fig. a The unit is indicated in the ( ) on the right side of WEIGHT. • [U] button: Enter the selection. the next screen appears automatically. go out of "Service mode" temporarily and return to "Display of load/integrated odometer". When measurement is finished. 10). • [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. iii) Load the dump truck to measure the weight of the fully loaded dump truck (Fig. a When loading is started. • [t] button: Return to the previous screen.(1). 11). you can check the current load. a If the weight of the empty dump truck has been input and the dump truck has been driven for about 3 minutes.metric ton (SHORT) ---. see the steps up to ii) . (METRIC) --. • [>]. etc. • Check the unit of the input value. HD605-7 20-197-4 (9) . the number of " * " increases. When indicating the current load for reference while the dump truck is being loaded. iv) Measure the weight of the fully loaded dump truck with the load meter and record it (Write it on a sheet of paper.short ton HD465-7.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR (6) Display the progress of measurement (Fig. On this screen. 9). a As measurement is executed. • [t] button: Return to the menu screen. a For the method of displaying the following screen. [<] buttons: Select "EMPTY WEIGHT" or "LOADED WEIGHT". the menu s cr een app ears automati cal ly. "LOADED WEIGHT" is displayed when the menu is selected (See Fig. 11).) v) Input the measured weight of the fully loaded dump truck and drive the dump truck for about 3 minutes.

If this button is pressed again. a Inputtable range HD465-7: A1 ± (A1 x 0.6 [t] (Operating weight) + 46 [t] (Load capacity)} HD605-7: A2 ± (A2 x 0. • [t] button: Return to the largest position of the number to input the value again. 20-197-5 (5) HD465-7. • [>] button: Select "YES". 6). (3) Input the measured weight of the fully loaded dump truck (Fig.8 [t] (Operating weight) + 63 [t] (Load capacity)} (4) Check the input value (Fig. inputting of the value is stopped and the previous screen appears. 5) • [U] button: Check that measurement has been completed and go to the next step. a Display on the screen (Fig. • [<] button: Number at cursor moves backward. A1 = {43. 7).25) (metric ton) However. • [U] button: Enter number at cursor. • [>] button: Number at cursor moves forward. • [t] button: Return to the previous screen. A2 = {46. HD605-7 .25) (metric ton) However. • [<] button: Select "NO". • [t] button: Enter.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR (2) Check that measurement of the weight of the fully loaded dump truck has been completed.

a Display on the screen (Fig. When measurement is finished. Enter it when it is stabilized.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR (5) Move the dump truck to a place where you can drive it. HD605-7 20-197-6 (5) . • [t] button: Stop measurement a n d r e t u r n t o th e p r e v i o u s screen. vi) Dump the load in the dump area (Fig. 3) Correction of level of inclination sensor i) Move the dump truck to a level place. If the load is dumped normally. correction is finished. • [t] button: Return to the menu screen. 13). ii) Input the clinometer reading (F) at the current position and that (R) after turning 180 degrees (stopping it in the opposite direction) on the same position and use the average value as the standard level. • [t] button: Return to the menu screen. 9). a The current standard level value is displayed on the upper line. a If the load is dumped with the dump lever. (6) Display the progress of measurement (Fig. 12). the menu screen appears automatically. the number of " * " increases. 8) • [U] button: After getting ready for drive. The clinometer value (F) at the current position flashes. (1) Enter value of (F) (Fig. press this button and start driving the dump truck. • [U] button: Enter the flashing value. a As measurement is executed. • [t] button: Return to the screen for inputting values. HD465-7. a Drive the dump truck for about 3 minutes (at a speed higher than 8 km/h) to enter the relationship between the weight of the dump truck and the suspension pressure under that weight. the next screen appears automatically.

• [>] button: Number at cursor moves forward.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR (2) Turn the dump truck 180 degrees (Stop it in the opposite direction). 15). (Default: 99 km/h) 5) Setting of payload to recognize start of loading Input a payload to recognize start of loading by pressing the following buttons (Fig. The clinometer value at the current position flashes. • [U] button: Enter the flashing value. • [<] button: Select "NO". a The current standard level value is displayed on the upper line. (Default: 15%) This function does not assure the operation because of the contrary phenomena shown below (on the next page). 4) Setting of criterion of maximum travel speed Input a criterion of the maximum travel speed by pressing the following buttons (Fig. 20-197-7 (5) HD465-7. HD605-7 . • [t] button: Enter. • [t] button: Stop inputting number. Enter it when it is stabilized.5%. (3) Enter value of (R). a The setting range is 0 – 99 km/h (0 – 62 MPH). a The setting range is 0 – 25. (4) Enter the standard level value (Fig. • [<] button: Number at cursor moves backward. 16). • [U] button: Enter number at cursor. • [>] button: Number at cursor moves forward. • [<] button: Number at cursor moves backward. • [U] button: Enter number at cursor. 17). • [t] button: Stop inputting number. • [>] button: Select "YES". • [t] button: Return to the menu screen.

a The unit is indicated in the ( ) on the right side of the input value [t].0 – +5. • [>] button: Number at cursor moves forward. Set A (Yellow lamp) higher than G (Green lamp) and set R (Red lamp) higher than A (Yellow lamp). • [t] button: Stop inputting number. • If the value is increased and a loader having a small-capacity bucket is used. • [U] button: Enter number at cursor. • Check the unit of the input value on the previous menu screen (Fig. HD605-7 20-197-8 (5) .0 [t]. • [t] button: Stop inputting number. 21). however. a The setting range is 0 – 130% of the load capacity. • [<] button: Number at cursor moves backward. 7) Setting of OFFSET function Input an offset range by pressing the following buttons (Fig. a The setting range is -5.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR If the value is reduced. start of loading may be recognized wrongly. • [>] button: Number at cursor moves forward. • [U] button: Enter number at cursor. 6) Setting of indication range of outside indicator lamps Input an indication range of the outside indicator lamps by pressing the following buttons (Fig.metric ton (SHORT) ---. (METRIC) --. 20). 19). the forecast function of the outside indicator lamps and the MMS communication may not operate normally.short ton • HD465-7. • [<] button: Number at cursor moves backward.

23). HD605-7 . • WHEN DUMPING (Setting at time of shipment) The payload measured when the dump lever is shifted from the "FLOAT" position to "another position" in the dump area is saved. • WHEN TRAVELING The data sampled while traveling from the loading area to the dump area is processed statistically and the hauled payload is entered and saved when it is dumped. • [<] button: Select "NO". • [U] button: Enter the selected method. • [>]. • [t] button: Enter. • [>] button: Select "YES". • [t] button: Return to the menu screen. 22). 16. 20-198 (5) HD465-7. Initialize function (INITIALIZE) (exclusive function for factory) a This is a special function for the factory and is not used for service. [<] buttons: Select "WHEN DUMPING" or "WHEN TRAVELING". ii) Enter the selected method (Fig.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR 8) Selection of method of entering saved payload i) Select the method of entering the saved payload (Fig.

its power supply is differentfrom many of the electronic equipment and electrical parts. operation. dirt. Handling monitoring system Always obey the following precautions when handling the monitoring system. 20-203-1 (10) HD465-7. the period needed for collecting data is clearly known and it becomes possible to store this data in the internal memory. or sensors of the system (equipment) caught or pulled by force. 2. see the Operation and Maintenance Manual for the machine.TESTING AND ADJUSTING BASIC PRECAUTIONS BASIC PRECAUTIONS 1. HD605-7 . 3) Do not damage or get the wiring harnesses. the VHMS uses the permanent power source to save to memory the data accumulated from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Handling machine. 2) Precautions when turning the permanent power source OFF When the starting switch is turned OFF. and maintenance of the machine. i) When removing VHMS from permanent power source When removing the VHMS from the permanent power source (for example. check that the monitor display (7-segment LED in the diagram below) of the VHMS controller is out. when carrying out repairs). the power supply is maintained for at least 3 minutes (the VHMS system shut-down time: the time taken for the VHMS system to save the data to memory and switch off). and then the permanent power source is turned OFF. safety. 1) When disassembling. or modifying the machine or system. If the VHMS system shut-down time is shorter than 3 minutes. inspection. 3. Therefore. the accumulated data may be damaged. Because this switch power source and permanent power source are provided. it is necessary to have a power supply that is connected directly to the battery and always supplies electricity (permanent power source) in addition to the power source (switch power source) that is cut when the starting switch is turned OFF or the engine is stopped. For the system to provide the above functions. Permanent power source for VHMS (battery direct power source) 1) Meaning and need of permanent power source The VHMS has the function of checking and collecting data on the condition of the machine from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. follow the instructions in the manual. This may cause short circuits or disconnections that will lead to failure or fire on the machine or system (equipment). 2) Do not touch the system (equipment) when operating the machine. connectors. or oil on the system (equipment). In other words. repairing. inspection and maintenance For details of safety items. Then the VHMS controller itself turns off the permanent power source. 4) Do not get water.

the VHMS controller carries out the initial check (LEDs flash). wait for at least 3 minutes before turning off the permanent power source. HD605-7 20-203-2 (10) . • If the above shut-down time is shorter than 3 minutes. Precautions when VHMS power source is ON • For the first few seconds after the power is switched ON. 4. b) When safety regulations for user make it impossible to avoid shutting down all electric power • Install a battery isolator so that the permanent power source is kept in the specified condition for at least 3 minutes after the starting switch is turned OFF before the permanent power source is shut down. HD465-7. Do not carry out any of the following operations until the initial check is completed. the data collected up to that point is lost.) 5. Precautions when replacing VHMS and transmission controller 1) Before starting replacement i) Download VHMS data When the VHMS controller is replaced. ii) Specified method of shutting down VHMS power source a) Use the starting switch to turn the normal power source OFF b) Maintain the permanent power source in the specified condition for at least 3 minutes. see the separate instruction manual for the technical analysis tool box. • Operation of manual snapshot switch • Downloading from PC (Check that the LEDs are displaying the aggregate numerals in turn before operating. send the accumulated data to web care. the accumulated data may be damaged. • If there is no timer. For details of the method of downloading. Next. c) Turn the permanent power source (battery direct) OFF.TESTING AND ADJUSTING BASIC PRECAUTIONS ii) When installing battery isolator or other battery shut-down device a) Basic connections It is a basic assumption that the engine stop switch is a type that will not shut off the permanent power source when the engine is stopped. so be sure to download the accumulated data before starting the replacement operation.

and carry out the initial setup. If the ORB controller is not used. turn on the ORB power ON (connect the connector). the transmission will be unauthorized and there will be problems with the communications system. please contact Komatsu or the person responsible for operation. 2) Finally. If there are any problems or any part is unclear. action after replacement When replacing the VHMS controller. connect the ORB controller connector (ORB-A. HD605-7 . 20-203-3 (2) HD465-7. For details. 6. be careful not to subject the VHMS controller or wiring harnesses to any excessive force or impact.TESTING AND ADJUSTING BASIC PRECAUTIONS 2) Method of replacement. it is impossible to carry out the request to open communications before starting to use. Handling communications controller (ORB • • • Orbcomm) 1) The ORB controller must be used. After the VHMS controller confirmation is completed. ORB-B). If the control power is turned on before completing the request. see the separate instruction manual for the technical analysis tool box.

HD605-7 20-203-4 (2) . 1.TESTING AND ADJUSTING OUTLINE OUTLINE a It is also possible to add this system to a machine that has already been shipped. Basic structure (1) HD465-7.

Basic structure (2) 20-203-5 (2) HD465-7.TESTING AND ADJUSTING OUTLINE 2. HD605-7 .

TESTING AND ADJUSTING OUTLINE HD465-7. HD605-7 20-203-6 (2) .

TESTING AND ADJUSTING OUTLINE 3. 20-203-7 (2) HD465-7. Position of equipment Install monitoring controller (VHMS controller) (1) on the machine. transmission. 1) Data collection function i) Data from connected sensors • Blow-by pressure {sensor (2)} • Engine oil temperature {sensor (3)} • Exhaust gas temperature {sensor (4)} • Ambient temperature {sensor (5)} ii) Data from controller mounted on machine • Engine speed • Fuel injection amount • Engine oil pressure • Data from transmission controller • Data from retarder controller • Data from PLM II controller • SMR (service meter) 2) Saving data • The above data is saved to memory. and PLM. HD605-7 . and collect the operation data for the engine.

(6): Ground level download connector (7): Download connector inside cab (8): Communications antenna/pole Antenna mount: Thread tightener (LT-2) HD465-7. HD605-7 20-203-8 (2) . and transmit the data through the Internet. • Send the data automatically from remote areas through the communications satellite (ORB). download the data.TESTING AND ADJUSTING OUTLINE 3) External communication function • Connect the PC (personal computer) to the VHMS controller.

Setup flow (outline) Procedure 1 Method (specific content. points to remember. see the instruction manual for the technical analysis tool box (for service). variation code • Engine model. sending checksheet • Sending download data 20-203-9 (12) HD465-7. • Time of start of data collection • Data collection unit (day) • Saving settings • Checking VHMS functions • Performing test (quick PM) • Downloading • Checking data (content of data) • Checking operation of Orbcomm • Setting up communications (need for communications file. repair or correct to return condition to normal • Check for generation of errors • Start setup tool Setting up VHMS Turn starting switch ON (starting switch ON) • Calendar (data.) Check that no error is generated by the VHMS controller or other controller If there is any error. 4) Transmission Serial No.TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER SETTING UP VHMS CONTROLLER 1. Serial No.. the following are needed 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) • For details of the setup method. Setting items • VHMS: For details of the setup method. interval. • For details of the method of setting PLM II and VHMS with PLM function. Serial No. summer time (daylight saving time)) 2) Machine model. time. Serial No. content of setup (data). see the separate PLM instruction manual. • Or contact Komatsu. communications frequency. time.. 1) Communications method (stop/start. time difference from GMT. Serial No. time difference from GMT. 1) Calendar (date. 1) When making the initial installation of the VHMS system 2) When replacing or overhauling the following components • VHMS controller • Engine • Transmission • PLM II (option) • When carrying out the setup. • The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. HD605-7 . 2. see the instruction manual for the technical analysis tool box (for service). summer time 2 • Machine model. see the instruction manual for the technical analysis tool box (for service). Setting up VHMS controller • In the following cases. variation code 3) Engine model. GCC code) (daylight saving time)) 3 4 5 6 Setting up PLM function or PLM II (when the PLM function is available or machine is PLM II specification) Starting switch OFF (starting switch OFF) Starting switch ON (starting switch ON) Start engine Test (quick PM) Starting switch OFF 7 • Check for errors • Start setup tool Starting switch ON (starting switch ON) 8 Starting switch OFF (starting switch OFF) • Setup completion report. • Transmission Serial No. always carry out the setup. etc. 1) Time of the start of data collection 2) Data collection unit (day) • Opening communications with Orbcomm: For details of the setup method. transmission time) 2) Time of PLM data collection 3) Country code for communications controller (GCC) 3.

TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER 4. transmission controllers show past errors. Collection of data a If there is no abnormality in the system. then give [00] display (no error exists) No display VHMS controller starts up. the machine will operate and the operation data for the machine will automatically be saved by the VHMS controller. Start Turn starting switch to [ON] position Display Normal Engine. HD605-7 20-203-10 (2) . then check connection of wiring harnesses again Turn starting switch again to [ON] position Display Normal Engine. LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display Possible abnormality in VHMS controller Display Normal 5. Checking operation. actuation a Check the functions of the VHMS system as follows. HD465-7. then give [00] display (no error exists) No display Abnormality in machine syastem See machine shop manual VHMS controller starts up. transmission controllers show past errors. LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display Display Normal Turn starting switch [OFF].

Method of downloading with PC (personal computer) To ensure safety.) 2. (There are limitations to the capacity of satellite communications. Carrying out quick PM a For details. HD605-7 . stop the machine on level ground and put chocks under the tires to prevent the machine from moving.) Check that no error is generated by VHMS controller or other controller If there is any error. TRANSMISSION OF DATA COLLECTION. 2) Automatic transmission by communications satellite (machines with Orbcomm specification) • Error data and other specified data are automatically sent by communications satellite to the file server in the computer center. 4. Sound the horn to warn people in the surrounding area before starting the engine. 1 2 3 Starting switch OFF (turn key to OFF) • Saving set values • Reporting completion of setup 3.TESTING AND ADJUSTING COLLECTION. 20-203-11 (10) HD465-7. see the instruction manual for the technical analysis tool box (for service). see the instruction manual for the technical analysis tool box (for service). When turning the starting switch ON. see TESTING AND ADJUSTING. check that the parking brake is ON and that the gearshift lever is at the N position. Performing PM clinic using manual snapshot. send the data to the file server in the computer center by e-mail (Internet). TRANSMISSION OF DATA 1. a The download connectors are provided in 2 places: rear of assistant's seat inside cab (7) and behind front left tire of machine (6). • To collect data under the normal working conditions. <Preparatory work> • Prepare a PC for downloading and a download wiring harness. Collection of data 1) Downloading with PC (personal computer) <Necessary tools> • PC (personal computer) • VHMS analysis tool (software) (799-608-3211) • Download cable (799-608-3220) When using a PC to download the collected data. carry out the quick PM (equivalent to PM clinic) before downloading with the PC. repair or correct to return condition to normal • Checking satellite communications data. points to remember. a For details of the method of using the PC. etc. Setup flow (outline) Procedure Turn starting switch ON (starting switch ON) • Check for generation of errors • Start setup tool Setting up communications Method (specific content. and to collect data when operating under such conditions as torque converter stall or high idle. setting communications frequency • Setting GCC code a For details of downloading and sending the data. so use this method to send all the data.

then download to the PC. 9) Turn the engine key and lock the front cover. the download operation is completed. (See Table 1) 6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures.TESTING AND ADJUSTING COLLECTION. If the turn switch is not off. 2) Connect the other end of the download wiring harness to the PC. 4) Fault history : This records errors that occurred in order of occurrence. the download operation is completed. the VHMS is actuated and pilot lamp (11) lights up. then carry out the PC download. 4. check that the monitor controller is working. 5) Check that pilot lamp (11) is lighted up. and aggregate numerals are displayed in order. check that the VHMS controller starts up. 3) Turn the machine starting switch ON. 2) Use the engine key to open the cover at the front of the box. LEDs flash (see diagram below). 3) Machine history : This records the actual engine operation data. 5) Turn the machine starting switch OFF. 7) Return the turn switch to its original position.. Types of data collection files 1) Index file : This records the common data for the machine model. HD605-7 20-203-12 (10) . 8) Check that pilot lamp (11) is out. (see Table 2) 7) Snapshot : This records the data for a specified time before and after the occurrence of an error (see Table 3. then install the cap. a To check that the VHMS controller is working. 3) Remove the cap of the download connector and install the download cable. serial No. remove the download cable. then close the box cover. TRANSMISSION OF DATA <Downloading from connector inside cab> 1) Remove the connected wiring harness and install the download cable. 4) When turn (wake-up) switch (10) is turned. then turn the PC power OFF.1. remove the download cable. 5) Trend analysis : This records the maximum or minimum values for each measurement device at the specified intervals. and service meter (SMR). and return the wiring harness to its original condition. Close the clamps at the top of the box also. 6) When [complete] is displayed on the download PC. <Downloading from ground level connector> 1) Remove the clamp at the top of the download box. 4) When [complete] is displayed on the download PC. 2) 8) Load map : This records the frequency of the applicable area. taking the engine speed and fuel injection amount as the axes 9) Cycle interval : This records the aggregate frequency of the changes in engine speed 10) Running area : This records the operation distribution for each area on the engine performance graph 11) Running direction : This records the track of movement for each area on the engine performance graph 12) Transmission shift change map: This records the transmission gearshift data 13) Transmission fill time trend : This records the transmission clutch engagement time data (See table 4) 14) Payload data (if equipped) : This records the payload meter data 15) Payload data cycle (if equipped) : This records the operating cycle data for the machine HD465-7. the cover will not close. 2) VHMS history : This records changes in the VHMS.

max. max.) Engine oil pressure at high idle (min.) Atmospheric pressure (average) Front brake oil pressure (max. E.) Rear engine exhaust temperture (max. press. max.) Engine coolant temperature (min.5. Ambient temp. ave. TRANSMISSION OF DATA TREND DATA ITEMS Table 1: Trend analysis data No. H min. Cool temp. Exh. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 SMR Calendar Engine speed max. 1 clutch 20-203-13 (12) HD465-7.C hPa kg/cm 2 Data collection point Remarks Engine controller Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor Engine controller Engine controller Engine controller Engine oil temperature sensor Engine controller Engine controller Engine controller Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller (ambient temperature sensor) Engine controller Retarder controller Retarder controller Maximum value within set trend data (Every 20 hours) See as below kg/cm2 Table 2: Machine trend data No. Time of use for each retarder oil temperature Retarder controller Content Unit h y/m/d h:m:s Transmission controller Data collection point Remarks Table 3.) Blow-by pressure (max.5. oil press.2.C Liter/h deg. 1 2 3 4 SMR Calendar T/C oil temp. max. 4. oil temp.) Engine oil pressure at low idle (min. E.2. max. 1 2 3 4 5 6 7 8 9 Content Failure code No. max. F. 140– Rtrdr.C deg.) Ambient temperature (average) Ambient temperature (min. R. T140– Item Service meter Calendar Time of use for each torque converter oil temperature sec. temp. R. Ambient temp. max. temp. Blow-by press. max. 130– T/C oil temp. brake P. max. min.3 cylinder exhaust temperature is high F@BYNR(n362) (stage 2) No. HD605-7 . 120– T/C oil temp. Fuel rate Cool temp. brake P.6 cylinder exhaust temperature is high F@BZNR(n372) (stage 2) Double meshing of transmission clutch Problem with lock-up clutch Problem with High clutch Problem with Low clutch 1500L0(b005) 1380MW(b021) 15H0MW(b022) 15J0MW(b023) 15K0MW(b024) 10 Problem with No.C deg. Item Service meter Calendar Engine speed (max. oil temp.) Ambient temperature (max.1 Observation items (trigger items) for auto snapshot No.) Front engine exhaust temperture (max. L min. 3 clutch Problem with No. oil P. E. oil P. min. Exh. 1. 11 12 13 14 15 16 17 18 19 20 Content Problem with No. T130– Rtrdr.C deg. 2 clutch Problem with No. 1.3 cylinder exhaust temperature is high F@BYNS(n361) (stage 1) No.6 cylinder exhaust temperature is high F@BZNS(n371) (stage 1) Blow-by pressure is high F@BBZL(n338) No.) Rear brake oil pressure (max. 4.) Fuel consumption rate (average) Engine coolant temperature (max. ave. Ambient temp. T120– Rtrdr. oil temp.) Engine oil pressure (max. oil temp. F. 4 clutch Problem with engine speed senser Overheating of water Overheating of fuel Overheating of torque converter Overheating of rear brake oil Overrun Abnormal drop in engine oil pressure Failure code 15L0MW(b025) 15M0MW(b026) 15N0MW(b027) C115KZ C151NS C261NS B@CENS(A0d2) B@C7NS(A0d4) A00N1(n201) C143ZG No. Atmos. Eng.C deg.C kg/cm2 kg/cm2 kg/cm2 deg.) Content Unit h y/m/d h:m:s rpm mmAq deg.C deg.TESTING AND ADJUSTING COLLECTION.) Engine oil temperature (max.

••• F7= 7 FLOAT = 0. time 3rd (fill time) Trig. exh. Eng. Ambient temp. brake press. 1. C kg/cm2 kg/cm2 ON-OFF ON-OFF Data collection point VHMS Engine controller Engine controller Crankcase internal pressure sensor Exhaust temperature sensor Exhaust temperature sensor Engine controller Oil temperature sensor Engine controller Engine controller (ambient temperature sensor) Engine controller Engine controller Retarder controller Transmission controller Transmission output shaft speed sensor Transmission controller Transmission controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller R = 10. 4. temp. T/M out. speed Shift indicator Lockup signal Retarder temp. temp. F. time High (fill time) Trig. RAISE = 3. TRANSMISSION OF DATA Table 3. C mmHg % — deg. R. oil. exh. C rpm — ON-OFF deg. C kg/cm2 deg. F. F1 = 1.2. time 2nd (fill time) Item Service meter Calendar Content Unit h y/m/d h:m:s Data collection point Remarks 3 Transmission fill-up time msec. 1 2 SMR Calendar Trig. time Low (fill time) Trig. Hoist lev. C deg. Accelerator pos.6 cylinders) Engine oil pressure Engine oil temperature Engine coolant temperature Ambient temperature Engine boost pressure Accelerator angle Hoist lever position Torque converter oil temperature Transmission output speed Gearshift range (position) Lock-up clutch Retarder oil temperature Front brake oil pressure Rear brake oil pressure Retarder brake use Foot brake use Content Unit sec. HOLD = 1.3 cylinders) Exhaust temperature (No. Max height = 4. cool. rpm mm3/st mmAq deg. LOWER = 2. temp. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Time Eng. Eng. speed Fuel inject Blow-by press. T/C oil temp. time 1st (fill time) Trig. press. Boost press.5. pos. time 4th (fill time) Trig. Retarder position Foot brake position Item Elapsed time Engine speed Fuel injection amount Blow-by pressure Exhaust temperature (No. HD605-7 20-203-14 (12) . C deg. Other = 5 Remarks Table 4: Transmission trend data No. (fill time) Trig. N = 0. Eng. R. Transmission controller (Every 200 h) HD465-7.2 Data items for manual snapshot No. oil. C deg.TESTING AND ADJUSTING COLLECTION. temp. brake press. time Rev.

torque converter stall) • Engine oil temperature (no PM data ••• reference value) 20-203-15 (9) HD465-7. TRANSMISSION OF DATA 5. torque converter stall) • Exhaust temperature (torque converter stall) • Engine oil pressure (low idle. see the instruction manual for the technical analysis tool box. For details of the method of clearing. HD605-7 . if there is no problem with the data.TESTING AND ADJUSTING COLLECTION. high idle. Check also that there is no abnormal data. see the instruction manual for the technical analysis tool box (for service). clear only the snapshot data. a After downloading. a Check that each file has been saved. torque converter stall) • Blow-by pressure (high idle. <Checking quick PM data> • Engine speed (high idle. a Compare the quick PM data and the PM clinic data to check that there are no abnormal values. Confirming data For details of the method of confirming the data.

Or contact Komatsu. HD465-7.) have been replaced.TESTING AND ADJUSTING INSPECTION AND MAINTENANCE. replace the antenna. • The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. replace. etc. damaged. 3. HD605-7 20-203-16 (2) . Inspection items a Carry out inspection and maintenance. REPLACING PARTS If initial setup of VHMS system has been made or VHMS controller has been replaced If the system has been newly installed or the VHMS controller or other components (transmission. 2) When removing the controller installed on one machine and installing it on another machine. • If there is any abnormality. check all sensors. Or contact Komatsu. and take the necessary action if there are any abnormalities. Inspection interval: Inspection and maintenance interval for machine Check the system at the same time as carrying out maintenance on the machine. 2) Every 1000 hours service i) Communications antenna • Check that there is no looseness at the antenna mount. • Check that there is no damage or looseness of the antenna itself. or connectors. 3) When required i) If there is any abnormality in the downloaded values. see the instruction manual for the technical analysis tool box (for service). so follow the instruction of the person in charge at your company. When replacing communications controller • In the following cases. (Check that there are no loose. Remedy If there is any abnormality. • Necessary tools 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) • For details of the setup method. or reinstall (tighten). it is necessary to carry out the initial setup of the system. such as opening and closing of the communications controller. there are important procedures to be carried out. repair. 4) When giving away or selling the machine with the controller installed. engine. 3) When disposing of the controller. or dirty mounts) • Blow-by sensor • Engine oil temperature sensor • Exhaust temperature sensor • Ambient temperature sensor • Communications antenna ii) Check that there are no disconnected or damaged wiring harnesses. 2. cables. 5) When disposing of a machine with a controller installed. 1) When replacing the controller installed on the machine with another controller. 1) Checks before starting (ask the customer also to carry out this inspection) i) Check that the sensors are installed properly. REPLACING PARTS INSPECTION AND MAINTENANCE 1. iii) Check that there is no leakage of oil or gas from the sensor mounts.

(Contact at least 3 days before) 1. Start the personal computer and click the icon of "VHMS initial setting tool". Click Apply to register the setting Check the 7-segment display in the VHMS controller inspection window. when the starting switch is turned ON. see the separate program operation instructions. see the shop manual. 2) Confirming machine model and setting serial No. 4) Setting engine Serial No. • Contact Komatsu before starting the setup operation. 4. but the setting operation must be carried out inside the cab. Initial setup of VHMS controller After starting up. Connect the other end to the RS232C port of the portable PC. It differs according to the machine model. • The display continues for several seconds after the starting switch is turned OFF. With normal operation of the LEDs. The ID is the part No. If the definition information of the connected machine is not in "Analysis tool" of the personal computer. the following setting is not necessary ** (Default setting) • Time when collection is started: 12 o'clock (Midnight) • Unit of collection (Day) : 1 day Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller. in engine Serial No. then displays the hexadecimal count-up. Start VHMS initial setup tool (VHMS technical tool box) (automatic updating of definition data) For details of the method of installing the VHMS initial setup program. It differs according to the machine model. Starting switch OFF 6. Press the YES button to update. Start up the personal computer and click the VHMS initial setup tool icon. 7. Before starting operation • Prepare necessary parts. Check that VHMS controller works properly Do not start engine yet. Select "Data Clear and Set up". • After checking the machine model. 5) Setting transmission Serial No. After the personal computer starts. 3) Setting of variation code Select and set by clicking (See the attached table). For the method of installing the program for setting the VHMS initially. For details.TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS PROCEDURE FOR INITIAL SETUP OF VHMS (Applicable machine models: HD465/605-7 Dump Truck) Timing Operation step Operation step * There are download connectors in two places (inside cabin. Connect PC and VHMS controller Starting switch ON 3. ground level download box). 5-1 Setting up machine data This sets the basic data for the machine in the VHMS controller. Saving of contents of setting Turn the starting switch OFF to save the data in the VHMS controller. Check that the saving-to-memory display goes out completely. 2. and check sheet. Press the "yes" button to update. Note: This program will not start if the VHMS controller and PC are not connected. Check machine and component nameplates Starting switch OFF 2. the 7-segment flashes in a rotating movement. set the machine serial No. The ID is the part No. download automatically from the VHMS controller and update the technical analysis tool box. Note: This program will not start if the VHMS controller and PC are not connected. for the VHMS controller. HD605-7 . see the Shop Manual. first input the ID (Service ID). Setting of payload meter 7-1 Check of operation of VHMS controller * The normal operation of the LED means that the 7 segments flash in the rotation state after the starting switch is turned to the ON position and then they count up in hexadecimal notation. click OK. Icon 5. (Cont'd) (Cont'd) 20-203-17 (12) HD465-7. * Check the 7-segment display window of the VHMS controller to see that the LED operation is normal. Starting switch ON ** When using the payload meter as shipped (default). • Machine • Engine • Transmission • VHMS controller Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). first from the following nameplates and enter the serial No. For details. tools. it is downloaded automatically from the VHMS controller and "Analysis tool" is updated. Finally. • Set the transmission Serial No. 1) Setting calendar • Set the present time and date. for the VHMS controller. If the definition data for the connected machine is not in the technical analysis tool box on the personal computer. Select "Set up". 799-608-3220 Download cable Program for setting(VHMS technical analysis tool box) 799-608-3211 Portable PC Check the serial No. input the ID (Service ID) first. 7-2 Starting of VHMS initial setting tool Icon see the separate operation manual for the program. on the check sheet.

Product Support Division. etc. Download all files. and "whether PLM. (Saving operation) Check that the segments go off perfectly. 2) Select the service mode with the monitor panel. Then. 13. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position. (*1) The transmission controller switch 2 (SW2) is used to notify the monitor panel "whether the VHMS is installed". Saving of contents of setting Turn the starting switch OFF to save the data in the VHMS controller.) • Check that the data of the quick Pm executed in [8] are saved in "Snap Shot". HD605-7 20-203-18 (12) . check the VHMS data with the "VIEW" function.jp TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu. display "SNAPSHOT". the LED of the VHMS displays SF and SH (Processing time of memory). R&M department. when carrying out the torque Starting switch OFF converter stall. Saving in VHMS Turn the starting switch OFF to save the data in the VHMS controller. VHMS/WebCARE Support Center (R&M Engineering Team. 14.TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS Timing Operation step 7-3 Setting up payload meter (Machine with PLM II or VHMS with PLM function (For details of setting up PLM. • The segments keep lighting for several seconds after the starting switch is turned off. [1] Send the check sheet by fax. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV). the power is not applied constantly. if the all system is normal. see the instruction manual for the technical analysis tool box. whether PLM is connected (Code: P2). Starting switch ON Check the 7-segment display in the VHMS controller inspection window. The setup of the database (Web server) is carried out by Komatsu. • Check that the set contents are displayed correctly. Starting switch ON Check lighting of the 7 segments in the inspection window of the VHMS controller. machine serial No. and whether the machine has the payload meter (PLM) function (Code: ST)". connect them normally. [2] Send the downloaded VHMS data by Notes or E-mail to the following address.co. see the Shop Manual. inform Komatsu as follows. and then the all operation is finished (the power for the VHMS is turned OFF). Execution of quick Pm clinic Execute the quick Pm clinic according to the procedure shown in the Shop Manual. Komatsu LTD) Welcome to WebCARE Use WebCARE to check the data https://wcare.. time. For details. (Date. the start time is set at 11 PM and the interval at 2 days. Click Apply to register the setting Starting switch OFF 8.jp Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM controller VHMS controller PLM function in VHMS controller — — Not installed Not installed Installed Card-type payload meter (PLM.is installed". a Since A and B of the short connector to be connected to connector No. Check of normal operation of VHMS controller Start engine [Outline of procedure] 10. Saving in VHMS Turn the starting switch OFF to save the data in the VHMS controller. After returning to office Finish setting of the VHMS and notify to KOMATSU This completes the initial setup of the VHMS. (See the section of adjustment of the transmission controller. Check that the VHMS controller is connected to the portable personal computer by the cable. and press the < > switch. run the engine at Lo/Hi idle Be extremely careful about safety and stall the torque converter in 7 minutes 30 seconds. 1) Execute the quick PM while the engine is warm. "whether the PLM function in the VHMS is turned on". 12. 9. Download Start the "VHMS analysis tool" (VHMS technical analysis tool box) on the personal computer display. For details. Starting switch OFF 1) After the starting switch is turned to the OFF position.komatsu. so after you have completed the operation. • The display continues for several seconds after the starting switch is turned OFF.) Not installed Installed Not installed Installed Not installed Payload meter (PLM) function Set position of rotary switch 2 (SW2) of transmission controller F F B F 9 Setting with VHMS initial setting manual (tool) (*1) Model — — HD465 or HD605 Type — — –7 Set variation code — — ST P2 PV Set properly Date Time Time difference (GMT) Summer time Not installed Not installed Installed Installed Installed Not installed Installed Not installed Installed Installed — — a A variation code is an item among the model. Check of downloaded data After downloading is finished. Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller. * The normal operation of the LED means that the 7 segments flash in the rotation state after the starting switch is turned to the ON position and then they count up in hexadecimal notation. service meter. HM-50 are not used. that are set with the personal computer software when the VHMS is set initially. etc. Check that the saving-to-memory display goes out completely. date.co. see the separate PLM instruction manual) Operation step Click the PLT tag to 1) Setting start time and interval (days) for data collection • In the example on the right. change the function.) HD465-7. 11.

6. Initial setup of VHMS controller 5–1 Set machine data This sets the basic data for the machine in the VHMS controller. Download 13. 3.co.TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS To: VHMS/WebCARE Support Center (R&M Engineering Team. yes yes yes yes yes yes yes yes no no no no no no no no 5. Komatsu LTD) TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu. Product Support Division. Save to VHMS memory Point of Contact VHMS/WebCARE Support Center (R&M Engineering Team. Komatsu LTD) Date of setup Date of fax Name of distributor/branch Name of person filling in check sheet Month Month Day Day Year Year FAX: 81-3-5561-4766 VHMS INITIAL SET-UP CHECK SHEET (For HD465/605-7 Dump Truck) Steps for setup 1. VHMS controller serial No. did LED (7 segments) go off? Results 2. do set values for SMR and time match? Are there any data missing in Snapshot? Are there any data in Transmission Shift Change Map? After saving operation. been input correctly? Was selection of variation code set correctly? Has engine serial No.jp 20-203-19 (12) HD465-7. did LED (7 segments) go off? Did LED operate normally? Have all files been downloaded? Time of download (use wrist watch) [Check data] Is there any MFAO error in Fault History? In Fault History. been input correctly? Has date been set to today's date? Has time been set to correct time? After saving operation. hexadecimal count-up display) Is selection of mode for setup tool "Data Clear and Set up" ? Is model name same as name of machine? Has machine serial No. Check machine and component nameplates Check items Name of machine Serial No. Save to VHMS memory 12. HD605-7 . Check downloaded data yes yes yes yes yes no no no no no 14. Service meter Engine serial No. 7. R&M department. Save settings Check of normal operation of VHMS controller After saving operation. Are they are properly connected? Does it work properly? (After rotation. did LED (7 segments) go off? Did LED operate normally? 10. Product Support Division. Transmission serial No. 9. Perform quick PM clinic Were service mode and "SNAPSHOT" selected and was switch pressed? After saving operation. did LED (7 segments) go off? yes yes yes yes no no no no 11. Connect PC and VHMS controller Check that operation of VHMS controller is normal Start VHMS initial setup tool yes yes no no 4. Save settings Setting of payload meter 7–1 Check of operation of VHMS controller 7–2 Starting of VHMS initial setting tool Did LED operate normally? Is selection of mode of setting tool "Set up"? Enter set value of PLM collection Time to start collection Collection interval (day) yes yes no no 7–3 Setting of payload meter (When PLM II or PLM function is installed) day yes yes no no 8. R&M department.

– – Decide the data to change. Start VHMS initial setup tool (VHMS technical tool box) (automatic updating of definition data) Icon For details of the method of installing the VHMS initial setup program. Check that VHMS controller works properly (Check that the Orbcomm controller works properly) (When an Orbcomm controller is installed) * With normal operation of the LEDs. For details. • Contact Komatsu before starting the setup operation. wait for 3 minutes after starting the VHMS. HD605-7 20-203-20 (12) . when the starting switch is turned ON. 4. With this operation is possible to set acceptance /refusal of satellite communications and the frequency of change. • Machine • Engine • Transmission • VHMS controller • Orbcomm controller Connect the cable (799-608-3220) to the VHMS controller download connector (VHMS). Connect PC and VHMS controller Starting switch ON Check the 7-segment display window of the VHMS controller to see that the LED operation is normal. the 7-segment flashes in a rotating movement. The ID is the part No. • OFF : ORBCOMM controller cannot communicate with ORBCOMM terminal. then displays the hexadecimal count-up. (Contact at least 3 days before) 1. Select "Set up". If the definition data for the connected machine is not in the technical analysis tool box on the personal computer. and the frequency of communications. • Quick flash : Communication with ORBCOMM terminal is OK. on the check sheet. • ON : Communication with ORBCOMM terminal is OK. then click on * Edit to change it. Terminal does not have communication data. 5-2 Set start of communications 2) Setting up GCC code – – Click Edit and select 130 (if Japan) for the GCC code. Press the YES button to update. click Apply to register the setting. Before starting operation • Prepare the necessary tools and check sheet. Connect the other end to the RS232C port of the portable PC. see the instruction manual for the setup tool. first from the following nameplates and enter the serial No. 5-1 Setting up communications (For machines with Orbcomm controller specifications) This sets up the selection of VHMS data to be sent by satellite communications 1) Selecting data to send – – There are 3 types of data that can be sent. 799-608-3220 Download cable 799-608-3211 VHMS technical analysis tool box Portable PC Check the serial No. GCC code 1 120 121 122 123 130 Territory (country) USA ITALY MALAYSIA KOREA BRAZIL JAPAN Finally. Terminal has communication data and has captured satellite. Check machine and component nameplates Starting switch OFF 2. ground level download box). 3. Start up the personal computer and click the VHMS initial setup tool icon.TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE PROCEDURE FOR OPENING ORBCOMM SERVICE (Applicable machine models: HD465/605-7 Dump Truck) a Make a communications contract with Orbcomm before performing this work. When checking that the operation of the Orbcomm controller is normal. see the shop manual. download automatically from the VHMS controller and update the technical analysis tool box. input the ID (Service ID) first. Note: This program will not start if the VHMS controller and PC are not connected. Initial setup of VHMS controller After starting. 5. (Cont'd) HD465-7. For details. see the separate program operation instructions. but the setup operation must be carried out inside the cab. then check the condition of the decimal point on the VHMS monitor (7-segment). • Slow flash : Communication with ORBCOMM terminal is OK. * (The setting of the machine data and PLM is already completed) *1: The default for the number of items in the Fault History is 8. Terminal has communication data and has not captured satellite. It differs according to the machine model. for the VHMS controller. Timing Operation step Operation step * There are download connectors at two places (inside cabin.

VHMS/WebCARE Support Center (R&M Engineering Team. so after you have completed the operation. 1) After the starting switch is turned to the OFF position. Product Support Division.co.jp TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu.TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE Timing Starting switch OFF Operation step 6. inform Komatsu as follows.jp 20-203-21 (12) HD465-7. and then the all operation is finished (the power for the VHMS is turned OFF).co. 2) Send the downloaded VHMS data by Notes or E-mail to the following address. Save to VHMS memory Turn the starting switch OFF to save the data in the VHMS controller. Check that the saving-to-memory display goes out completely.komatsu. R&M department. 2) If the power is turned OFF immediately after the starting switch is turned to the OFF position. the power is not applied constantly. the LED of the VHMS displays SF and SH (Processing time of memory). if the all system is normal. After returning to office Completing operation to set up VHMS and contacting Komatsu This completes the setup for Orbcomm. 1) Send the check sheet by fax. Komatsu LTD) Welcome to WebCARE Use WebCARE to check the data https://wcare. HD605-7 . Operation step Check the 7-segment display in the VHMS controller inspection window. • The display continues for several seconds after the starting switch is turned OFF. The setup of the reception inside of the satellite communications is carried out by Komatsu.

TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE To: VHMS/WebCARE Support Center (R&M Engineering Team. Service meter Engine serial No. Product Support Division. Orbcomm controller serial No. did LED (7 segments) go off? yes no VHMS/WebCARE Support Center (R&M Engineering Team. Check machine and component nameplates Check items Name of machine Serial No. Connect PC and VHMS controller 3. count-up display) Does VHMS monitor (7-segment) display decimal point? (OFF. Are they are properly connected? Results 2. Save settings Point of Contact After saving operation. HD605-7 20-203-22 (12) . Start VHMS initial setup tool yes no 5. Transmission serial No. VHMS controller serial No. R&M department. Initial setup of VHMS controller 5–1 Set up communications * (The setting of the machine data and PLM is already completed) 5–2 Set start of communications Input set value of short Fault History Condition of communications Number of items (default value: 8) Input set value of short Trend Analysis Condition of communications Interval (default value: 20 hrs) Input set value of short Payload data Condition of communications Time of start of data collection Data collection interval (day) Is GCC code set to 130 (if Japan) On items Off On Hrs Off On day Off yes no 6. Check that operation of VHMS controller is normal (Check operation of Orbcomm) yes yes yes no no no Does it work properly? (After rotation. Slow/Quick flash) Is selection of mode for setup tool "Data Clear and Set up"? 4. Komatsu LTD) TEL: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu. R&M department. Komatsu LTD) Date of setup Date of fax Name of distributor/branch Name of person filling in check sheet Month Month Day Day Year Year FAX: 81-3-5561-4766 VHMS INITIAL SET-UP CHECK SHEET (For HD465/605-7 Dump Truck) Steps for setup 1. ON.co. Product Support Division.jp HD465-7.

HD605-7 . see Special functions of vehicle monitor (EMMS). so it is possible to reduce the time taken for measurements in the Pm Clinic. the VHMS snapshot function saves all the data for a period of 5 minutes 30 seconds before the occurrence of the error and 2 minutes after the error (total: 7 minutes 30 seconds). the data sampling interval is one time every 10 seconds for the first 5 minutes and one time every 1 second for the next 2 minutes 30 seconds. Necessary tools • Personal computer • VHMS technical analysis toolbox (software) 799-608-3211 • Download cable 799-608-3220 To ensure safety. All data can be automatically collected in cases such as torque converter stall. Start the engine. 1. Select SNAPSHOT with the monitor panel (EMMS). To raise the precision of the data. a For details of the method of selecting. This snapshot function can be studied by pressing the manual switch. However. 2.TESTING AND ADJUSTING PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) What is quick Pm? If a serious error occurs. 20-204 (10) HD465-7. stop the machine on level ground and put chocks under the tires to prevent the machine from moving. After the button is pressed.) for this 2 minutes 30 seconds and record the data. etc. all data is automatically saved for seven minutes 30 seconds. it is necessary to create the conditions (torque converter stall.

return the transmission (gearshift) lever to the N position. "READY" is displayed. HD605-7 20-204-1 (10) . press the [ ] button to return to the Waiting status screen. Table 1 Measurement conditions Start 1 2 3 4 5 6 7 8 9 0 : 00 2 : 00 3 : 00 4 : 00 5 : 00 5 : 30 6 : 00 6 : 30 7 : 00 Finish Time Operation of machine mode Shift lever AISS switch Power setting Auto Auto Auto Auto Auto Auto Auto Auto Auto Economy Economy Economy Economy Economy Economy Power Power Power N N N N N D N D N Parking brake ON OFF ON ON ON OFF ON OFF ON Retarder ON OFF ON ON ON ON ON ON ON Dump lever Hold Hold Float Hold Hold Hold Hold Hold Hold (*2. *3) (*1) Remarks 2 : 00 120 sec Low idle (Low) 3 : 00 4 : 00 5 : 00 5 : 30 6 : 00 6 : 30 7 : 00 7 : 30 60 sec Low idle (Hi) 60 sec High idle (Stationary mode) 60 sec Low idle (Hi) 30 sec High idle (Economy mode) 30 sec Torque converter stall (Economy mode) 30 sec High idle (Power mode) 30 sec Torque converter stall (Power mode) High idle (Power mode) 30 sec + 20 pumping operations of foot brake (*1) (*2) (*3) Press the foot brake. When the [ ] button is pressed. After starting.] When setting the gearshift lever in the D position. Press the [ ] button. return the engine speed to low idle temporarily (to prevent the machine from running out). (Waiting status) 4. When stalling the torque converter [Portion marked with (*)]. operate the machine as shown in Table 1. (Running) If you want to stop. *3) (*2. When the oil temperature gauge reaches the top of the white range while the torque converter is stalled.TESTING AND ADJUSTING PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) 3. Run the engine at low idle and stabilize it for 2 minutes. a Check that the coolant temperature gauge and torque converter oil temperature gauge are in the white range. Snapshot is started and the time advances. HD465-7. [Stall of torque converter for 30 seconds is only a reference. 6. 5. do not overheat it.

20-204-2 (2) HD465-7. see Procedure for downloading VHMS data to personal computer. always download the data to the personal computer. and then it returns to the opening screen. HD605-7 . 9.TESTING AND ADJUSTING PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) 7. a For details of the method of using the technical analysis tool box. After 7 minutes 30 seconds. the data is overwritten. select Time and for the Yaxis. 5 & 6 5) Engine Oil Press and put a check mark against Graph value display at click position (marked by ). 2 & 3 4) Exhaust Temp 4. Use the technical analysis tool box to read the quick PM data. For details. NOTICE The quick PM data is only recorded once. select 1) Engine Speed 2) Blowby Press 3) Exhaust Temp 1. so after performing the quick PM. see the instruction manual. (Completion of Snapshot) 8. Download the snapshot data to the personal computer. the screen on the right is displayed for 5 seconds. If the operation is carried out again. • Open the quick PM data and make a graph • For the X-axis.

The relationship between the measurement conditions and the necessary data in the Pm Clinic is as shown below. HD605-7 20-204-3 (10) . Conditions Engine speed 1 2 3 4 5 6 7 8 Low idle Low idle High idle Low idle High idle Torque converter stall High idle Torque converter stall High idle + 20 pumping operations of foot brake Mode Low High Stationary mode Economy mode Economy mode Economy mode Power mode Power mode Engine speed Blow-by pressure Measurement items Lubricating oil Exhaust pressure temperature Brake oil pressure (*1) 9 Power mode (*1) Cut OUT oil pressure and brake cut IN. the values for each measured item on the X-axis are displayed on the graph. HD465-7. (Example of graph display) • Enter these values on the Pm Clinic check sheet.TESTING AND ADJUSTING PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM) • If the graph is clicked.

TESTING AND ADJUSTING PM-CLINIC SERVICE HD465-7. HD605-7 20-205 (10) .

TESTING AND ADJUSTING PM-CLINIC SERVICE 20-206 (10) HD465-7. HD605-7 .

HD605-7 20-207 (10) .TESTING AND ADJUSTING PM-CLINIC SERVICE HD465-7.

...........................................................................801 Troubleshooting for monitor system (MON mode) .... 20Connector arrangement location................................................................................................................................ HD605-7 20-301 (12) ....................................................................................................... 20Connection table for connector pin numbers ....................20-1151 Troubleshooting of electrical system (E mode) .......... 20. 20Sequence of events in troubleshooting ..............................20-1101 Troubleshooting of engine system (S mode) ....................................................................................................701 Troubleshooting for payload meter system (card type) (LC mode) .................................................................................................................. and method of using troubleshooting charts........................................................................................................................901 Troubleshooting of VHMS controller system (VHMS mode) .............................TROUBLESHOOTING Points to remember when troubleshooting ............... 20................................................................................................................................................................. 20Checks before troubleshooting ................................................................................................................ procedure.....................................401 Troubleshooting for transmission controller system (TM mode) ................................................................................ 20............................ 20-1201 Troubleshooting of ABS controller system (ABS mode) (If equipped) ............... 20Categories....................................................................... 20-1001 Troubleshooting of ASR controller system (ASR mode) .................................................... 20-1051 Troubleshooting of hydraulic and mechanical systems (H mode) ..................................................................................... 20Types and locations of connectors ............................... 20Points to remember when carrying out maintenance............... 20-1251 HD465-7......... 20302 303 304 312 313 318 341 344 356 Troubleshooting of engine controller system (ENG mode) .. 20...........................501 Troubleshooting for retarder controller system (BK mode) ....................... 20............................................................................................................................................................................................ 20T-adapter table ....

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level ground. if the root cause of the failure is not repaired. 3) Investigate other related parts or information. 3. If the radiator cap is removed when the engine is hot. 3) 4) 4. keep strictly to the agreed signals. and judge whether to handle it as a real failure or as a problem with the method of operation. so wait for the engine to cool down before starting troubleshooting. 1) Start from the simple points. 5. When installing measuring equipment. will also lose the confidence of the user or operator. or oil or grease. then use the troubleshooting flowchart to locate the position of the failure exactly. When removing the plug or cap from a location which is under pressure from oil. 2) Check the CHECKS BEFORE STARTING items. always investigate why the problem occurred. water. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. Confirming failure Confirm the extent of the failure yourself. For this reason. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. remove the root cause. always disconnect the negative (–) terminal of the battery first. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure. do not hurry to disassemble the components. and parking brake are securely fitted. or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. always release the internal pressure first. hot coolant may spurt out and cause burns. The basic procedure for troubleshooting is as follows. the same failure will occur again. The aim of troubleshooting is to pinpoint the basic cause of the failure. to carry out repairs swiftly. When carrying out troubleshooting. • It will become impossible to find the cause of the failure. so check any item that is considered to be necessary. When carrying out troubleshooting. and do not allow any unauthorized person to come near. 20-302 (10) HD465-7. and at the same time. Other inspection items. When disconnecting wiring. be sure to connect it properly. W hen operating the machine to reenact the troubleshooting symptoms. Other maintenance items can be checked externally. 2) Start from the most likely points. 6. do not carry out any investigation or measurement that ma y make the problem worse. chocks. It will also cause a waste of manhours. when carrying out troubleshooting. Then. 1. and to prevent reoccurrence of the failure. To prevent this. or air. HD605-7 . Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the ma chine before the failure occurred? 3) Did the failure occur suddenly. When carrying out the operation with two or more workers. Measures to remove root cause of failure Even if the failure is repaired. 2. and check that the safety pin. parts. and important point is of course to understand the structure and function. However. it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. etc.

serial number of machine • Details of jobsite. etc.TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING TEW00180 TEW00181 Step 1 Examination. details of maintenance. Step 4 Go to jobsite Step 5 Ask operator questions to confirm details of failure. locate and repair simple failures. Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes. 2) Ask questions to gain an outline of the problem. HD605-7 20-303 (2) . • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history. etc. • • • TEW00189 Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure? HD465-7. etc. confirmation of symptoms 1) When a request for repairs is received. Step 3 Preparation of troubleshooting tools 1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. 2) Look in the parts book and prepare the necessary replacement parts. and carry out troubleshooting. • T-adapter • Hydraulic pressure gauge kit. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual. TEW00187 Step 6 Re-enacting failure • Drive and operate the machine to confirm the condition and judge if there is really a failure. TEW00186 Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take 1) Before starting troubleshooting. • Name of customer • Type. first ask the following points. select a troubleshooting flowchart that matches the symptoms.

troubleshooting. the plating at the joint will peel and cause improper connection or breakage. they are frequently removed and installed again. or because one or both of the connectors is deformed or the position is not correctly aligned. 20-304 (10) HD465-7. and protectors or tubes used for protecting the wiring. • Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. or because there is corrosion or oxidization of the contact surfaces. For this reason. it gives sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil). it is necessary to be extremely careful when handling wiring harnesses. 1. heat. Compared with other electrical components fitted in boxes or cases. maintenance and inspection. and to prevent failures or other troubles before they occur. correct operation. during inspection and repair operations. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component. connectors used for connecting and disconnecting one wire from another wire.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period. Furthermore. Main failures occurring in wiring harness • Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector. or vibration. HD605-7 . so they are likely to suffer deformation or damage. water. and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose. wiring harnesses are more likely to be affected by the direct effects of rain. but if there is excessive force brought to bear on the wiring.

the crimping of the connector may separate. a When wiping the mating portion of the connector. wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. so there will be defective contact. HD605-7 20-305 (10) .TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE • Disconnections in wiring If the wiring is held and the connectors are pulled apart. water may enter the connector. As already said. • Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins. be careful not to use excessive force or deform the pins. or a heavy object hits the wiring. Therefore. the connector is designed to prevent water from entering. • High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure). but if high-pressure water is sprayed directly on the connector. immediately dry the connector or take other appropriate action before passing electricity through it. it is difficult for it to be drained. or components are lifted with a crane with the wiring still connected. or the wiring may be broken. the oil will not let the electricity pass. so remove the oil and water from the compressed air completely before cleaning with compressed air. so if any water gets in. the contacts will become even dirtier. depending on the direction of the water jet. if water should get into the connector. but at the same time. HD465-7. or the soldering may be damaged. the pins will be short-circuited by the water. If there is oil or grease stuck to the connector. a If there is oil or water in the compressed air. if water does enter.

a If the machine is left disassembled for a long time. or water from getting in the connector portion. When disconnecting the connectors. and drying connectors and wiring harnesses i) Disconnecting connectors a) Hold the connectors when disconnecting.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 2) Removing. b) When removing from clips When removing a connector from a clip. a Never pull with one hand. then hold the male and female connectors in each hand and pull apart. c) Action to take after removing connectors After removing any connector. it is particularly easy for improper contact to occur. oil. For connectors which have a lock stopper. so always cover the connector. pull the connector in a parallel direction to the clip. the housing may break. HD605-7 . hold the connectors and not the wires. For connectors held by a screw. 20-306 (10) HD465-7. dirt. cover it with a vinyl bag to prevent any dust. press down the stopper with your thumb and pull the connectors apart. loosen the screw fully. a If the connector is twisted up and down or to the left or right. installing.

water. wipe it off with a dry cloth. then insert it securely. or water stuck to the connector pins (mating portion). but be careful not to make it too hot as this will cause short circuits. defective contact. adjust it to its correct position. or the clamp is out of position. c) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots. • Check that there is no oil. • Check that there is no deformation. • Check that there is no damage or breakage to the outside of the connector. Check also that there are no loose clamps. a If there is any damage or breakage. corrosion. a If the connector cannot be corrected easily. be sure to return it to its original position. push in the connector until the stopper clicks into position. a If there is any oil. dirt. In addition. warm the inside of the wiring with a dryer.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ii) Connecting connectors a) Check the connector visually. b) Fix the connector securely. d) If the connector clamp has been removed. correct any protrusion of the boot. remove the clamp and adjust the position. or dirt stuck to the connector. if the wiring harness is misaligned. Align the position of the connector correctly. HD465-7. If any water has got inside the connector. HD605-7 20-307 (10) . For connectors with lock stopper. or damage to the connector pins. replace the connector.

If water gets directly on the connector. blow it with contact restorer and reassemble. do not use high-pressure water or steam directly on the wiring harness. 20-308 (10) HD465-7. If the connector must be washed in water. After drying. c) Carry out a continuity test on the connector. b) Dry the inside of the connector with a dryer. Avoid washing it in water or using steam. push them in until they click 2 times. a Hot air from the dryer can be used. but regulate the time that the hot air is used in order not to make the connector or related parts too hot. b. HD605-7 . If water gets inside the connector. wipe it off with a dry cloth. so remove all oil and water from the compressed air before blowing with air. as this will cause deformation or damage to the connector. there is the risk that oil in the air may cause defective contact. a) Disconnect the connector and wipe off the water with a dry cloth. Normal locking state (Horizontal): a. leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector. a If the connector is blown dry with compressed air. use a dryer to dry the connector. Female conector (2). do as follows.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE iii) Connecting DT connectors Since the DT 8-pole and 12-pole heavy duty wire connectors have 2 latches respectively. Male connector (1). d Incomplete locking state (Diagonal): c iv) Drying wiring harness If there is any oil or dirt on the wiring harness.

(Place it on a suitable dry stand). unnecessary abnormality displays will be generated. or soil. there is probably defective contact in that circuit. iv) Cover the control connectors with tape or a vinyl bag. do not leave the control box in a place where it is exposed to rain. disconnect all wiring harness connectors connected to the control box. 4) When carrying out troubleshooting of circuits (measuring the voltage. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. continuity. 2. a If the power is turned ON with the connectors still disconnected. or current). even for a short time. a Disconnect and connect the related connectors several times to check. Fit an arc welding ground close to the welding point. These control all of the electronic circuits on the machine. Never touch the connector contacts with your hand. or in any hot place. move the related wiring and connectors several times and check that there is no change in the reading of the tester. vii) Precautions when carrying out arc welding When carrying out arc welding on the body. water. resistance. ii) Do not open the cover of the control box unless necessary. 2) Before carrying out troubleshooting.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3) Handling control box i) The control box contains a microcomputer and electronic control circuits. v) During rainy weather. HD605-7 20-309 (10) . 3) Always connect any disconnected connectors before going on to the next step. HD465-7. check that all the related connectors are properly inserted. so be extremely careful when handling the control box. a If there is any change. iii) Do not place objects on top of the control box. vi) Do not place the control box on oil.

collect it and ask the customer to dispose of it. POINTS TO REMEMBER HYDRAULIC EQUIPMENT WHEN HANDLING With the increase in pressure and precision of hydraulic equipment. or vinyl bags to prevent any dirt or dust from entering. there is danger of dust entering the equipment. or when disassembling or assembling hydraulic equipment. so this is an even more effective method. or places where there is a lot of dust. so it is desirable to use unit exchange. 3) Sealing openings After any piping or equipment is removed. Do not simply drain oil out on to the ground. When adding hydraulic oil. and also use clean pumps and oil containers. it is necessary to be particularly careful. it is possible to filter out the dirt that has collected during storage. Be careful not to let any dirt or dust get in when refilling with hydraulic oil.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3. It is also difficult to confirm the performance after repairs. 1) Be careful of the operating environment. tapes. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field. If an oil cleaning device is used. the openings should be sealed with caps. HD605-7 . or take it back with you for disposal. 20-310 (1) HD465-7. there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Always keep the oil filler and the area around it clean. or repairing the machine in rain or high winds. the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Avoid adding hydraulic oil. If the opening is left open or is blocked with a rag. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop. replacing filters. and the performance should be confirmed with special test equipment. 4) Do not let any dirt or dust get in during refilling operations.

In addition. also drain the oil from the filter and from the drain plug in the circuit. carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. HD465-7. sludge. use flushing oil to remove the contaminants. When hydraulic oil or other oil is warm. and secondary flushing is carried out with the specified hydraulic oil. HD605-7 20-311 (1) . and old oil from the hydraulic circuit. as much as possible of the old hydraulic oil must be drained out. the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. the sludge can also be drained out easily from the circuit together with the oil. When changing the oil. it flows easily. 7) Cleaning operations After repairing the hydraulic equipment (pump.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 5) Change hydraulic oil when the temperature is high. control valve. (Drain the oil from the hydraulic tank.) or when running the machine. Normally. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove. or changing the oil. so it is best to change the oil when it is still warm. 6) Flushing operations After disassembling and assembling the equipment. so it is an extremely effective device.) If any old oil is left. flushing is carried out twice: primary flushing is carried out with flushing oil. etc.

Check oil level in hydraulic tank 5. Check mechanical monitor system 26. Check that there is no abnormality in exhaust color or sound Check before starting items — — — — — — — — — — — — — — — — — 1 19. Check fuel level Hydraulic oil. 135 mm Actuation 20 sec Label — Torque (see DISASSEMBLY AND ASSEMBLY) Action Add fuel Drain Add oil Add oil Add oil Add coolant Clean. Check that lamps flash properly Electrical components 23. replace Adjust Repair Repair Inflate or replace Tighten Adjust Adjust or repair Adjust or repair Adjust or repair Adjust Adjust or repair Adjust or repair Replace Repair Repair or replace Adjust or repair Adjust or repair Repair or replace Adjust or repair Retighten or clean Retighten or clean Retighten or clean 2. Check tire inflation pressure. Check hub nuts 13. Check emergency steering Air. Check parking brake effect 15. Check oil level in transmission case 4. Check that emergency brake works properly 16. Check foot brake effect 14. Check for looseness. corrosion of alternator terminal wiring 29. Check coolant level 7. Check for looseness. mechanical components 10.coolant Judgement value Fuel level — Sight gauge Sight gauge Oil level gauge — Dust indicator Max. HD605-7 . Check that steering wheel play is correct 9. check for damage 12. Check length of suspension cylinder 11. Water. Check oil level in engine oil pan 6.TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING (1. Check that retarder brake works properly 20. Check central warning lamp 27. Check that there is no abnormality in operation of steering 17. Check monitor panel 25. corrosion of battery terminal wiring 28. sediment in fuel tank 3. Check before starting and 2. Check that horn sounds 22. lubricating oil. Check that gauges work properly during operation 24. Check that body mount rubber is normal 21. Check for looseness. corrosion of starting motor terminal wiring 20-312 (10) HD465-7. Other check items) Item 1. hydraulic. Check that direction of rear view mirror and under mirror is correct 18. Check dust indicator 8.

Check for actuation sound from battery relay (when starting switch is turned ON-OFF) 2 HD465-7.5 – 29. Check for wet wiring (be particularly careful to check connectors and terminals) 38. Air bleed operation 33. Check for oil leakage 32. defective contact 39. Check for loose wiring clamps. Check for blown fuses.TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING Item Hydraulic. peeling of cover 36. burn marks. Check wiring for discoloration. Check alternator voltage after several minutes of running (engine at 1/2 throttle or above) 40. electrical components 34. HD605-7 20-312-1 (10) .5 V — Repair Repair Action 30. Check for abnormal noise or smell 31. mechanical equipment Judgement value — — — 24V — — — — — 27. Check battery electrolyte level 35. hanging wiring 37. Check battery voltage (engine stopped) Bleed air Charge or replace Add distilled water Replace Repair Dry Replace Replace Replace Other check items Electrics.

3) When machine monitor does not display failure code and fault history is also not recorded If a problem occurs but the failure code display cannot be checked on the machine monitor. but fault history is recorded If a problem occurs but the failure code display cannot be checked on the machine monitor. HD605-7 20-313 (11) . 1) When machine monitor displays failure code If a failure code is displayed on the machine monitor at the same time as the problem occurs. Category of troubleshooting code a If the machine monitor displays a failure code. a The hydraulic and mechanical system. PROCEDURE. so go to the applicable troubleshooting chart. PROCEDURE. it also displays the controller name at the same time. for which the machine monitor cannot display a failure code. HD465-7. If a failure code is recorded. so the troubleshooting codes are categorized to match each controller name. check the content of the display. or if it is felt that there is a problem. Troubleshooting procedure a If a problem occurs on the machine.TROUBLESHOOTING CATEGORIES. there is a high probability that this is the cause. use the fault history display function in the machine monitor service mode to check for a failure code. carry out troubleshooting as follows. then go to the applicable troubleshooting chart for the failure code. there is a probability that is a problem in the electrical system that cannot be detected by a controller or that a problem has occurred in the hydraulic and mechanical system. AND METHOD OF USING TROUBLESHOOTING CHARTS 1. and the problem is also not recorded by the fault history display function in the machine monitor service mode. AND METHOD OF USING TROUBLESHOOTING CHARTS CATEGORIES. In this case. 2) When machine monitor does not display failure code. is categorized as H Mode. Troubleshooting Code ENG TM BK LC MON HM H S E Troubleshooting System Troubleshooting of engine controller system Troubleshooting for transmission controller system Troubleshooting for retarder controller system Troubleshooting for payload meter system (card type) Troubleshooting for monitor system Troubleshooting VHMS controller system Troubleshooting of hydraulic and mechanical systems Troubleshooting of engine body Troubleshooting of electrical system 2. where some failure codes are not displayed). check the nature of the problem and go to the applicable troubleshooting chart. (This may also include the electrical system.

PROCEDURE. or water spurts back. the backup lamp and backup buzzer are not turned ON Abnormality in Backup lamp is not turned ON backup lamp (Backup buzzer is normal) and backup Backup buzzer is not turned ON buzzer (Backup lamp is normal) While shift lever is not operated. LOW SPEED control is selected When AISS switch is set in LOW SPEED. or coolant level goes down Oil pressure caution lamp lights up (drop in oil pressure) Oil level rises Coolant temperature becomes too high (overheating) Abnormal noise is made Vibration is excessive Failure in preheating AISS function does not work normally Engine is not preheated Engine is still preheated after preheating time When AISS switch is set in AUTO. on failure code display Troubleshooting No. AND METHOD OF USING TROUBLESHOOTING CHARTS Phenomena considered to be failures and troubleshooting No.TROUBLESHOOTING CATEGORIES. AUTO control is selected 21 22 Not error code is displayed in error code display mode Transmission controller related 23 24 25 26 27 Fuel level gauge does not operate normally (It always indicates "FULL") When the shift lever is set in the "R" position. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode S mode Error code related 1 Error code is displayed in error code display mode q ENG-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 ENG-2a) ENG-2b) ENG-3a) ENG-3b) TM1 – 27 Engine related 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Engine does not start Starting performance is poor (starting always takes time) Engine does not turn Engine turns but no exhaust smoke comes out Exhaust smoke comes out but engine does not start Engine does not pick up smoothly (follow-up is poor) Engine stops during operations Engine does not rotate smoothly (hunting) Engine lacks output (or lacks power) Exhaust smoke is black (incomplete combustion) Oil consumption is excessive (or exhaust smoke is blue) Oil becomes contaminated quickly Fuel consumption is excessive Oil is in coolant. HD605-7 . backup lamp and backup buzzer TM-1 TM-2a) TM-2b) TM-2c) TM-2d) 20-314 (10) HD465-7. q go to troubleshooting No.

AND METHOD OF USING TROUBLESHOOTING CHARTS Troubleshooting No. "SP:SP" does not go off Integrated pay load is not displayed Displayed and saved pay load is not correct Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in "FLOAT" position while truck is not dumping) Payload meter displays "F:09" (lowering of internal backup battery voltage) Payload meter displays " :FULL" (data saving memory is full) Payload meter displays "F-20" :failure in power source of suspension pressure sensor and clinometer system Payload meter displays "F-21" – "F-24" : disconnection or grounding fault in suspension pressure sensor signal system Payload meter displays "F-25" – "F-28" : short circuit with power source in suspension sensor signal system Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) Payload meter displays "F:43" – "F:45" (short circuit with power source in external pilot lamp relay system) Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) External pilot lamp indicates forecast while truck is not being loaded or clock is displayed while truck travels for 160 m after it is loaded Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal system Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal system Payload meter displays "F:18" (disconnection in charge level signal system) LC-1 LC-2 LC-3 LC-4 LC-5 LC-6 LC-7a) LC-7b) LC-7c) LC-7d) LC-7e) LC-8 LC-9 LC-10 LC-11 LC-12 LC-13 LC-14 LC-15 LC-16 LC-17 LC-18 LC-19 LC-20 HD465-7. HD605-7 20-315 (10) . PROCEDURE.TROUBLESHOOTING CATEGORIES. display of odometer does not increase Displayed logic When travel speed exceeds limit is abnormal speed. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode S mode Retarder controller related When the parking brake switch is set in the OFF position. "0" is kept displayed After loaded dump truck start traveling. any item is not displayed After starting switch is turned ON. the parking brake s not released When the parking brake switch is set in the PARK position. the parking brake does not work Retarder brake oil temperature gauge does not operate normally Inclination alarm is turned ON when dump body is raised (When chassis is not inclined laterally more than 15°) Parking brake does not operate normally Touch up/down and cancellation cannot be performed BK-1a) BK-1b) BK-2 BK-3 BK-4 28 29 30 31 Payload meter related 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 When starting switch is turned ON. all external pilot lamps do not light up External lamps light up while condition for lighting is not set Lighting level of external pilot lamps is abnormal Cycle data and engine ON/OFF data not recorded (charge level signal system: judges that engine is stopped) Calibration cannot be performed and displayed clock does not conform to condition (shift lever "N" position signal system) When loaded dump truck starts traveling.

however) When lamp switch is set in 1st or 2nd position. PROCEDURE. small lamp and night lamp do not light up When lamp switch is OFF. turn signal lamps flash normally) W h e n h a z a r d l a m p s w it c h i s turned ON. however. however. however. any of small lamp. turn signal lamps on either or both sides do not flash (When hazard lamp switch is operated. and head lamp does not light up When lamp switch is set in 1st position. turn signal lamps continue flashing (When turn signal lever is operated. small lamp and night lamp light up When dimmer switch is operated. machine monitor does not display any item When starting switch is turned OFF and machine monitor does not operate normally Alarm buzzer defective Items displayed by gauges. turn signal lamps flash normally) W h e n h a z a r d l a m p s w it c h i s turned OFF. and character display of machine monitor are abnormal Alarm buzzer does not sound Alarm buzzer does not stop sounding Items displayed by gauges are different from machine condition Items displayed by caution lamps are different from machine condition Character display does not display any item or it displays abnormally MON-1 MON-2 MON-3a) MON-3b) MON-4 MON-4 MON-4 MON-5 MON-6 MON-6 MON-7 MON-8a) MON-8b) MON-9a) 58 59 60 Operation of machine monitor cannot be checked normally Display of character display cannot be selected normally Machine monitor mode select switch 1 system is abnormal Machine monitor mode select switch 2 system is abnormal 61 62 Power mode select function does not work normally Seat belt caution lamp does not operate normally Lamp lights up while seat belt is fastened Lamp does not light up while seat belt is unfastened When turn signal lever and hazard lamp switch are operated. AND METHOD OF USING TROUBLESHOOTING CHARTS Troubleshooting No. the turn signal lamps do not flash but light up When turn signal lever is operated. caution lamps. any turn signal lamp does not flash When turn signal lever and hazard lamp switch are operated. any turn signal lamp does not flash (When turn signal lever is operated.TROUBLESHOOTING CATEGORIES. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode S mode Monitor related 56 57 When starting switch is turned ON. HD605-7 . brightness of night lighting does not change Head lamp "Hi" beam does not light up 63 MON-9b) MON-9c) 64 Turn signals and hazard lamp do not operate normally MON-9d) MON-9e) MON-9f) MON-10a) MON-10b) MON-10c) MON-10d) MON-10e) 65 Night lighting is abnormal 20-316 (10) HD465-7. turn signal lamps flash normally) Turn signal pilot lamps do not flash normally (Turn signal lamps flash normally. night lamp.

or effective only on one side HD465-7.TROUBLESHOOTING CATEGORIES. HD605-7 20-317 (10) . or effective only on one side Rear brake is ineffective. pilot lamp of machine monitor does not light up Left window does not work Right window does not work Air conditioner does not operate Air is not blown out or airflow cannot be adjusted Air is not cooled or temperature cannot be adjusted (Electric system) Defective air conditioner Inside air and fresh air cannot be selected Air outlet cannot be selected Cooling capacity is low (Mechanical system) Heating capacity is low (Defective hot water circuit) Abnormal noise comes out Water leaks VHMS Abnormality in satellite data communication Satellite communication data are not transmitted Downloading into PC VHMS-2 VHMS-3 Error code ENG mode TM mode BK mode LC mode MON mode MON-10f) MON-10g) MON-10h) MON11a) MON11b) MON12a) MON12b) MON12c) MON12d) MON12e) MON12f) MON12g) MON12h) MON12i) VHMS mode H mode S mode 65 Night lighting is abnormal 66 Power window does not operate normally 67 68 VHMS-1 69 70 Abnormality in saving in VHMS controller (Data are not saved) Engine blow-by pressure of monitoring display is low (when measurement equipment shows blow-by pressure is normal) Hydraulic and mechanical related 71 72 73 74 75 Machine does not start Machine does not travel smoothly Lock-up clutch cannot be disengaged Excessive shock when starting or shifting Transmission does not shift up Abnormality at all speed ranges 76 Machine lacks power or speed when traveling Torque converter lock-up does not engage Abnormality at specific speed ranges H-1 H-2 H-3 H-4 H-5 H-6a) H-6b) H-6c) H-7 H-8 H-9 H-10 H-11 77 78 79 80 81 Time lag is excessive when starting or shifting gear Torque converter oil temperature is high Torque converter oil pressure is low Front brake is ineffective. Phenomena considered to be failures Head lamp "Lo" beam does not light up Head lamp cannot be set to "Hi" or "Lo" When head lamp is set to "Hi" beam. AND METHOD OF USING TROUBLESHOOTING CHARTS Troubleshooting No. PROCEDURE.

HD605-7 .TROUBLESHOOTING CATEGORIES. AND METHOD OF USING TROUBLESHOOTING CHARTS Troubleshooting No. Phenomena considered to be failures Error code ENG mode TM mode BK mode LC mode MON mode VHMS mode H mode H-12 H-13 H-14 H-15 H-16 H-17 S mode 82 83 84 85 86 87 Steering wheel is heavy Steering wheel does not work Steering wheel vibrates Hoist cylinder lacks lifting force (lifting speed) Hoist cylinder does not work Excessive hydraulic drift of dump body 20-317-1 (9) HD465-7. PROCEDURE.

: 08055-00191 T-adapter Part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: red • Quantity: 20 — — — — 20-318 (10) HD465-7.: 08055-00391 4 799-601-7040 Part No.: 08055-00292 3 799-601-7030 Part No.: 08055-00491 Terminal part no.: 08055-00481 Terminal part no.: 08055-00381 Part No.: 08055-00282 Part No. of pins 1 X-type connector Male (female housing) Part No. No.: 08055-00181 Female (male housing) Part no. 799-601-7010 2 799-601-7020 Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins while the terms male housing and female housing refer to the mating portion of the housing.85 • Grommet: black • Quantity: 20 Terminal part no.0 • Grommet: red • Quantity: 20 Part No.: 79A-222-3390 • Electric wire size: 0.: 79A-222-3380 • Electric wire size: 2. HD605-7 .: 79A-222-3370 • Electric wire size: 0.85 • Grommet: black • Quantity: 20 Terminal part no.

11281 Part No.11291 14 799-601-7070 Part No.10681 Part No.11481 Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 08055.: 08055-11491 HD465-7. of pins SWP-type connector Male (female housing) Female (male housing) T-adapter Part No.10891 12 799-601-7310 Part No.10691 8 799-601-7060 Part No.: 08055.: 08055. 6 799-601-7050 Part No.: 08055-10881 Part No.: 08055.: Part No.: 08055.: 08055. HD605-7 20-319 (1) .

25 • Grommet: red • Quantity: 20 — — — — 20-320 (10) HD465-7.: • Electric wire size: 0.25 • Grommet: red • Quantity: 20 Part No.: • Electric wire size: 1. 16 799-601-7320 Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 08055-11691 Terminal part no.: • Electric wire size: 1. HD605-7 .85 • Grommet: black • Quantity: 20 Terminal part no.: 08055-11681 Terminal part no.85 • Grommet: black • Quantity: 20 Terminal part no.: • Electric wire size: 0. of pins SWP-type connector Male (female housing) Female (male housing) T-adapter Part No.

: 08056-00681 8 799-601-7340 Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 08056-00371 Part No.: 08056-00881 HD465-7.: 08056-00471 Part No. of pins 1 M-type connector Male (female housing) Part No. HD605-7 20-321 (7) .: 08056-00281 3 799-601-7110 Part No. 799-601-7080 2 799-601-7090 Part No.: 08056-00181 T-adapter Part No.: 08056-00671 Part No.: 08056-00171 Female (male housing) Part No.: 08056-00871 Part No.: 08056-00381 4 799-601-7120 Part No.: 08056-00481 6 799-601-7130 Part No.: 08056-00271 Part No.

: 08056-11271 Part No. of pins S-type connector Male (female housing) Female (male housing) T-adapter Part No.: 08056-10881 10 (white) 799-601-7150 Part No.: 08056-11081 12 (white) 799-601-7350 Part No.: 08056-10871 Part No.: 08056-11681 20-322 (10) HD465-7. 8 799-601-7140 Part No.: 08056-11071 Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. HD605-7 .: 08056-11671 Part No.: 08056-11281 16 (white) 799-601-7330 Part No.

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 08056-11282 16 (blue) 799-601-7170 Part No.: 08056-11672 Part No. of pins S-type connector Male (female housing) Female (male housing) T-adapter Part No. HD605-7 20-323 (1) . 10 (blue) — — — 12 (blue) 799-601-7160 Part No.: 08056-11272 Part No.: 08056-11682 HD465-7.

: 79A-222-2610 Qty. of pins 7 11 MIC type connector Male (female housing) Housing part No.: 79A-222-2660 Qty.: 5 Female (male housing) Housing part No.: 79A-222-2640 Qty.: 5 9 799-601-2950 Housing part No. HD605-7 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 79A-222-2650 Qty.: 2 20-324 (10) HD465-7.: 5 Housing part No.: 79A-222-2680 Qty.: 5 Housing part No.: 5 13 799-601-2720 Housing part No.: 79A-222-2710 Qty.: 2 Housing part No. — — 5 799-601-2710 Housing part No.: 79A-222-2630 Qty.: 5 Housing part No.: 5 T-adapter Part No.: 79A-222-2620 Qty.: 79A-222-2670 Qty.: 79A-222-2690 Qty.: 5 Housing part No.

: 79A-222-2730 Qty.: 79A-222-2750 Qty.: 2 Housing part No.: 50 — HD465-7.: 79A-222-2760 Qty. of pins MIC type connector Male (female housing) Female (male housing) T-adapter Part No. 17 799-601-2730 Housing part No.: 79A-222-2770 Qty.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 50 Housing part No.: 79A-222-2720 Qty.: 2 21 799-601-2740 Housing part No. HD605-7 20-325 (1) .: 2 Housing part No.: 2 Housing part No.: 79A-222-2740 Qty.

: 79A-222-3450 Qty.: 79A-222-3460 Qty.: 79A-222-3440 Qty. 8 799-601-7180 — Housing part No.: 79A-222-3430 Qty.: 79A-222-3470 (no relation with number of pins) 20-326 (1) HD465-7.: 5 16 799-601-7210 — Housing part No. HD605-7 . of pins AMP040-type connector Male (female housing) Female (male housing) T-adapter Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 5 20 799-601-7220 — Housing part No.: 5 12 799-601-7190 — Housing part No.: 5 aTerminal part No.

: 7821-92-7330 12 799-601-7520 — Part No.: 7821-92-7360 20 799-601-7550 — Part No. of pins AMP070-type connector Male (female housing) Female (male housing) T-adapter Part No.: 7821-92-7350 18 799-601-7540 — Part No.: 7821-92-7340 14 799-601-7530 — Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.: 7821-92-7370 HD465-7. 10 799-601-7510 — Part No. HD605-7 20-327 (9) .

2 — — — — No. of pins PA type connector Male (female housing) Female (male housing) T-adapter Part No. 10 799-601-3460 — — 20-328 (10) HD465-7. HD605-7 . 9 — — No. of pins L type connector Male (female housing) Female (male housing) T-adapter Part No. of pins Bendix MS connector Male (female housing) Female (male housing) T-adapter Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.

: 08027-10360 4 — Part No. of pins KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.: 08027-10460 (natural color) 08027-10470 (black) 6 — Part No.: 08027-10660 (natural color) 08027-10670 (black) HD465-7.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. HD605-7 20-329 (1) .: 08027-10310 Part No.: 08027-10210 (natural color) 08027-10220 (black) Part No.: 08027-10610 (natural color) 08027-10620 (black) Part No. 2 — Part No.: 08027-10260 (natural color) 08027-10270 (black) 3 — Part No.: 08027-10410 (natural color) 08027-10420 (black) Part No.

: 08027-10810 (natural color) 08027-10820 (black) Part No. HD605-7 . of pins KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.: 08027-10860 (natural color) 08027-10870 (black) 20-330 (1) HD465-7. 8 — Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.

5 799-601-7360 — — 6 799-601-7370 — — HD465-7. of pins Connector for relay (socket type) Male (female housing) Female (male housing) T-adapter Part No. HD605-7 20-331 (10) .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No.

4 — — — 20-332 (1) HD465-7.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins F-type connector Male (female housing) Female (male housing) T-adapter Part No. HD605-7 .

08191-12202. 08191-12202. 08191-22205. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No. 08191-24102 08191-24105. 08191-22202. 08191-24106 Pin (male terminal) 799-601-9220 Part No.: 08191-22201. 18-8 (1) Part No.: 08191-23101.: 08191-12201. 08191-21205. 08191-14102. 08191-23105. HD605-7 20-333 (10) . 08191-11202. 08191-13102. 08191-11205.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No.: 08191-14101. 08191-23106 HD465-7. 08191-13106 Pin (female terminal) 18-14 (2) Part No. 08191-14105. 08191-12205.: 08191-11201. 08191-12206 Pin (male terminal) Part No.: 08191-13101.: 08191-21201. 08191-22206 Part No.: 08191-24101. 08191-12206 Pin (female terminal) Part No. 08191-14106 Pin (male terminal) 799-601-9210 Part No. 08191-23102. 08191-13105. 08191-11206 Pin (female terminal) Part No.

: 08191-33101. 08191-44102 799-601-9240 Pin (male terminal) Part No. 08191-34102 799-601-9230 Pin (male terminal) Part No. 08191-31202 Pin (female terminal) Part No.: 08191-31201. 08191-42202 Part No.: 08191-32201.: 08191-43101. 08191-32202 Pin (male terminal) Part No.: 08191-44101. 18-20 (3) Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. 08191-43102 20-334 (10) HD465-7. 08191-42202 Pin (female terminal) Part No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No. 08191-33102 Pin (female terminal) 18-21 (4) Part No.: 08191-41201. HD605-7 .: 08191-34101.: 08191-42201.

08191-63106 HD465-7. 08191-54102 799-601-9250 Pin (male terminal) Part No. HD605-7 20-335 (10) . 08191-52202 Pin (male terminal) Part No. 08191-62202. 08191-62205.: 08191-64101. 08191-64102 08191-64105. 08191-62206 Pin (female terminal) Part No. 08191-63105.: 08191-53101. 08191-53102 Pin (female terminal) 24-16 (6) Part No.: 08191-54101.: 08191-52201. 24-9 (5) Part No. 08191-64106 799-601-9260 Pin (male terminal) Part No. 08191-62202 08191-61205.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No. 08191-63102. 08191-51202 Pin (female terminal) Part No.: 08191-51201. 08191-62206 Part No.: 08191-63101.: 08191-61201.: 08191-62201.

HD605-7 . 08191-81206 Pin (female terminal) Part No. 08191-71202. 08191-83102. 08191-74106 799-601-9270 Pin (male terminal) Part No. 08191-83104. 08191-81205. 08191-84103. 08191-74102.: 08191-72201.: 08191-83101.: 08191-74101. 08191-72205. 08191-84104. 08191-82202.: 08191-71201. 08191-83106 20-336 (10) HD465-7. 08191-84105. 08191-82206 Part No. 08191-73106 Pin (female terminal) 24-22 (8) Part No. 08191-83105. 08191-71206 Pin (female terminal) Part No. 08191-82204. 08191-84106 799-601-9280 Pin (male terminal) Part No. 08191-73105. 24-21 (7) Part No. 08191-74105. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No. 08191-71205.: 08191-73101. 08191-83103. 08191-81203. 08191-73102. 08191-82203. 08191-72202.: 08191-84101. 08191-84102. 08191-81204.: 08191-81201. 08191-72206 Pin (male terminal) Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. 08191-82205.: 08191-82201. 08191-81202.

08191-93104. HD605-7 20-337 (10) . is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female terminal) T-adapter Part No. 08191-94106 799-601-9290 Pin (male terminal) Part No.: 08191-92203.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. 08191-93106 HD465-7. 08191-93105.: 08191-94103. 08191-91205. 08191-94104. 24-31 (9) Part No. 08191-91206 Pin (female terminal) Part No. 08191-92204. 08191-92205. 08191-91204.: 08191-91203. 08191-94105.: 08191-93103. 08191-92206 Part No.

No.: 08192-12200 (normal type) 08192-22200 (fine wire type) Part No. is also marked on the connector (electric wire insertion end)] DT series connector Body (plug) Body (receptacle) T-adapter Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type) 6 799-601-9050 Part No. of pins 2 799-601-9020 Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type) Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type) Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type) 4 799-601-9040 Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type) Part No. HD605-7 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No.: 08192-16100 (normal type) 08192-26100 (fine wire type) 20-338 (10) HD465-7.: 08192-12100 (normal type) 08192-22100 (fine wire type) 3 799-601-9030 Part No.

is also marked on the connector (electric wire insertion end)] DT series connector Body (plug) Body (receptacle) T-adapter Part No. of pins 8 8Gr: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8Br: 799-601-9090 Part No.: 08192-1810 (normal type) 08192-2810 (fine wire type) 12 12Gr: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12Br: 799-601-9140 Part No.: 08192-1910 (normal type) 08192-2910 (fine wire type) HD465-7.: 08192-1820 08192-2820 (normal type) (fine wire type) Part No.: 08192-1920 (normal type) 08192-2920 (fine wire type) Part No. HD605-7 20-339 (10) .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. No.

31200 (contact size #12) 08192 .31100 (contact size #12) 08192 . is also marked on the connector (electric wire insertion end)] DTHD series connector Body (plug) Body (receptacle) T-adapter Part No.41100 (contact size #8) 08192 .: 08192 .51200 (contact size #4) Part No. No. of pins 2 799-601-9010 Part No.41200 (contact size #8) 08192 . of pins 1 Part No. HD605-7 .: 08192-02100 [The pin No.51100 (contact size #4) 20-340 (10) HD465-7.: 08192-02200 Part No.: 08192 . No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No. is also marked on the connector (electric wire insertion end)] DTM series connector Body (plug) Body (receptacle) T-adapter Part No.

of pins DRC26 Series connector Body (plug) Body (receptacle) T-adapter Part No.: 7821-93-3110 40 (A) 799-601-9350 — Part No. is also marked on the connector (electric wire insertion end)] No. 24 799-601-9360 — Part No.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS [The pin No.: 7821-93-3130 HD465-7. HD605-7 20-340-1 (9) .: 7821-93-3120 40 (B) 799-601-9350 — Part No.

Connector type Pin No. HD605-7 20-341 (12) — Q . 799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 For measuring box For measuring box For measuring box For measuring box Plate Plate Plate BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) BENDIX(MS) CASE MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Extension cable CASE X X X X SWP SWP SWP SWP Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 1P 2P 3P 4P 6P 8P 12P 14P Q Q Q Q Q Q Q Q Q Q Q HD465-7.TROUBLESHOOTING T-ADAPTER TABLE T-ADAPTER TABLE KIT No. 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 Port No.

HD605-7 — Port No. Connector type Pin No. Q Q Q Q .TROUBLESHOOTING T-ADAPTER TABLE KIT No. 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 SWP M M M M M M S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 16P 1P 2P 3P 4P 6P 8P 8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 10P 12P 14P 18P 20P 5p 6p 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Blown 12P-Gray 12P-Black 12P-Green 12P-Blown 18-8 18-14 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 20-342 (12) HD465-7.

fuel PVC socket 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT. HD605-7 20-343 (12) — Port No. Connector type Pin No. 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410 799-601-9420 799-601-9430 HD30 HD30 HD30 HD30 HD30 HD30 HD30 Plate For measuring box Case Case DRC26 DRC26 For NE.TROUBLESHOOTING T-ADAPTER TABLE KIT No. . HD Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 40P 24P 2P 3P 2P Q Q Q Q Q HD465-7. G sensor For boost pressure.

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. HD605-7 . connector of pin 01 02 03 04 05 06 07 08 11 12 12 13 14 15 16 17 18 20 21 22 23 1939 A A A1 A2 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal KES0 Terminal Terminal Terminal Terminal Terminal Terminal — — — — HD30 One-pin connector One-pin connector Address Location 3-dimensional wiring diagram ENG System diagram TM K-8 K-8 K-8 K-8 K-9 K-9 K-9 K-9 BK H-9 H-8 H-8 H-8 PLM K-9 K-8 K-8 K-8 MON VHMS N-9 N-8 N-8 N-8 ASR 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 9 1 1 1 1 3 6 1 2 3 3 5 5 Battery relay (B) Battery relay (M) Battery relay (B) Battery relay (M) Emergency steering relay (B) Emergency steering relay (M) Emergency steering relay (B) Emergency steering relay (M) Battery relay (E) Battery relay (BR) Washer tank motor Battery relay (E) Battery relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Emergency steering relay (E) Emergency steering relay (BR) Circuit breaker Circuit breaker Circuit breaker Circuit breaker Connector for connecting J1939 device B9 B9 B9 B9 A8 A8 A8 A9 B8 B8 — C8 C8 A8 A7 B7 B7 A9 A9 A9 B9 — — — X6 V8 AH5 O2 M3 T2 L4 K3 V3 M6 J-1 J-1 J-1 J-1 J-1 J-1 J-1 J-1 K-8 K-8 K-8 K-8 H-9 H-8 K-9 K-8 N-9 N-8 H-8 H-8 K-8 K-8 N-8 N-8 K-9 K-9 K-9 K-8 L-8 L-8 J-2 I-2 G-9 J-9 H-1 B-7 B-7 B-1 E-9 C-7 A-9 L-2 L-2 K-4 K-4 A-8 B-9 K-8 K-8 I-8 I-8 L-8 L-8 N-8 N-7 N-8 N-7 A-3 Lamp (Optional for payload meter) Lamp (Optional for payload meter) Emergency reset connector Emergency reset connector Air pressure sensor ABS system switch Air conditioner wiring harness Air conditioner blower motor ACC oil pressure sensor (Front) ACC oil pressure sensor (Rear) Temperature regulation servomotor Air outlet mode selection servomotor M M AAPR PACKARD ABS AC1 ACBM ACCF ACCR ACM1 ACM2 M One-pin connector YAZAKI DT-T DT-T AMP AMP 20-344 (10) HD465-7.

HD605-7 20-345 (5) . connector of pin ACM3 ACP1 ACP2 AMP AMP AMP 5 16 12 2 4 4 4 4 4 4 2 6 3 6 6 3 6 2 2 2 2 2 2 2 2 17 21 20 16 12 20 16 4 6 6 Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS A-7 B-9 B-9 A-8 A-8 A-8 A-7 A-7 A-7 A-8 A-8 ASR Recirculated/Fresh air selection servomotor W3 O7 O7 U2 W3 W4 W4 W4 W4 U2 U3 M3 P8 N3 N2 O2 O2 C2 L2 K3 L3 K3 L2 K1 T2 Z1 Z1 Z4 Z4 AA4 AA1 AA4 W4 K9 K8 L-7 L-7 L-8 L-8 A-7 A-7 A-6 A-6 A-5 A-5 A-4 A-3 E-1 E-1 E-1 F-1 E-1 E-1 E-1 L-2 C-8 L-5 F-9 C-1 Air conditioner control panel Air conditioner control panel Air conditioner pressure switch Blower main relay Blower Hi relay Blower M2 relay Blower M1 relay Compressor clutch relay Air conditioner blower resistor Thermistor AISS switch ARSC set switch ARSC system switch Acceleration sensor Acceleration sensor ASR system switch Steering angle sensor Shut off valve ASR valve (R) ASR valve (L) ASR oil pressure switch (R) ASR oil pressure switch (L) ASR oil ptessure switch (Main) Air suspension seat Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Transmission controller Software rewriting connector (Transmission controller) ACPS SUMITOMO ACR1 ACR2 ACR3 ACR4 ACR5 ACRE ACTH AISS ARC ARSC AS1 AS2 ASR ASR1 ASR2 ASR3 ASR4 ASR5 ASR6 ASR7 ASS ATC1 ATC2 Relay Relay Relay Relay Relay AMP YAZAKI M M M SWP X M DT-T-T DT-T-T DT-T-T DT-T-T DT-T DT-T DT-T DT-T MIC MIC F-9 F-9 F-5 C-9 D-9 D-9 E-9 E-9 F-9 F-9 H-1 ATC3A AMP040 ATC3B AMP040 ATC4 AMP040 I-1 ATC5A AMP040 ATC5B AMP040 ATC6 B01 B02 X DT-T DT-T Intermediate connector Intermediate connector M-5 M-5 HD465-7.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.

HD605-7 . connector of pin B03 B04 B05 B06 B07 B1 B1 B10 B11 B2 B2 B3 B3 BCOM BK BL BLS BR BRC1 BRC2 DT-T Terminal Terminal Terminal DT-T One-pin connector One-pin connector Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS M-6 F-9 F-9 F-9 K-5 I-9 H-1 G-9 M-4 M-5 J-9 H-1 J-9 H-1 A-2 H-2 I-8 C-9 C-7 M-2 M-6 M-6 M-6 ASR 6 1 1 1 3 1 1 1 1 1 1 1 1 1 8 1 6 1 17 21 20 16 12 20 16 4 6 — — — — 2 8 8 3 Winker lamp. tail lamp Backup lamp Backup alarm buzzer Backup alarm buzzer Body position sensor Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) J9 J9 J9 J9 K9 — — K8 L8 — — — — T9 F9 C7 N1 M4 Y2 Y2 Y4 Y4 Z4 Y1 Y2 S9 C9 X5 X7 X6 X6 R1 Q9 Q9 AJ6 H-9 B-9 L-6 L-4 L-4 L-3 I-2 H-6 E-3 E-2 E-2 E-2 F-3 F-3 C-1 J-9 C-1 C-1 J-9 C-1 A-8 A-7 A-6 A-5 A-5 A-4 A-3 A-2 G-8 J-6 E-7 E-7 E-6 E-6 D-1 D-1 D-1 Terminal Terminal One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector DT-T (Gray) One-pin connector Grounding Grounding Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) Beacon lamp Intermediate connector Intermediate connector Rotary lamp switch (If equipped) Air conditioner wiring harness Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Retarder controller Software rewriting connector (Retarder controller) M One-pin connector MIC MIC H-1 A-1 B-1 BRC3A AMP040 BRC3B AMP040 BRC4 AMP040 H-1 BRC5A AMP040 BRC5B AMP040 BRC6 BT BT1 BT2 BT3 BT4 BZ2 CAB1 CAB2 CAN X DT — — — — M DT-T (Gray) DT-T (Black) D-1 Intermediate connector Fuse box Fuse box Fuse box Fuse box Buzzer Intermediate connector Intermediate connector CAN connector M-9 K-3 I-3 K-3 I-3 D-9 F-1 F-4 DT M-3 A-2 20-346 (10) HD465-7. stop lamp.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. connector of pin CAN1 CAN2 CG1 CG2 CH1 CH2 CJA CJB CJB CJC CJD CJE2 CJE3 CJH1 CJH2 CJK CJL CJN CJP CJP1 CJP2 CJPR CJS CJSL CJT CJT1 CJT2 CJW CK1 DT-T DT-T One-pin connector Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS C-9 F-9 D-9 ASR 3 3 1 1 8 8 6 8 6 6 6 6 8 8 6 6 6 8 6 6 6 6 6 6 8 8 6 6 6 2 8 2 2 2 2 VHMS CAN connector Resistor Cigarette lighter Cigarette lighter Machine monitor mode selector switch 1 Machine monitor mode selector switch 2 T9 Q1 M5 M5 M1 M1 D8 B7 E8 D8 D8 AI9 A12 — — B8 L7 J3 I9 H9 I9 C8 L7 I9 L8 L7 H9 G-9 G-1 G-1 I-1 I-1 J-9 H-9 G-1 G-1 H-9 M-1 M-1 I-9 L-3 J-1 J-1 H-9 I-1 I-1 I-1 J-1 I-1 H-1 I-9 J-1 J-9 K-1 G-8 H-9 H-9 I-1 — S S DT-T DT-T (Black) E-9 E-9 L-9 M-9 L-9 Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Bulb breakage check switch Coolant temperature sensor Lighting switch. HD605-7 20-347 (10) . turn switch DT-T DT-T DT DT-T DT-T (Black) DT-T (Black) M-9 N-7 M-1 DT-T DT DT-T DT (Black) DT-T DT-T DT-T DT-T DT-T DT-T DT (Black) DT-T (Black) M-9 M-1 N-5 N-5 DT-T DT-T YAZAKI F-7 M2 AE8 Q8 AC9 AC9 AD7 AB9 M-8 M-8 M-8 M-6 G-2 K-4 A-1 B-2 F-9 CLTP PACKARD CM CN3 CN4 CN5 CN6 DT-T (Green) DT-T DT-T DT-T DT-T Input shaft speed sensor Intermediate shaft speed sensor Output shaft speed sensor Solenoid for transmission 1st clutch HD465-7. passing switch.

HD605-7 . connector of pin CN7 CN8 CN9 CN10 CN11 CN12 CN13 CN14 CN15 CN16 CN17 CN18 CN19 CN20 CN21 CN22 CN23 CN24 CNS1 CNS2 CNS3 COM D01 D02 D03 D04 D05 D07 D08 DL DPC1 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T (Brown) DT-T (Green) DT-T (Black) One-pin connector Address Location 3-dimensional wiring diagram ENG System diagram TM N-6 M-6 N-6 M-6 N-6 M-6 N-6 M-5 M-5 M-7 N-6 M-7 N-7 M-7 N-7 M-8 M-7 M-7 H-8 B-9 A-9 E-7 C-7 B-2 H-8 BK PLM MON VHMS ASR 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 2 12 12 12 1 2 2 2 2 2 2 2 12 20 18 12 18 12 Fill switch for transmission 1st clutch Solenoid for transmission 2nd clutch Fill switch for transmission 2nd clutch Solenoid for transmission R clutch Fill switch for transmission R clutch AB9 AB9 AA9 AA9 AA9 AA9 AA9 AA9 Z9 Z8 Z8 Y8 Y7 Z8 Z8 Z5 AA5 AC5 Solenoid for transmission 3rd clutch Fill switch for transmission 3rd clutch Solenoid for transmission 4th clutch Fill switch for transmission 4th clutch Solenoid for transmission L clutch Fill switch for transmission L clutch Solenoid for transmission H clutch Fill switch for transmission H clutch Solenoid for torque converter lockup clutch Fill switch for torque converter lockup clutch Torque converter intermediate pressure sensor Torque converter oil temperature sensor Transmission valve oil temperature sensor Intermediate connector (Power window switch) Intermediate connector (Gear shift lever) Intermediate connector (Parking brake switch) Air conditioner wiring harness Diode Diode Diode Diode Diode Diode Diode Intermediate connector Machine monitor Machine monitor Machine monitor Machine monitor Machine monitor M3 W8 W8 W8 M6 V8 P2 W8 X6 P8 P1 P1 P8 Q1 I-9 E-9 D-9 C-1 I-9 E-9 C-1 K-5 C-9 F-8 F-8 A-8 A-1 L-5 C-9 F-8 A-1 F-8 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T (Black) I-9 F-1 F-1 E-1 I-9 I-9 AMP070 A-7 A-6 A-6 A-5 A-5 F-1 DPC2A AMP070 DPC2B AMP070 DPC3A AMP070 DPC4 AMP070 20-348 (10) HD465-7.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.

C8.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. G9 H-1 N-3 F-3 F-2 F-3 F-1 I-2 H-2 G-1 F-3 F-2 F-3 F-2 A-3 A-8 C-8 N-5 N-4 N-4 N-4 K-5 K-5 M-3 N-5 N-4 N-5 N-4 Terminal Terminal Terminal DT-T DT-T DT DRC26 DRC26 DT-T (Brown) DT-T (Gray) L-1 L-1 K-8 K-8 M-4 M-4 B-3 H-2 I-1 H-3 J-8 J-7 H-8 J-3 J-7 M-7 M-8 Terminal HD465-7. connector of pin DPC6 DPC7 DSL DSR DT7 DT8 E E01 E02A E02B E03 E04 E05 E06 E07 E08 E09 E10 E11A E11B E12A E12B E13A E13B E15 E16A E16B E17A E17B E2B ECM A ECM B EG4 ENG ER AMP040 X — — DT-T DT-T Terminal Terminal DT-T DT-T DT-T DT-T Terminal Terminal DT-T DT-T Terminal Terminal Terminal Terminal Terminal Terminal DTHD (#4) DTHD (#4) Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS ASR 8 4 1 1 12 4 1 1 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 40 40 12 8 1 Machine monitor Software rewriting connector (Machine monitor) O7 N3 F1 T2 T2 J2 L-9 AE7 AH1 AH1 AF1 AH5 C2 AE6. E9. AF1 Door switch (Left) Door switch (Right) Intermediate connector Intermediate connector Emergency steering motor Alternator Starting motor Starting motor Engine speed sensor Oil level switch (If equipped) Oil filter switch Alternator Compressor Diode Alternator Grounding Heater relay Ribbon heater Heater relay Ribbon heater Intermediate connector Intermediate connector Grounding Grounding Grounding Diode Diode Diode Engine controller Engine controller Intermediate connector Intermediate connector Grounding D-2 F-1 H-1 H-2 G-2 N-3 M-3 M-2 N-3 M-3 H-9 L-4 K-3 N-7 H-1 N-4 N-7 AF8 AG9 AE6 AG9 AJ9 AH9 AJ9 AG9 AG1 AG1 AI2 AI9 AH9 AJ8 AJ8 AE5 AG5 AG9 V9 AJ7 C9. HD605-7 20-349 (10) .

connector of pin ER1 ER2 ER3 FBC FL01 FL04 FL05 FLB FLL Terminal Terminal Terminal M DT-T YAZAKI DT-T — — 1 1 1 6 2 2 2 1 1 2 6 2 2 2 2 2 2 1 1 — — 1 1 1 1 2 1 1 6 2 2 1 1 1 1 Grounding Grounding Grounding Address Location 3-dimensional wiring diagram ENG System diagram TM D-8 BK F-7 C-1 B-7 F-1 PLM MON VHMS ASR P1 X7 O2 N3 B3 B3 B2 R1 R1 AF9 N1 B7 X6 X7 X7 X7 X6 AE7 AE7 C9 C9 — — S1 AF8 K3 M4 M4 O7 AJ7 L5 — Q8 A4 A4 F-6 E-2 J-4 E-1 E-1 K-2 K-1 A-1 H-6 A-8 Front brake cutting switch Radiator coolant level sensor Washer motor Air conditioner dual switch Flasher Flasher Fuel temperature sensor Fog lamp switch (If equipped) Air cleaner clogging sensor Spare terminal Spare terminal Spare terminal Spare terminal Spare terminal Fuel shut-off valve – Fuel shut-off valve + Fuse box (30 A) Fuse box (120 A x 2) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) G-9 H-9 M-1 L-1 A-4 A-4 FLTP PACKARD FOG FR01 FS2 FS3 FS4 FS5 FS8 FSO– FSO+ FUA FUB G G G21 GND H01 H10 H20 HAZ HEAT HEPC HES HN HN1A HN1B M DT-T One-pin connector One-pin connector One-pin connector One-pin connector One-pin connector C-9 G-9 Terminal Terminal Terminal Terminal One-pin connector One-pin connector L-9 L-9 I-9 L-9 N-8 I-9 H-1 B-7 K-1 L-8 M-4 Terminal Terminal DT-T One-pin connector One-pin connector Grounding Engine block GND Steering flow switch Heater unit Heater unit Hazard switch Heater control Hoist EPC valve Grounding Horn switch Horn valve Horn valve M DT DT-T Terminal One-pin connector G-9 J-2 L-2 D-9 L-9 L-9 — — 20-350 (10) HD465-7.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. HD605-7 .

AN6 H1. connector of pin HN2A HN2B HSL HSL HSOL HTA HTB IMPR IMTP J01 J02 J03 J04 J05 J07 J08 J09 J10 JC01 JC02 JC03 JC04 JC11 JC12 JC13 JC14 JC15 JCA JCB JCC JCD JCE JCF JCG JT1 — — DT-T DT-T DT-T DT-T (Gray) DT-T (Black) Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS ASR 1 1 4 4 3 8 8 3 2 9 31 31 31 31 14 31 31 31 6 8 8 8 6 6 8 8 6 8 8 8 8 8 8 8 6 Horn valve Horn valve Intermediate connector Hoist lever potentiometer Hoist selector valve Intermediate connector Intermediate connector Intake air pressure sensor Intake air temperature sensor Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector A4 A3 V3 V3 L5 L6 L6 AF8 AF8 I2 I2 I2 H1.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. AN6 D-1 D-1 L-2 I-8 I-8 B-1 B-1 G-4 G-3 F-6 F-6 F-6 H-7 H-7 H-6 H-5 F-5 F-5 F-5 G-6 G-4 A-4 A-5 A-5 A-6 E-9 E-9 F-9 G-9 H-9 K-1 K-1 L-1 E-1 K-6 K-6 K-6 K-7 J-8 K-8 C-1 B-1 B-1 B-1 D-1 A-3 J-1 A-1 A-2 A-1 A-2 A-3 F-1 C-1 C-1 C-1 C-1 E-1 F-1 G-1 G-1 G-1 G-1 H-1 I-1 L-7 L-7 L-6 M-3 M-3 A-2 K-1 K-1 L-7 M-4 F-4 F-4 H-4 H-3 G-3 I-5 I-5 H-4 H-3 G-7 G-6 G-5 G-4 G-4 G-4 C-5 C-4 C-4 C-3 I-6 I-6 I-5 I-5 C-7 C-7 C-6 J-3 K-3 J-4 M-2 PACKARD PACKARD HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 HD30 DT DT (Black) DT (Black) DT (Black) H1 G1 G1 G1 AI6 AI5 AH5 AG5 AG5 AH5 AI5 AI6 AI6 X5 X5 X5 X4 X4 S9 V3 AD7 DT DT DT (Black) DT (Black) DT DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T (Black) DT-T HD465-7. HD605-7 20-351 (10) .

O9 N8. O9 M8. H-6 F-7. E-9 J-1 J-1 K-1 K-1 K-1 J-1 K-1 D-7 A-4 C-8 F-6.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. connector of pin JT2 LINK LKO LKO LP LS M MON1 MON2 MON3 MS11 MS12 MS21 MS22 MS31 MS32 DT-T DT DT-T DT-T DT (Gray) Address Location 3-dimensional wiring diagram ENG System diagram TM J-1 BK PLM MON VHMS ASR 6 6 2 2 12 3 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 21 3 16 Joint connector Data link crossover Intermediate connector Lever kick-out solenoid Intermediate connector Rheostat Emergency steering motor Rear view monitor (If equipped) Rear view monitor (If equipped) Rear view monitor (If equipped) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) Model selection connector (Transmission controller) AD7 AJ6 U3 V3 I2 M1 F-7 J-3 K-7 D-1 D-1 H-8 K-2 D-9 M Terminal One-pin connector One-pin connector One-pin connector K-9 N7 N7 O7 U9 U9 U9 U9 U9 V3 AE5 M8. O9 M8. H-7 Terminal MIC DT-T S (Natural color) 20-352 (10) HD465-7. HD605-7 . N9 M8. N9 M8. O8 N8. O8 I-9 I-9 I-9 A-4 A-4 A-4 A-4 A-4 A-4 B-1 A-5 A-5 A-5 A-5 A-5 A-5 A-4 M M M M M M OLPR PACKARD OP1 OP2 OP3 OP4 OP5 OP6 OP7 OPS PL01 PL02 PL03 PL04 PL05 PL06 PL07 PM1 PM3 PM4 M M M M M M M DT-T M M One-pin connector One-pin connector One-pin connector One-pin connector Engine oil pressure sensor Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Machine monitor setting connector Seat heater Left head lamp (LOW) Left head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (If equipped) Grounding VHMS wiring harness Pitch angle sensor VHMS wiring harnes T2 D1 D2 E1 E1 E1 D1 D2 T9 X7 T9 I-8 E-7 D-8 D-8.

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. HD605-7 20-353 (10) . connector of pin PM5 PM6 PM7 PM7 PM8 PM9 PM10 PM11 PMLA MIC AMP040 AMP AMP BENDIX MIC S (Natural Address Location 3-dimensional wiring diagram ENG System diagram TM E-9 BK PLM A-9 D-9 A-9 MON VHMS G-8 G-8 H-8 ASR 13 12 9 9 5 21 16 21 12 3 6 21 2 2 1 1 1 1 1 2 2 3 1 6 1 1 1 5 5 5 5 6 6 5 5 Payload meter controller Payload meter controller VHMS wiring harnes Payload meter controller Connector VHMS wiring harness VHMS wiring harnes Intermediate connector Intermediate connector Fuel pump pressure sensor Intermediate connector Intermediate connector Right head lamp (LOW) Right head lamp (HIGH) Clearance lamp Clearance lamp Turn signal Fog lamp (Optional) Grounding Parking brake solenoid Parking brake switch Fuel pump actuator Power window motor (Left) Power mode switch Power window motor (Right) Lamp (Payload meter) (If equipped) Lamp (Payload meter) (If equipped) T9 U9 I-8 E-9 N7 N7 T9 T9 V9 H9 AF5 D8 AJ7 A5 A4 A5 A5 A5 A6 A4 L6 K3 AF5 I2 M4 C7 J-9 H-1 AB4 AB3 AB3 AB3 AB2 AC4 AB4 AB3 H-8 E-1 B-1 G-7 B-2 B-2 A-9 D-1 D-1 D-1 A-8 D-1 F-1 G-9 F-1 L-3 L-3 F-4 H-4 J-7 K-9 J-9 K-9 K-9 K-9 J-9 K-8 C-1 I-3 I-7 E-9 E-9 K-5 H-7 H-6 color) MIC DT-T (Gray) PMPR PACKARD PMRA POW PR01 PR02 PR03 PR04 PR05 PR06 PR07 PSOL PSW DT-T HD30 M M One-pin connector One-pin connector One-pin connector One-pin connector Terminal DT-T DT-T PUMP PACKARD PWL PWM PWR R R R01 R02 R03 R04 R05 R06 R07 R08 One-pin connector M One-pin connector One-pin connector One-pin connector Relay Relay Relay Relay Relay Relay Relay Relay Engine starting relay Transmission Neutral relay Parking brake relay Brake lamp relay (RL) Backup lamp. buzzer relay Fog lamp relay AISS relay Brake lamp relay (CTR) HD465-7.

connector of pin R09 R10 R11 R14 R15 R16 R17 R19 R21 R22 R25 R29 R30 R32 R33 R34 R35 R37 R40 R43 R44 R45 RAD RAIL RDC RE1 RE2 RE3 RE4 RESW RETV RL RL2 RP RPR Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay YAZAKI Relay Relay Relay Relay YAZAKI YAZAKI Relay Relay Relay Relay Relay YAZAKI PACKARD Address Location 3-dimensional wiring diagram ENG System diagram TM BK A-9 A-7 D-1 A-8 B-2 C-1 C-1 A-8 A-6 B-1 B-1 C-1 B-1 B-3 E-8 H-9 H-9 PLM MON VHMS E-1 ASR 5 5 5 5 5 6 5 5 6 5 11 5 5 5 6 7 7 5 6 5 5 5 9 3 9 2 2 2 2 2 2 2 1 6 3 Brake lamp timer relay PLM GDL relay Horn relay Brake cutting relay Transmission cutting relay Hazard relay 1 Hazard relay 2 Parking brake safety relay Side lamp relay Rotary lamp relay Power window relay Head lamp Hi relay Head lamp Lo relay Dust indicator relay Parking brake manual switch Power window switch (Left) Power window switch (Right) Auto preheater relay Payload meter relay (If equipped) Green outside pilot lamp relay of payload meter Yellow outside pilot lamp relay of payload meter Red outside pilot lamp relay of payload meter AB2 AC4 AC4 AB4 A2 AB1 AC1 AC4 AC4 AD3 AC1 AD2 AD1 AC1 R9 S1 S9 AD3 AD2 AD2 AD2 AD1 O2 AF5 O2 S9 S9 P8 P8 L4 L4 E9 G9 A6 AI6 C-1 A-7 D-1 G-8 B-3 A-6 A-5 A-5 A-5 AM/FM radio Fuel rail actuator Cassette stereo Resistor Resistor Resistor Resistor Retarder switch Retarder valve Room lamp Room lamp 2 Intermediate connector Fuel rail pressure sensor YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI DT-T DT-T YAZAKI One-pin connector C-9 A-8 F-9 F-9 L-1 L-1 N-1 DT-T PACKARD K-8 20-354 (10) HD465-7. HD605-7 .TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No. connector of pin RT2 RT6 RT7 RT8 RTL S01 S02 S03 S04 S05 SBS SDE SF1 SF2 SIG SLG SLG SLL SLR Terminal Terminal Terminal Terminal DT-T DT-T DT-T DT-T DT-T DT-T DT-T M DT-T (Green) Address Location 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS ASR 1 1 1 1 6 2 2 2 2 2 2 6 12 2 31 1 1 1 1 5 2 2 4 12 6 2 2 3 2 3 3 3 3 2 6 Emergency steering timer Emergency steering timer Emergency steering timer Emergency steering timer Retarder potentiometer Service brake switch Secondary brake switch Front brake cutting solenoid (If equipped) Auto suspension solenoid 1 (If equipped) Auto suspension solenoid 2 (If equipped) M4 M5 M5 M4 P8 B7 E9 E9 F9 F9 U2 N2 R9 Q9 AJ7 C8 J2 J2 C7 T1 AJ8 AJ8 A-1 A-1 C-6 C-5 F1 G9 F9 P1 X7 H1 B7 L8 J9 G9 H9 I-9 J-8 F-9 B-1 H-1 G-9 K-5 K-5 K-5 K-6 K-5 K-5 A-9 F-6 H-4 J-7 I-8 I-2 G-2 J-9 J-5 B-3 B-9 A-7 B-2 H-9 C-9 G-2 G-2 G-2 H-2 H-1 F-1 N-2 N-2 C-8 Seat belt switch Side lamp switch (If equipped) Shift lever Shift lever Intermediate connector Grounding Grounding Side lamp (If equipped) Side lamp (If equipped) S-NET monitor Engine speed sensor (Master) Engine speed sensor (Backup) Spare connector 1 Spare connector 2 Spare connector 3 Speaker (Left) Speaker (Right) Steering speed sensor Pitch angle sensor Suspension oil pressure sensor(FL) (If equipped) Suspension oil pressure sensor(FR) (If equipped) Suspension oil pressure sensor(RL) (If equipped) Suspension oil pressure sensor(RR) (If equipped) DT-T HD30 Terminal Terminal M M S-NET MS3102A 14S SP1 SP2 SPA1 SPA2 SPA3 SPL SPR SR2 SR3 SUFL SUFR SURL SURR T01 T02 PACKARD PACKARD DT-T DT-T DT-T YAZAKI YAZAKI X X DT-T DT-T DT-T DT-T DT-T DT-T Fuel level gauge sensor Retarder oil temperature sensor HD465-7. HD605-7 20-355 (10) .

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.exhaust temperature amp intermediate connector AU2 AO1 AV3 AP4 AP2 AP2 AM6 AN8 AN7 AR8 AQ7 AR8 AQ7 AN1 AM1 AU2 AQ6 E-5 A-7 E-6 A-6 A-7 A-7 B-4 B-2 B-2 J-2 J-2 J-2 J-2 B-4 B-8 H-8 I-8 HM-31 HM-35 HM50 HM55 Engine oil temperature sensor Ambient temperature sensor Short connector Short connector 20-355-1 (10) HD465-7. connector of pin T05 T1 TEST TG TG2 Terminal Terminal One-pin connector One-pin connector One-pin connector Address Location 3-dimensional wiring diagram ENG System diagram TM BK K-1 I-3 F-5 PLM MON VHMS ASR 1 1 1 1 1 3 21 31 2 3 6 8 6 6 12 2 2 Grounding Grounding TEST switch Tachograph Tachograph Timing rail actuator Intermediate connector Intermediate connector Transmission oil filter sensor Timing rail pressure sensor Brake lamp timer Intermediate connector Front wiper motor Front wiper relay Wiper switch Wheel speed sensor (RL) Wheel speed sensor (RR) I9 AC9 V8 S9 S9 AG9 AD8 AD8 J3 AI6 X7 C2 Q1 R1 Q8 K1 K1 C-1 D-1 H-5 H-5 I-9 TIMG PACKARD TM2 TM3 TMF TPR TR VHM WFM WFR WPS WSRL WSRR HD30 HD30 DT-T PACKARD J-4 — DT-T (Black) E-1 M Relay DT-T (Black) A-4 A-3 B-3 B-9 C-9 DT-T DT-T VHMS controller related CAN1 DLSW EG4 GDL GR1 GR2 HM-12 HM-21A HM-21B HM-22A HM-22B HM-23A HM-23B DT-T Terminal DT-T DT-T Terminal Terminal DT-T DT DT DT DT DT-T DT-T DT DT DT-T DT-T 3 1 12 12 1 1 3 2 2 2 2 3 3 2 2 3 3 VHMS intermediate connector Ground level download box VHMS intermediate connector Ground level download box intermediate connector Ground level download box Ground level download box Blow-by sensor Exhaust temperature sensor Exhaust temperature sensor Exhaust temperature sensor .amp intermediate connector Exhaust temperature sensor .amp intermediate connector VHMS .exhaust temperature amp intermediate connector VHMS . HD605-7 .

H-7 F-6. oil temperature sensor intermediate connector VHMS download connector Ground level download box HD465-7. H-6 E-5 C-6 C5 A-7 B-4 K-4 A-7 AT2 AQ2 AR2 AS8 AT7 AU7 AT8 AS8 AU7 AT8 AP3 AP3 AS2 AS2 AP2 AQ6 AV3 AU7 AV6 AO6 AO6 AP3 AM6 AT2 AP2 HM-2130 YAZAKI HM-2140 YAZAKI Resistor Resistor VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller Ground level download box lamp terminal Ground level download box lamp terminal HM-CN1 AMP070 HM-CN2A AMP070 HM-CN2B AMP070 HM-CN3A AMP070 HM-CN3B AMP070 HM-CN4A AMP070 HM-CN4B AMP070 LM1 LM2 ORB-A ORB-B Terminal Terminal AMP070 AMP070 MS MS MIC S MIC DT-T DT-T MS DT-T MS Terminal Orbcomm controller Orbcomm controller Ground level download box PLM connector PDL PLM PM1 PM4 PM11 SPA1 SPA2 VDL VHM VHMS WAKE PLM II download connector PLM II intermediate connector PLM II intermediate connector VHMS intermediate connector Ambient temperature sensor intermediate connector Ground level download box intermediate connector Ground level download box VHMS connector Blow-by. HD605-7 20-355-2 (10) . connector of pin HM81 M 8 2 2 20 18 12 18 12 14 10 1 1 14 10 5 5 21 16 21 4 12 5 8 5 1 Address Location VHMS .Orbcomm controller intermediate connector 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS ASR L-3 H-8 H-8 I-8 J-8 J-8 J-8 K-8 K-8 L-8 B-7 B-7 K-2 L-2 A-7 K-4 F-7.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ConType Numnector of ber No.

HD605-7 . connector of pin ABS ABS1 ABS1 ABS2 ABS2 ABS3 ABS3A ABS3B ABS4 ABS4 ABS5 ABS5A ABS6 ABS7 ABS8 ABSFL ABSFR ABSRL ABSRR BPFL BPFR BPRL BPRR BRC3B BRC4 BRC5A CHK CVF CVR CVSF CVSR DA1 FOGF FOGM J06 JABS RABS RABS2 S01F S01M S02F S02M WSFL WSFR WSRL2 WSRR2 M MIC DT-T MIC DT-T DT-T 040 040 040 DT-T DT 040 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T 040 040 040 Yazaki DT-T DT-T DT-T DT-T DT-T M M HD30 DT-T KES1 KES1 DT-T DT-T DT-T DT-T DT-T DT-T DT-T DT-T 6 17 6 21 8 6 20 16 12 6 6 20 6 6 6 2 2 2 2 3 3 3 3 16 12 20 6 2 2 3 3 2 12 6 6 31 12 6 6 3 3 3 3 2 2 2 2 Address Location ABS system switch ABS controller Joint connector ABS controller Joint connector Joint connector ABS controller ABS controller ABS controller Joint connector Joint connector ABS controller Joint connector Joint connector Joint connector ABS valve ABS valve ABS valve ABS valve Brake oil pressure Brake oil pressure Brake oil pressure Brake oil pressure Retarder controller Retarder controller Retarder controller System check switch ABS cut solenoid ABS cut solenoid ABS cut switch ABS cut switch Diode Machine monitor Fog lamp switch Fog lamp switch Intermediate connector Intermediate connector ABS cut relay ABS cut valve relay Service brake switch Service brake switch Secondary brake switch Secondary brake switch Wheel speed sensor Wheel speed sensor Wheel speed sensor Wheel speed sensor P1 C-1 A-6 F-1 Y4 Z4 Y1 J-9 C-1 A-5 A-5 A-4 D-1 H-1 3-dimensional wiring diagram ENG System diagram TM BK PLM MON VHMS ASR E-9 ABS BK7 BR3 BF9 BR3 BD2 BE2 BR8 BQ9 BR8 BE2 BF3 BR8 BG8 BH8 BE9 AX9 AX9 BH7 BF9 AW9 AX9 BH8 BG9 BO9 BP9 BQ9 BL8 AZ8 BG9 AY8 BH8 BE9 P1 BM1 BK8 BD1 BA9 BS7 BS7 BC1 AZ1 BC9 BC9 BC1 AY7 BG9 BF9 O2 DPC2B AMP070 20-355-3 (12) HD465-7.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS ABS control related Connec.Type Numtor of ber No.

HD605-7 .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION CONNECTOR ARRANGEMENT LOCATION 20-356 (5) HD465-7.

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION HD465-7. HD605-7 20-357 (5) .

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION 20-358 (1) HD465-7. HD605-7 .

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION HD465-7. HD605-7 20-359 (1) .

HD605-7 .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION 20-360 (1) HD465-7.

HD605-7 20-361 (1) .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION HD465-7.

HD605-7 .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION VHMS control related (1/2) 20-362 (2) HD465-7.

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION (2/2) HD465-7. HD605-7 20-363 (2) .

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION ABS control related (1/2) 20-364 (12) HD465-7. HD605-7 .

HD605-7 20-365 (12) .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION HD465-7.

HD605-7 .TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION (2/2) 20-366 (12) HD465-7.

TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION HD465-7. HD605-7 20-367 (12) .

............................ 20-412 [C117KX] Abnormally low level in timing rail pressure sensor system ........................................................... 20-406 [C111KT] Abnormality in engine controller memory ............................................ 20-432 [C261NS] Abnormal rise of fuel temperature .. 20-415 [C122KX] Abnormally high level in boost pressure sensor system ......................................................................................................................................... 20-424 [C148KX] Abnormality in FM throttle: Out of input signal range .. 20-439 [C431L4] Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed) . 20-422 [C143ZG] Lowering of engine oil pressure .................... 20-410 [C116KX] Abnormally high level in timing rail pressure sensor system ... 20-421 [C141KX] Abnormally low level in engine oil pressure sensor system ............................. 20-443 [C441KX] Abnormally low level in battery voltage system ............ 20-420 [C135KX] Abnormally high level in engine oil pressure sensor system .................................................................................................... 20-431 [C259FS] Abnormality in fuel shut-off valve .............................................................................................................................................................................................. 20-437 [C423L6] Abnormality in in-range of timing rail pressure sensor system .............................. HD605-7 20-401 (10) .................................................................................. 20-404 Information in troubleshooting table ....................................................................................................................................................... 20-408 [C113KZ] Abnormal current in timing rail actuator system ................................................................................................................................................................... 20-425 [C151NS] Rise of engine coolant temperature .................................... 20-446 [C452KX] Abnormally low level in fuel rail pressure sensor system .............................................. 20-445 [C442KG] Abnormally high level in battery voltage system ............. 20-430 [C234NI] Over-speed ........ 20-445 [C451KX] Abnormally high level in fuel rail pressure sensor system ............................... 20-430 [C254KZ] Abnormal voltage of fuel shut-off valve............................................................. 20-432 [C263KX] Abnormally high level in fuel temperature sensor system ....................................................................................... 20-422 [C144KX] Abnormally high level in engine coolant temperature sensor system .................... 20-447 [C455KZ] Abnormal current of fuel rail actuator ........................................................................................ 20-408 [C112LK] Abnormality in timing rail actuator ..................................... 20-409 [C115KZ] Abnormality in engine speed sensor 2 systems ............................................................................................................. 20-448 HD465-7.......................................... 20-433 [C265KX] Abnormally low level in fuel temperature sensor system .........................................................TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE) Electrical system diagram related engine control .. 20-426 [C153KX] Abnormally high level in air intake temperature sensor system ......................................... 20-423 [C145KX] Abnormally low level in engine coolant temperature sensor system .................................................................................... 20-414 [C119KX] Abnormally low level in fuel pump pressure sensor system ....................................... 20-427 [C154KX] Abnormally low level in air intake temperature sensor system ................. 20-413 [C118KX] Abnormally high level in fuel pump pressure sensor system ....................... 20-428 [C221KX] Abnormally high level in atmospheric pressure sensor system .............................................................................................................................................................................................................................................................................................. 20-434 [C316KZ] Abnormal current of fuel pump actuator ...................................................................................................................................................................................................... 20-418 [C132KX] Abnormally low level in throttle sensor system ............................................................ 20-415 [C121LC] Abnormality in engine speed sensor 1 systems ................................................. 20-435 [C318LK] Abnormality in fuel pump actuator ............................. 20-417 [C131KX] Abnormally high level in throttle sensor system ............................................................................................... 20-441 [C432L5] Error in idle validation process ( *See separate list (L5))..... 20-436 [C346KT] Abnormality in power-down unit of engine controller .................................................. 20-429 [C222KX] Abnormally low level in atmospheric pressure sensor system .................................................................. 20-416 [C123KX] Abnormally low level in boost pressure sensor system .................

............................................ HD605-7 ..................................... 20-451 [C554L6] Abnormality in in-range of fuel rail pressure sensor system .................................................................... 20-462 ENG-3 AISS function does not work normally ....................... 20-450 Abnormality in idle validation switch system: *See separate list (L4) (Either signal voltage of 2 systems is not sensed) ................................................................................. 20-459 b) Preheating is actuated even under non-actuation conditions for preheating..[C467LK] [C468LK] [C514LK] [C551L4] Abnormality in timing rail actuator control .............................................................. 20-459 a) Engine is not preheated.................................................................... LOW SPEED control is selected........ 20-465 20-402 (10) HD465-7.......................................... 20-464 a) When AISS switch is set in AUTO............................................ 20-449 Abnormality in fuel rail actuator control ............................................................ 20-449 Abnormality in fuel rail actuator ........................................................................................... 20-453 ENG-1 Engine does not start............................................................................................................................................. 20-464 b) When AISS switch is set in LOW SPEED.......... AUTO control is selected.............. 20-455 ENG-2 Failure in preheating ..........................................

TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL Engine serial No. : 310169 – 310414 20-404 (9) HD465-7. HD605-7 .

TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL HD465-7. HD605-7 20-405 (2) .

HD605-7 .TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL Engine serial No. : 310415 – 310798 20-405-1 (8) HD465-7.

TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL HD465-7. HD605-7 20-405-2 (8) .

: 310799 and up 20-405-3 (8) HD465-7. HD605-7 .TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL Engine serial No.

HD605-7 20-405-4 (8) .TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL HD465-7.

5 • Connect negative (–) lead to pin No. 4 • If connector No. has marks of "male" and "female". Action code Display on panel Failure code Controller code Display on panel Display on panel Trouble Trouble in machine Contents of trouble Contents of trouble detected by monitor panel or controller Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble or monitor panel Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment <Troubles in harness> • Disconnection Connector is connected imperfectly or harness is broken. • Connect positive (+) lead to pin No. • Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. • Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Short circuit Independent harnesses are in contact with each other abnormally. unless otherwise specified. unless otherwise specified. • If connector No. disconnect connector and insert T-adapters in both male side and female side. disconnect connector and connect T-adapter to only male side or female side. HD605-7 . has no marks of "male" and "female".TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting. and handling of T-adapter indicate priority) Insert or connect T-adapter as explained below for troubleshooting. 1 2 Possible causes Possible causes of trouble and standard value (Given numbers are refer<Precautions for troubleshooting> 3 in normal state ence numbers. 20-406 (10) HD465-7. which do not 1) Method of indicating connector No. or harness entered on rear side. Before carrying out troubleshooting. understand that information fully. 2) Entry order of pin Nos. or harness entered on front side.

Fill signal is OFF when command current to ECMV is ON. HD605-7 20-407 (10) . Fill signal is ON when command current to ECMV is OFF.TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE Related electrical circuit diagram Part of electric circuit diagram related to trouble • Connector No. etc. Fuel pressure is above maxim specified value. terminal C signal. Engine rotation signal. rpm signals in two systems are inconsistent. HD465-7. ON and OFF signals at two systems are inconsistent. Phenomenon code KA KB KK KQ KR KT KX KY KZ MA MB MW NS ZG ZK Contents Disconnection in wiring Short circuit Source voltage reduction/ input Type select signal inconsistency Defective communication Abnormality in controller Outside input signal range Short circuit with power source (Hot short) Disconnection or short circuit Malfunction Performance reduction Sliding Overheat Oil pressure reduction Coolant level reduction Phenomenon code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents Fill signals at two or more channels which are not set as combination are turned ON at the same time. PHENOMENON CODE TABLE a Regarding phenomenon code provided with instruction "Refer to table". are inconsistent with operation state or stop state. Switch is pressed for usually unthinkable long time. coolant temperature sensor signal. Analog signals in two systems are inconsistent. oil pressure switch signal.: Indicates (Model – Number of pins) and (Color). • Arrows ( ): Indicate rough location of connector in machine. Object part is uncontrollable. check it against table below.

Possible causes and standard value 3 Defective timing rail actuator Check timing rail actuator directly for defective operation. in normal state Clogging of timing rail actua4 Check timing rail actuator screen directly for clogging. appears on machine Related information • Method of reproducing failure code: Turn starting switch ON. 2) Run engine at low idle. troubleshooting cannot be carried out. 3) Check failure code. breakage. (Since trouble is in system. looseness. appears on machine Related information • Method of reproducing failure code: Start engine. engine controller may be defective. Cause Possible causes and standard value 1 Defective engine controller in normal state Standard value in normal state/Remarks on troubleshooting Reset according to following procedure. 1) Keep starting switch at OFF position for 5 seconds. Problem that • Engine speed lowers. looseness. engine controller is defective. [C112LK] ABNORMALITY IN TIMING RAIL ACTUATOR Action code E03 Failure code Controller code C112LK ENG Trouble Abnormality in timing rail actuator (Engine controller system) • Displayed fuel value of timing rail is excessively different from actual timing fuel.TROUBLESHOOTING [C111KT]. • Limits engine speed to 1. Clogging. Cause 1 Defective related systems Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. Action of controller • Flashes warning lamp and turns on alarm buzzer. HD605-7 .500 rpm. If code related to engine controller is displayed. carry out troubleshooting for it first. or leakage of fuel filter/ leakage. and 2 age. piping If causes 1 – 5 are not detected. breakCheck fuel filter/piping directly for clogging. tor screen 5 Breakage of injector O-ring 6 Defective engine controller Check injector O-ring directly for breakage. Action of controller • Flashes warning lamp and turns on alarm buzzer. [C112LK] [C111KT] ABNORMALITY IN ENGINE CONTROLLER MEMORY Action code E03 Failure code Controller code C111KT ENG Trouble Abnormality in engine controller memory (Engine controller system) Contents of trouble • Memory in controller has trouble or processor in controller has communication trouble. Contents of trouble • Judgment value (for reference): Error is above 400 mm3/st or below – 750 mm3/st (When coolant temperature is below 0°C).) 20-408 (10) HD465-7. If failure code E is displayed at this time. Problem that • Engine cannot be started.

TROUBLESHOOTING [C113KZ] [C113KZ] ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM Action code E03 Contents of trouble Failure code Controller code C113KZ ENG Trouble Abnormal current in timing rail actuator system (Engine controller system) • Current in timing rail actuator is out of normal range. • Engine output lowers. then carry out troubleshooting without turning starting switch ON. 1 M z it Wiring harness between ECMA (female) (20) – TIMG (female) (C) with wiring harness around Resistance Min. 1 M z it aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (1) – TIMG (female) (A) with wiring harness around Resistance Min.35 A (When engine is stopped) Action of controller • Flashes warning lamp and turns on alarm buzzer. 10 z TIMG (female) (C) aPrepare with starting switch OFF. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. 4 Defective engine controller ECMA (female) Between (1) – (20) Wiring harness between (1). then carry out troubleshooting without turning starting switch ON. 1 M z Circuit diagram related to timing rail actuator HD465-7. HD605-7 20-409 (11) . 1 Defective timing rail actuator (Internal trouble) TIMG (male) Between (A) – (C) Between (A). Problem that appears on machine • Exhaust gas becomes white. (20) – wiring harness around it Resistance 7–9z Min. ness Wiring harness between ECMA (female) (1) – 2 (Disconnection in wiring or Resistance Max.40 ± 0. 100 kz Possible causes and standard value in normal state aPrepare with starting switch OFF. • Method of reproducing failure code: Turn starting switch ON (or start engine). 10 z TIMG (female) (A) defective contact in connecWiring harness between ECMA (female) (20) – tor) Resistance Max. • Normal range (for reference): 0. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (C) – chassis ground Resistance 7–9z Min. Related information • Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.

1 Mz SP (female) (2) with wiring harness around it Wiring harness between ECMA (female) (28) – Resistance Min. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON Defective engine speed sen1 sor (Internal trouble) SP (male) Between (2) – (1) and (3) – (4) Between (2) – (3) Between (1) – (4) Between (2). 10 z SP (female) (2) Wiring harness between ECMA (female) (28) – Resistance Max. 10 z Min. ECMA (female) 5 Defective engine controller Between (27) – (28) Between (27). aPrepare with starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz SP (female) (3) with wiring harness around it Wiring harness between ECMA (female) (38) – Resistance Min. 1 Mz SP (female) (1) with wiring harness around it Wiring harness between ECMA (female) (37) – Resistance Min. 10 z SP (female) (3) Wiring harness between ECMA (female) (38) – Resistance Max. then carry out troubleshooting without turning starting switch ON. appears on machine • Inputting from engine speed sensor (rpm) can be checked in monitoring mode. (3) – chassis ground 2 Damage of engine speed sensor Check engine speed sensor directly. 10 Mz Possible causes and standard value in normal state 20-410 (10) HD465-7. Problem that • Engine stops. • Outputs speed signal of 0 rpm. (38) – chassis ground Resistance 1 – 2 kz Min. 10 z Max. 01002: Engine speed) Related information • Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor. Action of controller • Flashes warning lamp and turns on alarm buzzer. 1 Mz 1 – 2 kz Min. 10 z SP (female) (4) aPrepare with starting switch OFF. 10 z SP (female) (1) Wiring harness between ECMA (female) (37) – Resistance Max. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMA (female) (27) – Resistance Max. HD605-7 . (28) – chassis ground Between (37) – (38) Between (37). then start engine and carry out troubleshooting. (Code 01001.TROUBLESHOOTING [C115KZ] [C115KZ] ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS Action code E03 Failure code Controller code C115KZ ENG Trouble Abnormality in engine speed sensor 2 systems (Engine controller system) Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems. Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between ECMA (female) (27) – Resistance Min. • Method of reproducing failure code: Start engine. 1 Mz SP (female) (4) with wiring harness around it aPrepare with starting switch OFF. 1 Mz Resistance 1 – 2 kz Max.

HD605-7 20-411 (8) .TROUBLESHOOTING [C115KZ] Circuit diagram related to engine speed sensor HD465-7.

75 – 5. • Method of reproducing failure code: Start engine. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min.78 V.TROUBLESHOOTING [C116KX] [C116KX] ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM Action code E03 Failure code Controller code C116KX ENG Trouble Abnormally high level in timing rail pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4. Wiring harness between ECMA (female) (5) – Resistance Max. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5)– Resistance Min.25 V 0. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) – Resistance Max. Cause Defective timing rail pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. TPR Between (A) – (B) Between (C) – (B) Voltage 4. then carry out troubleshooting without turning starting switch ON. 1 Mz TPR (female) (C) with wiring harness around it aPrepare with starting switch OFF. HD605-7 . then turn starting switch ON and carry out troubleshooting. then turn starting switch ON and carry out troubleshooting.500 rpm. Related information • Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.58 V Possible causes and standard value in normal state Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) aPrepare with starting switch OFF. then its speed is set to Problem that appears on machine 1. • Limits engine speed to 1. • Flashes warning lamp and turns on alarm buzzer. Action of controller • Opens and controls timing rail.58 V Circuit diagram related to timing rail pressure 20-412 (11) HD465-7. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) – Resistance Min.25 V 0.75 – 5. 4 Defective engine controller ECMA Between (5) – (18) Between (33) – (18) Voltage 4.500 rpm. then carry out troubleshooting without turning starting switch ON. 10 z TPR (female) (C) aPrepare with starting switch OFF.42 – 0. • Engine makes abnormal combustion sound or discharges white smoke.42 – 0.

30 V • Flashes warning lamp and turns on alarm buzzer. • Engine makes abnormal combustion sound or discharges white smoke. HD605-7 20-413 (10) . Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C116KX].500 rpm. • Limits engine speed to 1. then its speed is set to Problem that appears on machine 1. Action of controller • Opens and controls timing rail.TROUBLESHOOTING [C117KX] [C117KX] ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM Action code E03 Failure code Controller code C117KX ENG Trouble Abnormally low level in timing rail pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.500 rpm. Related information • Method of reproducing failure code: Start engine. HD465-7.

10 z PMPR (female) (B) Wiring harness between ECMA (female) (32) – Resistance Max.78 V.58 V Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) aPrepare with starting switch OFF. • Opens and controls fuel pump. Wiring harness between ECMA (female) (5) – Resistance Max. then turn starting switch ON and carry out troubleshooting. Wiring harness between ECMA (female) (5) – PMPR (female) (A) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF.42 – 0.75 – 5. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.TROUBLESHOOTING [C118KX] [C118KX] ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM Action code E01 Failure code Controller code C118KX ENG Trouble Abnormally high level in fuel pump pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4. then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller ECMA (female) Between (5) – (18) Between (32) – (18) Resistance 4. Action of controller Problem that appears on machine Related information • Flashes warning lamp and turns on alarm buzzer. 10 z PMPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max.75 – 5.25 V 0. 10 z PMPR (female) (C) aPrepare with starting switch OFF.25 V 0.58 V Circuit diagram related to fuel pump pressure sensor 20-414 (11) HD465-7. • Method of reproducing failure code: Start engine. • Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.42 – 0. HD605-7 . 1 Mz it Wiring harness between ECMA (female) (32) – PMPR (female) (C) with wiring harness around Resistance Min. Cause Defective fuel pump pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz it Wiring harness between ECMA (female) (18) – PMPR (female) (B) with wiring harness around Resistance Min. PMPR (male) Between (A) – (B) Between (C) – (B) Voltage 4.

Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C115KZ]. HD605-7 20-415 (10) .TROUBLESHOOTING [C119KX]. Action of controller Problem that appears on machine • Flashes warning lamp and turns on alarm buzzer. • Opens and controls fuel pump. Related information • Method of reproducing failure code: Start engine. Possible causes and standard value in normal state HD465-7.30 V. Action of controller • Flashes warning lamp and turns on alarm buzzer. [C121LC] ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS Action code E01 Failure code Controller code C121LC ENG Trouble Abnormality in engine speed sensor 1 systems (Engine controller system) Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems. (Code 01001: Engine speed) • Method of reproducing failure code: Start engine. [C121LC] [C119KX] ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM Action code E01 Failure code Controller code C119KX ENG Trouble Abnormally low level in fuel pump pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0. Problem that appears on machine Related information • Inputting from engine speed sensor (rpm) can be checked in monitoring mode. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C118KX].

then turn starting switch ON and carry out troubleshooting. Cause Defective boost pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.72 V. then turn starting switch ON and carry out troubleshooting.42 – 0.42 – 0. 1 Mz it Wiring harness between ECMA (female) (35) – IMPR (female) (C) with wiring harness around Resistance Min. 1 Mz it aPrepare with starting switch OFF. • Method of reproducing failure code: Start engine. HD605-7 . Wiring harness between ECMA (female) (6) – Resistance Max. IMPR (male) Between (A) – (B) Between (C) – (B) Voltage 4. 10 z IMPR (female) (C) aPrepare with starting switch OFF.75 – 5. Wiring harness between ECMA (female) (6) – IMPR (female) (A) with wiring harness around Resistance Min. then carry out troubleshooting without turning starting switch ON. 10 z IMPR (female) (B) Wiring harness between ECMA (female) (35) – Resistance Max. exhaust gas color is bad. then carry out troubleshooting without turning starting switch ON.58 V Circuit diagram related to boost pressure sensor 20-416 (11) HD465-7.58 V Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) aPrepare with starting switch OFF. • Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor. 10 z IMPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max.75 – 5. 1 Mz it Wiring harness between ECMA (female) (17) – IMPR (female) (B) with wiring harness around Resistance Min.TROUBLESHOOTING [C122KX] [C122KX] ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM Action code E03 Action of controller • When machine is accelerated suddenly.25 V 0. Problem that appears on machine • Engine output rises. 4 Defective engine controller ECMA Between (6) – (17) Between (35) – (17) Voltage 4.25 V 0. Related information Failure code Controller code C122KX ENG Trouble Abnormally high level in boost pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.

HD605-7 20-417 (10) . appears on machine Related information • Method of reproducing failure code: Start engine.30 V.TROUBLESHOOTING [C123KX] [C123KX] ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM Action code E03 Action of controller Problem that • Engine output lowers. HD465-7. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C122KX]. Failure code Controller code C123KX ENG Trouble Abnormally low level in boost pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of boost pressure sensor circuit is below 0.

1 Mz harness around it aPrepare with starting switch OFF.0 kz aPrepare with starting switch OFF.80 V. Problem that • Engine output and speed rise suddenly. 10 z AS1 (female) (3) Wiring harness between ECMB (female) (11) – Resistance Max.0 kz 0. Short circuit in wiring harness 3 (with another wiring harness) Short circuit of wiring harness between ECMB (female) (26) – AS1 (female) (3) with wiring Resistance Min. Defective throttle potentiom1 eter (Internal trouble) AS1 (male) Between (3) – (1) Between (3) – (2) Between (2) – (1) Resistance 4.25 – 7. 10 z AS1 (female) (2) aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.30 – 4.TROUBLESHOOTING [C131KX] [C131KX] ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM Action code E03 Failure code Controller code C131KX ENG Trouble Abnormally high level in throttle sensor system (Engine controller system) Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is above 4. 10 z AS1 (female) (1) Wiring harness between ECMB (female) (29) – Resistance Max.80 V Possible causes and standard value in normal state 20-418 (10) HD465-7. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (29) – AS1 (female) (2) with wiring Resistance Min. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMB (female) (26) – Resistance Max.0 kz 0.0 – 6. • Keeps engine speed at constant level. 4 Defective engine controller ECMB Between (29) – (11) Voltage 0. then carry out troubleshooting without turning starting switch ON. appears on machine • Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode. then turn starting switch ON and carry out troubleshooting. HD605-7 .25 – 7. Action of controller • Flashes warning lamp and turns on alarm buzzer. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Related information (Code 31701: throttle potentiometer voltage) • Method of reproducing failure code: Turn starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 Mz harness around it Short circuit of wiring harness between ECMB (female) (11) – AS1 (female) (1) with wiring Resistance Min.

HD605-7 20-419 (1) .TROUBLESHOOTING [C131KX] Circuit diagram related to deceleration potentiometer HD465-7.

HD605-7 . • Keeps engine speed at constant level. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C131KX].30 V. Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that • Engine speed and output lower suddenly.TROUBLESHOOTING [C132KX] [C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM Action code E03 Failure code Controller code C132KX ENG Trouble Abnormally low level in throttle sensor system (Engine controller system) Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0. Related information (Code 31701: throttle potentiometer voltage) • Method of reproducing failure code: Turn starting switch ON. 20-420 (10) HD465-7. appears on machine • Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode.

then carry out troubleshooting without turning starting switch ON. • Method of reproducing failure code: Start engine. Short circuit of wiring harness between ECMA (female) (6) – OLPR (female) (A) with wiring Resistance Min. 1 Mz harness around it aPrepare with starting switch OFF. Problem that appears on machine Related information • Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor. 10 z OLPR (female) (B) Wiring harness between ECMA (female) (24) – Resistance Max. HD605-7 20-421 (10) . 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) – OLPR (female) (B) with wiring Resistance Min.TROUBLESHOOTING [C135KX] [C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM Action code E01 Failure code Controller code C135KX ENG Trouble Abnormally high level in engine oil pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of engine oil pressure sensor circuit is above 4.75 – 5. then turn starting switch ON and carry out troubleshooting.25 V 0.88 V.25 V 0.42 – 0.58 V Circuit diagram related to engine oil pressure sensor HD465-7. 10 z OLPR (female) (C) aPrepare with starting switch OFF. Action of controller • Flashes warning lamp and turns on alarm buzzer. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (24) – OLPR (female) (C) with wiring Resistance Min. OLPR Between (A) – (B) Between (C) – (B) Voltage 4.58 V aPrepare with starting switch OFF. Cause Defective engine oil pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 10 z OLPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max. then turn starting switch ON and carry out troubleshooting. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (6) – Resistance Max.75 – 5.42 – 0. 4 Defective engine controller ECMA Between (6) – (17) Between (24) – (17) Voltage 4. then carry out troubleshooting without turning starting switch ON.

20-422 (10) HD465-7. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C135KX]. carry out troubleshooting for it first.18 MPa {1. HD605-7 .000 rpm Action of controller • Limits fuel injection rate to 50% after 10 seconds.15 MPa {1.05 MPa {0. • Criterion (for reference): Max.5 kg/cm2} at 1. Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.09 MPa {0. 0. Carry out troubleshooting for failure codes [C135KX] and [C141KX].000 rpm Contents of trouble Max.500 rpm Max.TROUBLESHOOTING [C141KX].31 V. 0. 0. See Shop Manual for engine (170-3 Series).9 kg/cm2} at 1. 0.85 kg/cm2} at 1.800 rpm Max. Problem that appears on machine Related information • Method of reproducing failure code: Start engine. [C143ZG] [C141KX] ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM Action code E01 Failure code Controller code C141KX ENG Trouble Abnormally low level in engine oil pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.21 MPa {2.1 kg/cm2} at 2. 0. If code related to engine controller is displayed. Cause 1 Defective related systems Possible causes and standard value Defective engine oil presin normal state 2 sure sensor system 3 Defective engine Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. [C143ZG] LOWERING OF ENGINE OIL PRESSURE Action code E03 Failure code Controller code C143ZG ENG Trouble Lowering of engine oil pressure (Engine controller system) • Engine oil pressure sensor detected pressure lower than pressure set in controller.5 kg/cm2} at 600 rpm Max.

95 V. 10 z CLTP (female) (B) aPrepare with starting switch OFF. 10 z CLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. • Method of reproducing failure code: Start engine. then carry out troubleshooting without turning starting switch ON. Cause Defective engine coolant 1 temperature sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Action of controller • Flashes warning lamp and turns on alarm buzzer. 1 Mz harness around it aPrepare with starting switch OFF. 1 Mz harness around it Short circuit of wiring harness between ECMA (female) (17) – CLTP (female) (B) with wiring Resistance Min. 4 Defective engine controller ECMA (female) Between (22) – (17) Resistance 600 – 36 kz Circuit diagram related to engine coolant temperature sensor HD465-7. CLTP Between (A) – (B) Resistance 600 – 36 kz Possible causes and standard value in normal state aPrepare with starting switch OFF. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (22) – Resistance Max. Problem that appears on machine Related information • Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor. HD605-7 20-423 (10) . then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. Short circuit in wiring harness 3 (with another wiring harness) Short circuit of wiring harness between ECMA (female) (22) – CLTP (female) (A) with wiring Resistance Min.TROUBLESHOOTING [C144KX] [C144KX] ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C144KX ENG Trouble Abnormally high level in engine coolant temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4. then carry out troubleshooting without turning starting switch ON.

21 V. Problem that appears on machine Related information • Method of reproducing failure code: Start engine. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C144KX]. Action of controller • Flashes warning lamp and turns on alarm buzzer. 20-424 (10) HD465-7.TROUBLESHOOTING [C145KX] [C145KX] ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C145KX ENG Trouble Abnormally low level in engine coolant temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0. HD605-7 .

4) Connect the connector. 4 Engine controller defective • Check that the failure code disappears. aIf the failure code does not disappear. Wiring harness between ECMB (female) (17) – ATC3A (female) (5) Resistance between ECMB (female) (17). 1 Mz male) (5) – chassis ground 2 Possible causes and standard value in normal state Ground fault in wiring harness 1) Turn the starting switch OFF. 3) Insert T-adapter. HD605-7 20-425 (10) . 3) Connect T-adapter.500 rpm (Throttle: 35%). 2) Turn the starting switch ON. 2) Disconnect connectors ECMB and ATC3A. Disconnection in wiring har.TROUBLESHOOTING [C148KX] [C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE Action code E03 Failure code Controller code C148KX ENG Trouble Abnormality in FM throttle: Out of input signal range Contents of trouble • The frequency of the FM throttle is below 150 Hz or above 400 Hz. Frequency 170 – 380Hz Circuit diagram related to engine abnormality in FM throttle HD465-7. replace the engine controller. appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Off idle: 35%). 2) Disconnect connector ATC3A. 1 (Disconnection or defective Wiring harness between ECMB (female) (17) – contact) Resistance Max. Between ATC3A (male) (5) – chassis ground 1) Connect all the connectors.2) Disconnect connector ECM. 3 fective 5) Turn the starting switch ON. 10 z ATC3A (female) (5) 1) Turn the starting switch OFF. Problem that • The engine speed is kept at low idle or 1. ATC3A (feMin. • The throttle sensor signal is conformed to the idle validation switch (In idle: 0%. Action of controller • Flashes warning lamp and turns on alarm buzzer. Transmission controller de. ness 3) Connect T-adapter.

TROUBLESHOOTING [C151NS] [C151NS] RISE OF ENGINE COOLANT TEMPERATURE Action code E02 Contents of trouble Failure code Controller code C151NS ENG Trouble Rise of engine coolant temperature (Engine controller system) • Engine coolant temperature sensor detected temperature higher than temperature set in controller. • Criterion (for reference): Min. Problem that appears on machine Related information • Method of reproducing failure code: Start engine. HD605-7 . If code related to engine controller is 1 Defective related systems Possible causes displayed. and standard value Defective engine coolant in normal state 2 Carry out troubleshooting for failure codes [C144KX] and [C145KX]. Cause Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. 20-426 (10) HD465-7. temperature sensor system 3 Defective engine See Shop Manual for engine (170-3 Series). carry out troubleshooting for it first. 105°C Action of controller • Limits fuel injection rate to 50% after 10 seconds.

TROUBLESHOOTING [C153KX] [C153KX] ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C153KX ENG Trouble Abnormally high level in air intake temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4. then carry out troubleshooting without turning starting switch ON. 1 Mz it Wiring harness between ECMA (female) (17) – IMTP (female) (B) with wiring harness around Resistance Min. HD605-7 20-427 (10) . 1 Mz it aPrepare with starting switch OFF. 10 z IMTP (female) (B) aPrepare with starting switch OFF. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. 4 Defective engine controller ECMA (female) Between (23) – (17) Resistance 36 – 600 z Circuit diagram related to air intake temperature sensor HD465-7. • Method of reproducing failure code: Start engine. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (23) – IMTP (female) (A) with wiring harness around Resistance Min. Cause Defective air intake temper1 ature sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Action of controller • Flashes warning lamp and turns on alarm buzzer. Problem that appears on machine Related information • Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor. 10 z IMTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. then carry out troubleshooting without turning starting switch ON. IMTP (female) Between (A) – (B) Resistance 36 – 600 z Possible causes and standard value in normal state aPrepare with starting switch OFF.88 V. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (23) – Resistance Max.

Problem that appears on machine Related information • Method of reproducing failure code: Start engine.08 V. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C153KX]. HD605-7 . 20-428 (10) HD465-7. Action of controller • Flashes warning lamp and turns on alarm buzzer.TROUBLESHOOTING [C154KX] [C154KX] ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C154KX ENG Trouble Abnormally low level in air intake temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of air intake temperature sensor circuit is below 0.

1 Mz it aPrepare with starting switch OFF.42 – 0. then carry out troubleshooting without turning starting switch ON.25 V 0.75 – 5. 4 Defective engine controller ECMA Between (6) – (17) Between (34) – (17) Voltage 4. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (6) – Resistance Max. then carry out troubleshooting without turning starting switch ON. 1 Mz it Wiring harness between ECMA (female) (34) – AAPR (female) (C) with wiring harness around Resistance Min. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. HD605-7 20-429 (10) .TROUBLESHOOTING [C221KX] [C221KX] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM) Action code E03 Failure code Controller code C221KX ENG Trouble Abnormally high level in atmospheric pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is above 4. 10 z AAPR (female) (A) Wiring harness between ECMA (female) (17) – Resistance Max. 10 z AAPR (female) (B) Wiring harness between ECMA (female) (34) – Resistance Max.25 V 0. 1 Mz it Wiring harness between ECMA (female) (17) – AAPR (female) (B) with wiring harness around Resistance Min. Problem that appears on machine Related information • Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor. then turn starting switch ON and carry out troubleshooting AAPR Between (A) – (B) Between (C) – (B) Voltage 4. Wiring harness between ECMA (female) (6) – AAPR (female) (A) with wiring harness around Resistance Min. • Method of reproducing failure code: Turn starting switch ON. then turn starting switch ON and carry out troubleshooting.58 V Circuit diagram related to atmospheric pressure sensor HD465-7. 10 z AAPR (female) (C) aPrepare with starting switch OFF.78 V Action of controller • Flashes warning lamp and turns on alarm buzzer.42 – 0.58 V Defective atmospheric pres1 sure sensor (Internal trouble) aPrepare with starting switch OFF.75 – 5.

carry out troubleshooting for it first. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C221KX]. See Shop Manual for engine (170-3 Series). [C234NI] [C222KX] ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM Action code E03 Failure code Controller code C222KX ENG Trouble Abnormally low level in atmospheric pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V. Action of controller • Flashes warning lamp and turns on alarm buzzer.400 rpm Action of controller • Closes fuel rail actuator fully (Cuts out fuel). Cause Possible causes and standard value 1 Defective related systems in normal state 2 Defective engine Standard value in normal state/Remarks on troubleshooting Check displayed failure codes.TROUBLESHOOTING [C222KX] . • Criterion (for reference): Min. 2. 20-430 (10) HD465-7. Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON. Problem that appears on machine Related information • Method of reproducing failure code: Start engine. If code related to engine controller is displayed. HD605-7 . [C234NI] OVER-SPEED Action code E02 Contents of trouble Failure code Controller code C234NI ENG Trouble Over-speed (Engine controller system) • Engine speed sensor detected speed higher than speed set in controller.

appears on machine Related information • Method of reproducing failure code: Turn starting switch ON. 1 Defective fuel shut-off valve (Internal trouble) FSO (Valve side) Between (+) – (–) Between (+) – chassis ground Resistance 23 – 40 z 100 kz aPrepare with starting switch OFF. 10 z side) (–) – chassis ground and standard value in normal state aPrepare with starting switch OFF. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (30) – Resistance Max. then carry out troubleshooting without turning starting switch ON. HD605-7 20-431 (10) . Problem that • Engine stops. 10 z FSO (wiring harness side) (+) defective contact in connecWiring harness between FSO (wiring harness Possible causes tor) Resistance Max. Action of controller • Turns off power for fuel shut-off valve. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz around it aPrepare with starting switch OFF.Resistance Min. 1 Mz 3 ness around it (with another wiring harness) Wiring harness between FSO (wiring harness side) (–) – chassis ground with wiring harness Resistance Min. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. Short circuit in wiring harWiring harness between ECMA (female) (30) – ness FSO (wiring harness side) (+) with wiring har.TROUBLESHOOTING [C254KZ] [C254KZ] ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE Action code E03 Failure code Controller code C254KZ ENG Trouble Abnormal voltage of fuel shut-off valve (Engine controller system) Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6. 4 Defective engine controller ECMA Between (30) – chassis ground Resistance 23 – 40 z Circuit diagram related to fuel shut-off valve HD465-7.0 V (below 20 z).

Carry out troubleshooting for failure codes [C263KX] and [C264KX]. 20-432 (10) HD465-7.) [C261NS] ABNORMAL RISE OF FUEL TEMPERATURE Action code E02 Contents of trouble Failure code Controller code C261NS ENG Trouble Abnormal rise of fuel temperature (Engine controller system) • Fuel temperature sensor detected temperature lower than temperature set in controller. Possible causes Clogging. Problem that appears on machine Related information • Method of reproducing failure code: Start engine. Problem that • Engine cannot be stopped. appears on machine Related information • Method of reproducing failure code: Start engine. See Shop Manual for engine (170-3 Series). engine controller may be defective. looseness. If causes 1 – 4 are not detected. • Turns off power for fuel shut-off valve. carry out troubleshooting for it first.TROUBLESHOOTING [C259FS]. carry out troubleshooting for it first. If code related to engine controller is displayed. troubleshooting cannot be carried out. breakage. and 3 age. [C261NS] [C259FS] ABNORMALITY IN FUEL SHUT-OFF VALVE Action code E03 Failure code Controller code C259FS ENG Trouble Abnormality in fuel shut-off valve (Engine controller system) Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off). If code related to engine controller is displayed. 76°C Action of controller • Limits engine speed to 800 rpm after 30 seconds. Cause 1 Defective related systems Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. Action of controller • Flashes warning lamp and turns on alarm buzzer. Cause 1 Defective related systems Possible causes and standard value Defective fuel temperature in normal state 2 sensor system 3 Defective engine Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. looseness. HD605-7 . or leakage of fuel filter/ in normal state leakage. piping 4 Trouble in injector 5 Defective engine controller Check inside of injector directly. 2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly. (Since trouble is in system. breakand standard value Check fuel filter/piping directly for clogging. • Criterion (for reference): Min.

1 Mz it aPrepare with starting switch OFF. Problem that appears on machine Related information • Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor. 4 Defective engine controller ECMA (female) Between (26) – (17) Resistance 600 – 36 kz Circuit diagram related to fuel temperature sensor HD465-7.95 V. ness 2 (Disconnection in wiring or Wiring harness between ECMA (female) (26) – Resistance Max. then carry out troubleshooting without turning starting switch ON. Cause Defective fuel temperature 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz it Wiring harness between ECMA (female) (17) – FLTP (female) (B) with wiring harness around Resistance Min. 10 z FLTP (female) (B) aPrepare with starting switch OFF. FLTP (female) Between (A) – (B) Resistance 600 – 36 kz Possible causes and standard value in normal state aPrepare with starting switch OFF. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (26) – FLTP (female) (A) with wiring harness around Resistance Min. Action of controller • Flashes warning lamp and turns on alarm buzzer. HD605-7 20-433 (10) .TROUBLESHOOTING [C263KX] [C263KX] ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C263KX ENG Trouble Abnormally high level in fuel temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. then carry out troubleshooting without turning starting switch ON. • Method of reproducing failure code: Turn starting switch ON. 10 z FLTP (female) (A) defective contact in connecWiring harness between ECMA (female) (17) – tor) Resistance Max. then carry out troubleshooting without turning starting switch ON.

21 V. Action of controller • Flashes warning lamp and turns on alarm buzzer. 20-434 (10) HD465-7. HD605-7 . Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.TROUBLESHOOTING [C265KX] [C265KX] ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM Action code E01 Failure code Controller code C265KX ENG Trouble Abnormally low level in fuel temperature sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel temperature sensor circuit is below 0. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C263KX].

then carry out troubleshooting without turning starting switch ON. Problem that appears on machine Related information • Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.TROUBLESHOOTING [C316KZ] [C316KZ] ABNORMAL CURRENT OF FUEL PUMP ACTUATOR Action code E01 Contents of trouble Failure code Controller code C316KZ ENG Trouble Abnormal current of fuel pump actuator (Engine controller system) • Current of fuel pump actuator circuit is out of normal range. 1 Defective fuel pump actuator (Internal trouble) PUMP (male) Between (A) – (C) Between (A). 10 z PUMP (female) (C) aPrepare with starting switch OFF. (40) – another wiring harness Resistance 7–9z Min. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 10 z PUMP (female) (A) defective contact in connecWiring harness between ECMA (female) (40) – tor) Resistance Max. • Method of reproducing failure code: Start engine. then carry out troubleshooting without turning starting switch ON. (C) – chassis ground Resistance 7–9z Min. 4 Defective engine controller ECMA (female) Between (11) – (40) Between (11). then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. 1 Mz it aPrepare with starting switch OFF. 1 Mz Circuit diagram related to fuel pump actuator HD465-7. Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (11) – PUMP (female) (A) with wiring harness around Resistance Min. 1 Mz it Wiring harness between ECMA (female) (40) – PUMP (female) (C) with wiring harness around Resistance Min.35 A (When engine is stopped) Action of controller • Flashes warning lamp and turns on alarm buzzer. ness Wiring harness between ECMA (female) (11) – 2 (Disconnection in wiring or Resistance Max.40 ± 0. then carry out troubleshooting without turning starting switch ON. • Normal range (for reference): 0. 100 kz Possible causes and standard value in normal state aPrepare with starting switch OFF. HD605-7 20-435 (10) .

tor Defective electric system of Carry out troubleshooting for failure codes [C118KX] and [C119KX]. Clogging. piping 3 Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. (Since trouble is in system. Check fuel filter directly. Check it directly.TROUBLESHOOTING [C318LK] [C318LK] ABNORMALITY IN FUEL PUMP ACTUATOR Action code E01 Contents of trouble Failure code Controller code C318LK ENG Trouble Abnormality in fuel pump actuator (Engine controller system) • Displayed pressure of fuel pump is excessively different from actual value. If code related to engine controller is displayed.) 7 Trouble in injector 8 Defective engine controller Circuit diagram related to fuel pump actuator 20-436 (10) HD465-7.1 kg/cm2} (when coolant temperature is 38°C) Action of controller • Flashes warning lamp and turns on alarm buzzer. engine controller may be defective. If causes 1 – 6 are not detected. looseness. 2 age. Check it directly.21 MPa {2. breakCheck fuel filter and piping directly for clogging. • Criteria for difference (for reference): ±0. or leakage of fuel filter/ and leakage. Problem that • Engine speed is unstable. Cause 1 Defective related systems Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. troubleshooting cannot be carried out. looseness. Suction resistance of fuel filter may be large. Negative suction pressure (Tank side) 27 kPa {203 mmHg} Possible causes and standard value Large suction resistance of 4 in normal state fuel filter 5 6 Trouble in fuel pump actuaFuel pump actuator may malfunction. HD605-7 . If fuel level fuel level in tank gauge is in red range. fuel pump pressure sensor Inside of injector may be defective. supply fuel. carry out troubleshooting for it first. breakage. appears on machine Related information • Method of reproducing failure code: Start engine.

1 Mz around it aPrepare with starting switch OFF. FS1-4) Standard value in normal state/Remarks on troubleshooting If fusible link is broken. then turn starting switch ON and carry out troubleshooting. current controller information. 5 Defective engine controller ECMA. aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. (5) – BT2-(30) outlet Resistance Max. 10 z BT2-(6) outlet Wiring harness between ECMA (female) (4). If fuse is broken. • Power-down data (maintenance information.TROUBLESHOOTING [C346KT] [C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER Action code E03 Failure code Controller code C346KT ENG Trouble Abnormality in power-down unit of engine controller (Engine controller system) Contents of trouble • Data recorded in power-down unit of engine controller has error. (8) Voltage 17. Cause 1 Defective fusible link (34 A) 2 Defective fuse (FS1-1. engine operating hours.3 – 34. Wiring harness between ECMB (female) (3) – Resistance Min. Action of controller • Flashes warning lamp and turns on alarm buzzer. (5) – ECMA (7). 10 z (FUA) – battery relay terminal B aPrepare with starting switch OFF. 1 Mz BT2-(6) outlet with wiring harness around it Wiring harness between ECMA (female) (4).7 V HD465-7. (Code: 04301) • Method of reproducing failure code: Turn starting switch ON. Related information • Charge level of battery can be checked in monitoring mode. (5) – BT2-(30) outlet with wiring harness around it Resistance Min. HD605-7 20-437 (10) . Problem that appears on machine etc. 1 Mz Wiring harness between FS1 inlet – fusible link – battery relay terminal B with wiring harness Resistance Min. 10 z Possible causes and standard value in normal state Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between FS1 inlet – fusible link Resistance Max. (4). circuit probably has short circuit with chassis ground. ECMB Between ECMB (3).) are lost. circuit probably has short circuit with chassis ground. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between ECMB (female) (3) – Resistance Max. then carry out troubleshooting without turning starting switch ON.

HD605-7 .TROUBLESHOOTING [C346KT] Circuit diagram related to engine controller power supply 20-438 (1) HD465-7.

HD605-7 20-439 (11) . then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller ECMA (female) Between (5) – (18) Between (33) – (18) Resistance 4.58 V aPrepare with starting switch OFF. Check fuel filter directly. 2. Action of controller Problem that appears on machine Related information • Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.58 V HD465-7.42 MPa {24. Cause Defective timing rail pres1 sure sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.65 kg/cm2} when starting switch is turned on • Flashes warning lamp and turns on alarm buzzer.75 – 5. 10 z TPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max.75 – 5. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) – Resistance Max.42 – 0. TPR (male) Between (A) – (B) Between (C) – (B) Voltage 4. then carry out troubleshooting without turning starting switch ON.25 V 0.25 V 0. Negative suction pressure (Tank side) 27 kPa {203 mmHg} aPrepare with starting switch OFF. • Method of reproducing failure code: Turn starting switch ON. then turn starting switch ON and carry out troubleshooting.500 rpm. 1 Mz TPR (female) (C) with wiring harness around it 4 Large suction resistance of fuel filter Suction resistance of fuel filter may be large.TROUBLESHOOTING [C423L6] [C423L6] ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM Action code E03 Contents of trouble Failure code Controller code C423L6 ENG Trouble Abnormality in in-range of timing rail pressure sensor system (Engine controller system) • Timing rail pressure sensor detected abnormal pressure. Wiring harness between ECMA (female) (5) – Resistance Min. 1 Mz TPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (33) – Resistance Min. 10 z TPR (female) (B) Wiring harness between ECMA (female) (33) – Resistance Max. • Criterion (for reference): Min. 1 Mz TPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. then carry out troubleshooting without turning starting switch ON. 10 z TPR (female) (C) aPrepare with starting switch OFF. • Limits high idle speed to 1.42 – 0.

HD605-7 .TROUBLESHOOTING [C423L6] Circuit diagram related to timing rail pressure sensor 20-440 (1) HD465-7.

Wiring harness between ECMB (female) (12) – Resistance Max. 3) Connect T-adapter. 100 z Press the accelerator pedal Resistance Min. 1 Mz Between AS1 (male) (4) – (6) Press the accelerator pedal Resistance Max. 1) Turn the starting switch OFF. AS1 (female) Min. 2) Disconnect connectors ECMB and AS1. 3) Press the accelerator pedal 3 times repeatedly. Release the accelerator pedal "Idle ON". 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max. CHECK/REPAIR. HD605-7 20-441 (10) . • Check that the failure code disappears. 3) Connect T-adapter. 2) Disconnect connectors ECMB and AS1. 2) Turn the starting switch ON. Problem that appears on machine no problems appear in the truck body.TROUBLESHOOTING [C431L4] [C431L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (BOTH SIGNAL VOLTAGES OF 2 SYSTEMS ARE SENSED) Action code E01 Failure code Controller code C431L4 ENG Trouble Abnormality in idle validation switch system: *See separate list (L4) (Both signal voltages of 2 systems are sensed) Contents of trouble • Both idle validation switch signals 2 and 3 are open (above 4. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) – Resistance Max. a If the failure code does not disappear. Related information Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Action of controller • (The controller displays action code E01. 1 Mz (4) – chassis ground Possible causes and standard value in normal state 3 Ground fault in wiring harness 4 Engine controller defective 1) Connect the all connectors. 1 Mz (5) – chassis ground Resistance between ECMB (female) (21). Disconnection in wiring har. 1 M z (6) – chassis ground Resistance between ECMB (female) (13). Resistance Max. replace the engine controller.5 V). AS1 (female) Min. AS1 (female) Min. Between AS1 Idle validation switch defec(male) (4) – (5) 1 tive Release the accelerator pedal "Idle ON". Wiring harness between ECMB (female) (12) – AS1 (female) (6) Wiring harness between ECMB (female) (13) – AS1 (female) (5) Wiring harness between ECMB (female) (21) – AS1 (female) (4) Resistance between ECMB (female) (12). HD465-7. 100 z "Idle OFF". 3) Connect T-adapter.) • None in particular. Resistance Min. 2) Disconnect connector AS1. (Since the controller controls according to the throttle sensor signal (potentiometer). 1 Mz "Idle OFF". 1 z AS1 (female) (4) 1) Turn the starting switch OFF.

HD605-7 .TROUBLESHOOTING [C431L4] Circuit diagram related to engine idle validation switch 20-442 (10) HD465-7.

Wiring harness between ECMB (female) (12) – AS1 (female) (6) Wiring harness between ECMB (female) (13) – AS1 (female) (5) Wiring harness between ECMB (female) (21) – AS1 (female) (4) Resistance between ECMB (female) (12). Release the accelerator pedal "Idle ON".TROUBLESHOOTING [C432L5] [C432L5] ERROR IN IDLE VALIDATION PROCESS ( *SEE SEPARATE LIST (L5)) Action code E03 Contents of trouble Failure code Controller code C432L5 ENG Error in idle validation process: *See separate list (L5) Trouble (Potentiometer signal and switch signal do not agree with each other) • The throttle potentiometer signal of the accelerator pedal is not conformed to idle validation switch signal 2 and signal 3. AS1 (female) Min. AS1 (female) Min.75V HD465-7. HD605-7 20-443 (10) . 1 z AS1 (female) (4) 1) Turn the starting switch OFF.55V 3. • Flashes warning lamp and turns on alarm buzzer. Resistance Max. 3) Connect T-adapter. 3) Connect T-adapter. appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. • The throttle is conformed to the idle validation switch (In idle: 0%. 1 Mz "Idle OFF". 3) Connect T-adapter.35 – 0.55 – 3. 100 z Press the accelerator pedal Resistance Min. 1 Mz (5) – chassis ground Resistance between ECMB (female) (21). 3) Connect T-adapter. Problem that • The engine speed is kept at low idle or 1. Between AS1 (male) (1) – (2) Release the accelerator pedal "Idle ON". 100 z "Idle OFF".500 rpm (Throttle: 35%). Action of controller • If this failure is detected when the throttle sensor signal is on the low speed side (idle side). Between AS1 Idle validation switch defec(male) (4) – (5) 1 tive Release the accelerator pedal "Idle ON". 1) Turn the starting switch OFF. 1 Mz Between AS1 (male) (4) – (6) Press the accelerator pedal Resistance Max. AS1 (female) Min. 1 M z (6) – chassis ground Resistance between ECMB (female) (13). 2) Disconnect connector AS1. 2) Disconnect connectors ECMB and AS1. Resistance Min. the throttle is conformed to the throttle sensor. Disconnection in wiring har. 5) Startin switch ON. 1 z AS1 (female) (5) Possible causes and standard value in normal state Wiring harness between ECMB (female) (21) – Resistance Max. Off idle: 35%). 2) Disconnect connectors ECMB and AS1. Press the accelerator pedal "Idle OFF". 4) Connect connector.Wiring harness between ECMB (female) (12) – Resistance Max. Voltage Voltage 0. 1 Mz (4) – chassis ground 3 Ground fault in wiring harness 4 Slottle sensor defective 1) Turn the starting switch OFF. 2) Disconnect connector AS1. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max.

TROUBLESHOOTING [C432L5] Cause Possible causes and standard value 5 Engine controller defective in normal state Standard value in normal state/Remarks on troubleshooting 1) Connect the all connectors. a If the failure code does not disappear. 3) Press the accelerator pedal 3 times repeatedly. 2) Turn the starting switch ON. HD605-7 . Circuit diagram related to engine idle validation process 20-444 (10) HD465-7. replace the engine controller. • Check that the failure code disappears.

HD605-7 20-445 (10) . Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT].TROUBLESHOOTING [C441KX]. Failure code Controller code C442KG ENG Trouble Abnormally low level in battery voltage system (Engine controller system) Contents of trouble • Voltage of controller power supply circuit is below 38 V. [C442KG] [C441KX] ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM Action code E01 Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON. Failure code Controller code C441KX ENG Trouble Abnormally low level in battery voltage system (Engine controller system) Contents of trouble • Voltage of controller power supply circuit is below 12 V. HD465-7. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C346KT]. [C442KG] ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM Action code E01 Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Turn starting switch ON.

1 Mz RPR (female) (C) with wiring harness around it aPrepare with starting switch OFF. • Method of reproducing failure code: Start engine. 4 Defective engine controller ECMA Between (5) – (18) Between (31) – (18) Voltage 4. then turn starting switch ON and carry out troubleshooting.75 – 5.42 – 0. • Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. then turn starting switch ON and carry out troubleshooting.78 V. • Opens and controls fuel rail.TROUBLESHOOTING [C451KX] [C451KX] ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM Action code E03 Failure code Controller code C451KX ENG Trouble Abnormally high level in fuel rail pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is above 4. HD605-7 .58 V aPrepare with starting switch OFF. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max.25 V 0. Action of controller Problem that appears on machine Related information • Flashes warning lamp and turns on alarm buzzer. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min.58 V Circuit diagram related to fuel rail pressure sensor 20-446 (10) HD465-7. Wiring harness between ECMA (female) (5) – Resistance Min.42 – 0. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) – Resistance Max. 10 z RPR (female) (C) aPrepare with starting switch OFF. RPR Between (A) – (B) Between (C) – (B) Voltage 4. then carry out troubleshooting without turning starting switch ON.75 – 5. Cause Defective fuel rail pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.25 V 0. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) – Resistance Min. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) – Resistance Max. then turn starting switch ON and carry out troubleshooting.

TROUBLESHOOTING [C452KX] [C452KX] ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM Action code E03 Failure code Controller code C452KX ENG Trouble Abnormally low level in fuel rail pressure sensor system (Engine controller system) Contents of trouble • Signal voltage of fuel rail pressure sensor circuit is below 0. HD465-7. HD605-7 20-447 (10) . Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C451KX]. • Reduces current for fuel rail actuator to 0 A.15 V. Action of controller Problem that appears on machine • Flashes warning lamp and turns on alarm buzzer. Related information • Method of reproducing failure code: Start engine.

TROUBLESHOOTING [C455KZ] [C455KZ] ABNORMAL CURRENT OF FUEL RAIL ACTUATOR Action code E03 Contents of trouble Failure code Controller code C455KZ ENG Trouble Abnormal current of fuel rail actuator (Engine controller system) • Current of fuel rail actuator circuit is out of normal range. HD605-7 . 10 z RAIL (female) (C) Short circuit in wiring harness 3 (with another wiring harness) aPrepare with starting switch OFF. Wiring harness between ECMA (female) (3) – Resistance Min. then carry out troubleshooting without turning starting switch ON.40 ± 0. Action of controller Problem that appears on machine Related information • Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator. ness Wiring harness between ECMA (female) (3) – Resistance Max. 4 Defective engine controller ECMA (female) Between (3) – (10) Between (3). • Limits engine speed to 1. • Normal range (for reference): 0. 1 Mz RAIL (female) (A) with wiring harness around it Wiring harness between ECMA (female) (10) – Resistance Min. 1 Mz Circuit diagram related to fuel rail actuator 20-448 (10) HD465-7. 10 z 2 (Disconnection in wiring or RAIL (female) (A) defective contact in connecWiring harness between ECMA (female) (10) – tor) Resistance Max. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (10) – another wiring harness Resistance 7–9z Min. (C) – chassis ground Resistance 7–9z Min. 1 Defective fuel rail actuator (Internal trouble) RAIL (male) Between (A) – (C) Between (A). then carry out troubleshooting without turning starting switch ON. 100 kz Possible causes and standard value in normal state aPrepare with starting switch OFF. • Method of reproducing failure code: Turn starting switch ON or start engine.35 A (When engine is stopped) • Flashes warning lamp and turns on alarm buzzer. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. 1 Mz RAIL (female) (C) with wiring harness around it aPrepare with starting switch OFF.500 rpm.

Check it directly. carry out troubleshooting for it first. troubleshooting cannot be carried out. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C112LK]. Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Start engine. [C468LK] ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL Action code E03 Contents of trouble Failure code Controller code C468LK ENG Trouble Abnormality in fuel rail actuator control (Engine controller system) • Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be obtained. Check it directly. • Flashes warning lamp and turns on alarm buzzer. Possible causes and standard value 3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. If code related to engine controller is displayed. engine controller may be defective. looseness. • Limits engine speed to 1. breakage.) HD465-7. Check it directly.500 rpm. • Flashes warning lamp and turns on alarm buzzer. looseness. Cause 1 Defective related systems Standard value in normal state/Remarks on troubleshooting Check displayed failure codes. • Limits maximum injection rate to 217 mm3/st. Clogging.TROUBLESHOOTING [C467LK]. piping If causes 1 – 5 are not detected. HD605-7 20-449 (10) . [C468LK] [C467LK] ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL Action code E03 Contents of trouble Failure code Controller code C467LK ENG Trouble Abnormality in timing rail actuator control (Engine controller system) • Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot be obtained. (Since trouble is in system. Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Start engine. in normal state Clogging of fuel rail actuator 4 Fuel rail actuator screen may be clogged. or leakage of fuel filter/ leakage. breakCheck fuel filter/piping directly for clogging. screen 5 Breakage of injector O-ring 6 Defective engine controller Injector O-ring may be broken. and 2 age.

Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for failure code [C468LK]. HD605-7 . • Limits maximum injection rate to 217 mm3/st. Action of controller Problem that appears on machine Related information • Method of reproducing failure code: Start engine. 20-450 (10) HD465-7. • Flashes warning lamp and turns on alarm buzzer. • Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.TROUBLESHOOTING [C514LK] [C514LK] ABNORMALITY IN FUEL RAIL ACTUATOR Action code E03 Contents of trouble Failure code Controller code C514LK ENG Trouble Abnormality in fuel rail actuator (Engine controller system) • Displayed injection rate of fuel rail is excessively different from actual injection rate.

Disconnection in wiring har. 1 Mz (4) – chassis ground Possible causes and standard value in normal state 3 Ground fault in wiring harness 4 Engine controller defective 1) Connect the all connectors. 1 Mz (5) – chassis ground Resistance between ECMB (female) (21). 2) Disconnect connectors ECMB and AS1. 1 z AS1 (female) (4) 1) Turn the starting switch OFF. HD465-7.TROUBLESHOOTING [C551L4] [C551L4] ABNORMALITY IN IDLE VALIDATION SWITCH SYSTEM: *SEE SEPARATE LIST (L4) (EITHER SIGNAL VOLTAGE OF 2 SYSTEMS IS NOT SENSED) Action code E01 Failure code Controller code C551L4 ENG Trouble Abnormality in idle validation switch system: *See separate list (L4) (Either signal voltage of 2 systems is not sensed) Contents of trouble • Both of idle validation switch signals 2 and 3 are closed (connected to GND).Wiring harness between ECMB (female) (12) – Resistance Max. 100 z "Idle OFF". appears on machine Related information Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. replace the engine controller. 1 Mz Between AS1 (male) (4) – (6) Press the accelerator pedal Resistance Max. 2) Disconnect connector AS1. 1 Mz "Idle OFF". Wiring harness between ECMB (female) (12) – AS1 (female) (6) Wiring harness between ECMB (female) (13) – AS1 (female) (5) Wiring harness between ECMB (female) (21) – AS1 (female) (4) Resistance between ECMB (female) (12). 3) Connect T-adapter. 1) Turn the starting switch OFF. 3) Press the accelerator pedal 3 times repeatedly. • Check that the failure code disappears. Problem that • Engine speed is kept at low idle. Action of controller • Flashes warning lamp and turns on alarm buzzer. Resistance Min. 1 M z (6) – chassis ground Resistance between ECMB (female) (13). AS1 (female) Min. • Controller sets engine speed to low idle. 3) Connect T-adapter. Release the accelerator pedal "Idle ON". Between AS1 Idle validation switch defec(male) (4) – (5) 1 tive Release the accelerator pedal "Idle ON". 100 z Press the accelerator pedal Resistance Min. 3) Connect T-adapter. 2) Turn the starting switch ON. AS1 (female) Min. 1 z ness AS1 (female) (6) 2 (Disconnection or defective Wiring harness between ECMB (female) (13) – contact) Resistance Max. 1 z AS1 (female) (5) Wiring harness between ECMB (female) (21) – Resistance Max. Resistance Max. AS1 (female) Min. a If the failure code does not disappear. 2) Disconnect connectors ECMB and AS1. HD605-7 20-451 (10) .

HD605-7 .TROUBLESHOOTING [C551L4] Circuit diagram related to idle validation switch 20-452 (10) HD465-7.

• Criterion (for reference): Min. • Method of reproducing failure code: Turn starting switch ON. Check fuel filter directly. 1 Mz RPR (female) (A) with wiring harness around it Wiring harness between ECMA (female) (18) – Resistance Min. 1 Mz RPR (female) (C) with wiring harness around it 4 Large suction resistance of fuel filter Suction resistance of fuel filter may be large. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON.75 – 5.75 – 5. 1 Mz RPR (female) (B) with wiring harness around it Wiring harness between ECMA (female) (31) – Resistance Min. • Limits maximum injection rate to 270 mm3/st Action of controller Problem that appears on machine Related information • Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor. RPR Between (A) – (B) Between (C) – (B) Voltage 4.42 – 0.25 V 0. Cause Defective fuel rail pressure 1 sensor (Internal trouble) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.58 V aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller ECMA Between (5) – (18) Between (31) – (18) Voltage 4.17 MPa {1.58 V HD465-7. 10 z RPR (female) (A) Wiring harness between ECMA (female) (18) – Resistance Max. HD605-7 20-453 (11) . Negative suction pressure (Tank side) 27 kPa {203 mmHg} aPrepare with starting switch OFF. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Short circuit in wiring harness 3 (with another wiring harness) Wiring harness between ECMA (female) (5) – Resistance Max. then turn starting switch ON and carry out troubleshooting.76 kg/cm2} when starting switch is turned on • Flashes warning lamp and turns on alarm buzzer. Wiring harness between ECMA (female) (5) – Resistance Min. 10 z RPR (female) (B) Wiring harness between ECMA (female) (31) – Resistance Max.25 V 0.42 – 0. 10 z RPR (female) (C) aPrepare with starting switch OFF.TROUBLESHOOTING [C554L6] [C554L6] ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM Action code E03 Contents of trouble Failure code Controller code C554L6 ENG Trouble Abnormality in in-range of fuel rail pressure sensor system (Engine controller system) • Fuel rail pressure sensor detected abnormal pressure. 0.

HD605-7 .TROUBLESHOOTING [C554L6] Circuit diagram related to fuel rail pressure sensor 20-454 (1) HD465-7.

TROUBLESHOOTING ENG-1 ENG-1 ENGINE DOES NOT START Action code Not set Failure code Controller code Not set ENG Trouble Engine does not start Contents of trouble • Engine does not start. 2) Replace R02 with normal one. Diode (D01) is defective. perform troubleshooting for it first. Do not apply voltage between (1) – (2). is failure repaired? Yes 1) Turn the starting switch OFF. Diode (D01) is normal. Problem that • Engine does not start. 3) Check R01. 2) Disconnect connector R02. is failure repaired? 1) Turn the starting switch OFF. When transmission neutral relay (R02) is replaced. 3) Turn the starting switch ON. 3) Turn the starting switch ON. Between R02 (male) (3) – (6) Apply 24 V between (1) – (2). 2) Disconnect connector R01. Failure is not repaired. 3) Check R02. 3) Check R01. Cause 1 Battery defective Standard value in normal state/Remarks on troubleshooting Specific gravity Voltage 1) Turn the starting switch OFF. 2) Disconnect connector R01. appears on machine Related information • If any failure code related to the engine controller or transmission controller is indicated. 1 z Relay (R01) normal Relay (R01) defective Min. Between R01 (male) (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF.26 Min. When engine starting relay (R01) No is replaced. 3) Turn the starting switch to the START position. 2) Replace diode (D01). 25 V 2 Engine starting relay (R01) defective Possible causes and standard value in normal state 1) Turn the starting switch OFF. 1 Mz Resistance Max. Resistance Min. 1 Mz Resistance Max. 2) Replace R01 with normal one. 2) Disconnect connector R02. 4) Apply voltage between R02 (male) (1) – (2). HD465-7. Resistance Min. HD605-7 20-455 (10) . Do not apply voltage between (1) – (2). Between R01 (male) (3) – (6) Apply 24 V between (1) – (2). 4) Apply voltage between R01 (male) (1) – (2). Action of controller • None in particular. 1. 1 z No Yes Relay (R02) normal Relay (R02) defective 3 Transmission neutral relay (R02) defective 4 Diode (D01) defective 1) Turn the starting switch OFF. Between R02 (male) (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF. 3) Check R02. Failure is repaired.

HD605-7 . Failure is repaired. 03 (B). Diode (D01) is defective. diode (D01). 3) Turn the starting switch to the START position. 02 (M). – chassis ground 9 1) Turn the starting switch ON. 3) Turn the starting switch ON. 12 V nal R (on the harness side). 2) Disconnect the negative (-) terminal of the battery relay. 2) Replace diode (D01). Disconnection of wiring har. 12 V 10 Diode (D08) defective Diode (D08) is normal. and starting motor terminal R. 20 – 30 V Possible causes and standard value in normal state 7 Diode (D01) defective 8 Hot short in wiring harness of starting motor terminal R Wiring harness between diode (D01). alternator terminal R. 02 (M). 03 (B). Wiring harness between batVoltage between battery tertery – battery terminal 01 minal 01 (B). Failure is not repaired. 5 ness between battery relay and related wiring harness Wiring harness between bat.Wiring harness between bat6 ness related to starting mo. Max. 04 (M) Max.Resistance between battery tery relay terminal 02 (M). starting motor termiMax. Wiring harness between the negative (-) termiResistance Max. Disconnection in wiring har. – alternator terminal R 1) Turn the starting switch OFF.2) Disconnect fuse BT3 terminal (9) – battery relay terminal 02 (M) and 04 (M). 1 z nal of the battery relay – chassis ground 1) Turn the starting switch to the START position. 3) Turn the starting switch to the START position. Diode (D08) is defective. and 04 and 04 (M) – chassis ground (M) 1) Turn the starting switch OFF. Alternator (Regulator) defecVoltage between starting motor terminal R – chassis tive ground 1) Turn the starting switch OFF. 20 – 30 V (B). 1 z (M) – fuse BT3 (9) – fuse BT3 (10) 1) Turn the starting switch OFF.TROUBLESHOOTING ENG-1 Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch ON. 2) Replace diode (D08). Voltage between diode (D01). Failure is not repaired. 04 relay terminal 02 (M). 2) Disconnect connector ATC3B. Diode (D01) is normal.tery relay terminal 02 (M). starting motor terminal R. 04 Voltage between starting motor terminal B – chassis tor terminal B (M) – starting motor terminal ground B 1) Turn the starting switch OFF. Failure is repaired. 20-456 (10) HD465-7.

12 (BR) Resistance between starting switch terminal B – battery Max. battery relay terminal 14 (BR). 1 z Max. 1 z 15 Starting motor defective • If the check result of the starting motor is normal. 3) Connect T-adapter.2) Disconnect connector R02 and S2 (connector of shift lever side).(female) (2).TROUBLESHOOTING ENG-1 Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 z Wiring harness between Resistance between R02 R02 (female) (2). ness (Disconnection or defective 13 contact) • Wiring harness related to transmission neutral relay (R02) Wiring harness between R02 (female) (1) – S2 (female) (4) Resistance between R02 (female) (1) – S2 (female) (4) Max. (3) – chassis sis ground ground 1) Disconnect the starting switch terminals. HD605-7 20-457 (10) .Max. Turn the starting switch to the START position. 2) Check the starting switch. 1) Check the starting motor. 1 z relay terminal 14 (BR). 2) Disconnect connectors R01 and R02. 1 z 1) Turn the starting switch OFF. Resistance between terminals B – C Max. HD465-7. Disconnection in wiring harness Possible causes (Disconnection or defective and standard value 12 contact) in normal state • Wiring harness related to engine starting relay (R01) Wiring harness between Resistance between fuse fuse BT3 terminal (10) – R01 BT3 terminal (10) – R01 (fe. and starting switch terminals BR and C. Disconnection in wiring har. 3) Connect T-adapter. (3) – chas.Max. the starting motor is normal. fuse BT3 terminal (10). 1 z relay terminal 01 (B) and 03 (B) Resistance between starting switch terminal BR – battery Max. Wiring harness between starting switch terminal C – R01 (female) (3) Resistance between starting switch terminal C – R01 (fe.battery relay terminals 01 (B) and 03 (B). and starting motor terminal S. ness 11 (Disconnection or defective contact) • Wiring harness related to starting switch Wiring harness between starting switch terminal BR – battery relay terminal 14 (BR). 2) Disconnect connector R01. 12 (BR) aMeasure at starting switch terminal BR (+ side of tester) with a tester in the diode range. Wiring harness between starting switch terminal B – Disconnection in wiring har. 12 (BR). 1 z (female) (1) male) (1) Wiring harness between R01 (female) (2) – R02 (female) (6) Wiring harness between R01 (female) (6) – starting motor terminal S Resistance between R01 (female) (2) – R02 (female) (6) Resistance between R01 (female) (6) – starting motor terminal S Max. 1 z male) (3) 1) Turn the starting switch OFF. 1 z 14 Starting switch defective Max.

HD605-7 .TROUBLESHOOTING ENG-1 Circuit diagram related to engine does not start 20-458 (1) HD465-7.

Relay (R37) is defective. 1 z Resistance Min.2) Replace diode (E17A. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 3) Check the heater. When the automatic preheater relay (R37) is replaced. is failure repaired? 1) Turn the starting switch OFF. E17B) defec. Between E11A – chassis ground Between E12A – opposite Intake air heater relay defec. perform troubleshooting for it. Failure is repaired.27z Possible causes and standard value in normal state 3 Automatic preheater relay (R37) defective 1) Turn the starting switch OFF. 3) Turn the starting switch ON. 2) Replace R37 with a normal relay. E11B. 2) Disconnect connectors E11A. HD465-7. 2) Disconnect connector R37. Between R37 (male) (3) – (6) Apply 24 V between (1) – (2). E12A. Problem that • Engine is not preheated.terminal of relay switch 1 tive When relay is ON When relay is OFF When relay is ON When relay is OFF Resistance 19 – 25 z Resistance Max. Diode (E17A. 4 tive Failure is not repaired. 2) Disconnect the heater terminal. 3) Check connector R37. appears on machine Related information • If any failure code related to the engine controller or transmission controller is indicated.TROUBLESHOOTING ENG-2 ENG-2 FAILURE IN PREHEATING a) Engine is not preheated Action code Not set Failure code Controller code Not set ENG Trouble 1.17 – 0. Do not apply voltage between (1) – (2). (Engine coolant temperature is below 0°C. 3) Check the disconnected connectors. 1 Mz Between E11B – chassis ground Between E12B – opposite terminal of relay switch 2 Intake air heater (Ribbon heater) defective 1) Turn the starting switch OFF. 1M z Resistance 19 – 25 z Resistance Max. 1 z Resistance Min. Diode (D01) is normal. and E12B. Diode (D01) is defective. Between heater terminal – chassis ground 1) Turn the starting switch OFF. 3) Check connector R37. 1M z Resistance Max. Between R37 (male) (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF. 1 z No Yes Relay (R37) is normal. 4) Apply voltage between R37 (male) (1) – (2).) Action of controller • None in particular. E17B). Resistance Min. 2) Disconnect connector R37. Resistance 0. HD605-7 20-459 (10) . Failure in preheating a) Engine is not preheated Contents of trouble • Engine is not preheated.

E11B Max. 1 z Wiring harness between Resistance between fuse fuse BT4 terminal (4) – R37 BT4 terminal (4) – R37 (fe(female) (3) male) (3) Wiring harness between bat. 1 z Max. 3) Insert T-adapter. E12B – E12A. 1 z Max. 0°C Between At the heater operation ECMA (2) – (7). 2) Disconnect connector ECMA. Wiring harness between ECMA (female) (2) – R37 (female) (1) Resistance between ECMA (female) (2) – R37 (female) (1) Resistance between R37 (female) (2) – chassis ground Resistance between R37 (female) (5) – E11A. 4) Connect the connector. E12A. E11B Max.Resistance between battery tery relay terminal 02 (M).R37 (female) (2) – chassis ness ground 5 (Disconnection or defective Wiring harness between contact) R37 (female) (5) – E11A. 2) Disconnect connectors ECMA. 1 z Possible causes and standard value in normal state Wiring harness between Disconnection in wiring har. 04 relay terminal 02 (M).TROUBLESHOOTING ENG-2 Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. E12B 1) Turn the starting switch OFF. 1 V 20-460 (10) HD465-7. 3) Connect T-adapter. HD605-7 . E11A. 6) Engine coolant temperature: Max. R37. and fuse BT4 terminal (4). 5) Turn the starting switch ON. E11B. 1 z 6 Engine controller defective 20 – 30V Max. (8) At the heater un operation Voltage Voltage Max. 04 (M) (M) – E12A. E12B.

TROUBLESHOOTING ENG-2 Circuit diagram related to preheating HD465-7. HD605-7 20-461 (1) .

Between E11A – chassis ground Between E12A – opposite Intake air heater relay defec.TROUBLESHOOTING ENG-2 b) Preheating is actuated even under non-actuation conditions for preheating Action code Not set Failure code Controller code Not set ENG Failure in preheating Trouble b) Preheating is actuated even under non-actuation conditions for preheating Contents of trouble • Preheating is actuated even under non-actuation conditions for preheating. appears on machine Related information • If any failure code related to the engine controller or transmission controller is indicated. 1 V Measure only on E12A side for wiring harness marked with (a). E11B – chassis ground Voltage between AC5A (female) (20). 1 z Resistance Min. HD605-7 . 1 Mz Resistance 19 – 25 z Resistance Max. perform troubleshooting for it. 6) Engine coolant temperature: Max. 1 V Max. 1 V Max. 3) Insert T-adapter. 4) Connect the connector. E11B. 0 °C Between At the heater operation ECMA (2) – (7). and E12B. 3) Connect T-adapter. 2) Disconnect the connector. Problem that • Preheating is actuated even under non-actuation conditions for preheating. HES – chassis ground Max. 1 Mz Between E11B – chassis ground Between E12B – opposite terminal of relay switch Possible causes and standard value in normal state 2 Hot short in wiring harness 1) Turn the starting switch OFF. 1) Turn the starting switch OFF. 4) Turn the starting switch ON. 1 V 3 Engine controller defective 20-462 (10) HD465-7. E11A. 5) Turn the starting switch ON.terminal of relay switch 1 tive When relay is ON When relay is OFF When relay is ON When relay is OFF Resistance 19 – 25 z Resistance Max. (8) At the heater un operation Voltage Voltage 20 – 30V Max. Wiring harness between ECMA (female) (2) – R37 (female) (1) Wiring harness between R37 (female) (5) – E11A. 2) Disconnect connector ECMA. Action of controller • None in particular. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connectors E11A. 1 z Resistance Min. 3) Check the disconnected connectors. E12A. E11B Wiring harness between AC5A (female) (20) – HES (a ) Voltage between ECMA (female) (2). R37 (female) (1) – chassis ground Voltage between R37 (female) (5).

HD605-7 20-463 (1) .TROUBLESHOOTING ENG-2 Circuit diagram related to preheating time HD465-7.

3) Connect T-adapter. 1 z Set the AISS switch in LOW. Resistance Min. LOW SPEED control is selected Action code Not set Failure code Controller code Not set Not set When AISS switch is operated. Between ECMB Set the AISS switch in AUTO.TROUBLESHOOTING ENG-3 ENG-3 AISS FUNCTION DOES NOT WORK NORMALLY a) When AISS switch is set in AUTO. 4) Apply voltage between R07 (male) (1) – (2). 1 z R07 (female) (1) Wiring harness between R07 (female) (2) – chassis ground 1) Turn the starting switch OFF. 2) Replace R07 with normal one. LOW SPEED control is selected Contents of trouble • When AISS switch is set in AUTO. When AISS relay (R07) is replaced. LOW SPEED control is selected Action of controller • None in particular. 3) Turn the starting switch ON. 3) Insert T-adapter. Resistance Min. 4) Connect the connector. – fuse BT2 terminal (2). R07. 3) Check the relay Between R07 (male) (1) – (2) Resistance 200 – 400 z 1) Turn the starting switch OFF. Problem that • When AISS switch is set in AUTO. Disconnection in wiring har. HD605-7 . 2) Disconnect connector R07. (33) – chassis ground Set the AISS switch in LOW. 3) Check the relay. 2) Disconnect connector AISS. Do not apply 24 V between (1) – (2). is failure corrected? 1) Turn the starting switch OFF. 1 Mz Resistance Max. Between R07 (male) (3) – (6) Apply 24 V between (1) – (2). 1 z ness (female) (1) 3 (Disconnection or defective Wiring harness between AISS (female) (2) – contact) Resistance Max. 1 Mz 1 AISS switch defective 1) Turn the starting switch OFF. 2) Disconnect connector R07. 3) Check the connector. AISS function does not work normally Trouble a) When AISS switch is set in AUTO. Between AISS (male) (1) – (2) Set the AISS switch in AUTO Resistance Max. 1 z No Yes Relay (R07) is normal Relay (R07) is defective 2 AISS relay (R07) defective Possible causes and standard value in normal state 1) Turn the starting switch OFF. 2) Disconnect connectors AISS.Wiring harness between fuse BT2 (2) – AISS Resistance Max. 2) Disconnect connector ECMB. 5) Turn the starting switch ON. LOW SPEED control is selected appears on machine Related information • Failure code is not indicated. 1 z 4 Engine controller defective 20-464 (10) HD465-7. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Voltage Voltage 20 – 30 V Max. 1 V Resistance Max.

1 Mz Resistance Max. Resistance Min. AUTO control is selected Contents of trouble • When AISS switch is set in LOW SPEED. R07 (female) (6) (33) – R07 (female) (6) – chassis ground Resistance Max. 3 (Disconnection or defective Wiring harness between R07 (female) (3) – contact) chassis ground 1) Turn the starting switch OFF. 3) Check the relay Between R07 (male) (1) – (2) Possible causes and standard value in normal state Resistance 200 – 400 z 1) Turn the starting switch OFF. 1 z No Yes Relay (R07) is normal Relay (R07) is defective 2 AISS relay (R07) defective 1) Turn the starting switch OFF. 1 z Set the AISS switch in LOW Resistance Min. 2) Replace R07 with normal one. HD605-7 20-465 (10) . 1 V HD465-7.TROUBLESHOOTING ENG-3 b) When AISS switch is set in LOW SPEED.2) Disconnect connector R07. Problem that • When AISS switch is set in LOW SPEED. AISS function does not work normally Trouble b) When AISS switch is set in LOW SPEED. 1 V Voltage Max. 3) Connect T-adapter. 3) Turn the starting switch ON. Wiring harness beWiring harness between AISS (female) tween AISS (female) (2). AUTO control is selected Action of controller • None in particular. 1 z 4 Hot short in wiring harness Voltage Max. 2) Disconnect connector R07. 2) Disconnect connector R07. 3) Check the connector. AUTO control is selected Action code Not set Failure code Controller code Not set Not set When AISS switch is operated. AUTO control is selected appears on machine Related information • Failure code is not indicated. Between AISS (male) (1) – (2) Set the AISS switch in AUTO Resistance Max. R07 (female) (1) – (2) – R07 (female) (1) chassis ground Wiring harness beWiring harness between ECMB (female) tween ECMB (female) (33). 2) Disconnect connectors AISS and R07. 4) Apply voltage between R07 (male) (1) – (2). 2) Disconnect connector AISS. Between R07 (male) (3) – (6) Apply 24 V between (1) – (2). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Mz 1 AISS switch defective 1) Turn the starting switch OFF. Disconnection in wiring har. ness 3) Connect T-adapter. When AISS relay (R07) is replaced. Do not apply 24 V between (1) – (2). is failure corrected? 1) Turn the starting switch OFF. 3) Check the relay.

5) Turn the starting switch ON. 2) Disconnect connector ECMB. HD605-7 . Voltage Voltage 20 – 30 V Max. 4) Connect the connector. 3) Insert T-adapter. (33) – chassis ground Set the AISS switch in LOW. auto control 20-466 (1) HD465-7.TROUBLESHOOTING ENG-3 Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Between ECMB Set the AISS switch in AUTO. 1 V Possible causes and standard value 5 Engine controller defective in normal state Circuit diagram related to low speed.

................................. 20-535 [989A00] Engine overrun prevention command signal: Operation (00) .............................................................................................. 20-524 [15SEL1] 1st clutch solenoid: *See separate list (L1) ............................................. 20-519 [15SBMA] R clutch solenoid: Malfunction (MA) ................................................. 20-547 [DAQ1KK] Main power line of transmission controller: Lowering of source/input voltage (KK) ...................................................................................... 20-505 [1380MW] Lockup clutch: Slip (MW)............................................................... 20-525 [15SEMA] 1st clutch solenoid: Malfunction (MA). 20-546 [DAQ0KK] Transmission controller: Lowering of source/input voltage (KK) ............ 20-528 [15SGL1] 3rd clutch solenoid: *See separate list (L1) ................................................................. 20-510 [15H0MW] Hi clutch: Slip (MW) .......................... 20-554 [DAQ9KQ] Transmission controller wiring harness: Disagreement of model selection signals (KQ) ............................................................................... 20-527 [15SFMA] 2nd clutch solenoid: Malfunction (MA)........................................................................................................ grounding fault...... 20-533 [15SJMA] Lockup clutch solenoid: 15SJ (MA) ......................................................................................................................................................................................... 20-530 [15SHL1] 4th clutch solenoid: *See separate list (L1) ................................................................................................................................................... 20-520 [15SCL1] Hi clutch solenoid: *See separate list (L1)........................................... 20-507 [15B0NX] Clogging of transmission oil filter: Clogging (NX) ............................................ 20-517 [15N0MW] 4th clutch: Slip (MW) ....................................................................... 20-503 Information in troubleshooting table ............................................................................................................... 20-556 [DAQSMA] Transmission controller: Malfunction (MA) ......... 20-506 [1500L0] Detection of double engagement: *See separate list (L0) ....................................................................................................................................................................................... 20-516 [15M0MW] 3rd clutch: Slip (MW) .. 20-526 [15SFL1] 2nd clutch solenoid: *See separate list (L1) ............................. 20-511 [15J0MW] Lo clutch: Slip (MW) . 20-556 HD465-7................................................ 20-521 [15SCMA] Hi clutch solenoid: Malfunction (MA) ...................................................................................... 20-541 [B@BCZK] Lowering of radiator water: Lowering of level (ZK) ............................................................................................................ or short circuit in engine output mode command line: Disconnection or short circuit (KZ) ................................................................ 20-509 [15G0MW] R clutch: Slip (MW)................................................................. 20-537 [989AKZ] Engine overrun prevention command signal: Disconnection or short circuit (KZ) .... 20-534 [2F00KM] Parking brake: Mistake in operation or setting (KM)....................................................................................................................................... HD605-7 20-501 (10) ........... 20-515 [15L0MW] 2nd clutch: Slip (MW) .............................................................................................................................. 20-532 [15SJL1] Lockup clutch solenoid: 15SJ (L1)............................................................................................................................................................................ 20-555 [DAQAKQ] Transmission controller rotary switch: Disagreement of model selection signals (KQ) ................................................................................................................................. 20-543 [D1BOKZ] Transmission controller cutout: Disconnection or short circuit (KZ) ................................................................................ 20-553 [DAQ9KM] Transmission controller wiring harness: Mistake in operation or setting (KM) ............................. 20-544 [D5ZMKZ] Disconnection.......................................... 20-551 [DAQ3KK] Direct line of transmission controller battery: Lowering of source/input voltage (KK) ................ 20-513 [15K0MW] 1st clutch: Slip (MW)................................ 20-539 [AB00MA] Alternator: Malfunction (MA)... 20-508 [15E0KM] R to F gear shift abuse 1: Mistake in operation or setting (KM) ............................................................................................... 20-529 [15SGMA] 3rd clutch solenoid: Malfunction (MA) ................ 20-518 [15SBL1] R clutch solenoid: *See separate list (L1).............................................................................................................................TROUBLESHOOTING FOR TRANSMISSION CONTROLLER SYSTEM (TM MODE) Electrical system diagram related to transmission control ............................ 20-504 Phenomenon code table ....................... 20-531 [15SHMA] 4th clutch solenoid: Malfunction (MA).................................................. 20-549 [DAQ2KK] Transmission controller load power line: Lowering of source/input voltage (KK) ....................................... 20-538 [AA10NX] Air cleaner element: Clogging (NX) ... 20-523 [15SDMA] Lo clutch solenoid: Malfunction (MA)......................................................................... 20-509 [15E7KM] R to F gear shift abuse 2: Mistake in operation or setting (KM) .................... 20-522 [15SDL1] Lo clutch solenoid: *Seee separate list (L1) ...........................................................................................

............. 20-606 Short circuit in output circuit of 4th clutch solenoid: Short circuit (KB) . 20-584 Transmission intermediate shaft speed sensor: Disconnection (KA) ........ 20-565 Shift lever: Short circuit (KB) ........................................................................ 20-583 Transmission input shaft speed sensor: *See separate list (LC) .................... 20-595 Short circuit in output circuit of Lo clutch solenoid: Short circuit (KB) .................... 20-581 Engine speed sensor: *See separate list (LC) .TROUBLESHOOTING TESTING AND ADJUSTING INVERTED TYPE REAR SUSPENSION CYLINDER [DDTGKA] [DDTHKA] [DDTJKA] [DDTKKA] [DDTLKA] [DDTMKA] [DDTNKA] [DDTPKA] [DF10KA] [DF10KB] [DGF1KX] [DGT1KX] [DHT5KX] [DHT5L6] [DJF1KA] [DK11KX] [DLE2KA] [DLE2LC] [DLF1KA] [DLF1LC] [DLF2KA] [DLF2LC] [DLT3KA] [DLT3LC] [DXH1KA] [DXH1KB] [DXH2KA] [DXH2KB] [DXH3KA] [DXH3KB] [DXH4KA] [DXH4KB] [DXH5KA] [DXH5KB] [DXH6KA] [DXH6KB] [DXH7KA] [DXH7KB] [DXHHKA] [DXHHKB] TM-1 TM-2 Lockup clutch fill switch: Disconnection (KA) ............. 20-592 Short circuit in output circuit of Hi clutch solenoid: Short circuit (KB) ... HD605-7 ................. 20-588 Disconnection in output circuit of lockup clutch solenoid: Disconnection (KA) ......................................... 20-577 Fuel level sensor: Disconnection (KA) ....................................... 20-569 Transmission valve oil temperature sensor: Out of input signal range (KX) ...... 20-602 Short circuit in output circuit of 3rd clutch solenoid: Short circuit (KB) ........................................................ 20-590 Short circuit in output circuit of lockup clutch solenoid: Short circuit (KB) .......... 20-560 2nd clutch fill switch: Disconnection (KA) ............. 20-578 Throttle angle sensor: Out of input signal range (KX) ......................................................................................................................................... 20-603 Disconnection in output circuit of R clutch solenoid: Disconnection (KA) ............ 20-557 Hi clutch fill switch: Disconnection (KA)........................... 20-593 Disconnection in output circuit of Lo clutch solenoid: Disconnection (KA) .................................... 20-596 Disconnection in output circuit of 1st clutch solenoid: Disconnection (KA) ........ 20-599 Disconnection in output circuit of 2nd clutch solenoid: Disconnection (KA) . 20-604 Short circuit in output circuit of R clutch solenoid: Short circuit (KB) ..................................................................................................................... 20-609 b) Backup lamp is not turned ON (Backup buzzer is normal)........................................... 20-559 1st clutch fill switch: Disconnection (KA) ................................................................................. 20-574 Torque converter oil pressure sensor: Out of input signal range (KX) ............ 20-610 c) Backup buzzer is not turned ON (Backup lamp is normal) . 20-585 Transmission intermediate shaft speed sensor: *See separate list (LC) .......................................................................................................................................................... 20-558 Lo clutch fill switch: Disconnection (KA) ........................................................................................................................... backup lamp and backup buzzer are turned ON ..................................................................................................................... 20-587 Transmission output shaft speed sensor: *See separate list (LC) .... 20-562 R clutch fill switch: Disconnection (KA) .................... 20-609 a) When the shift lever is set in the "R" position............................................ 20-610 d) While shift lever is not operated..................................................................................... 20-579 Engine speed sensor: Disconnection (KA) ................................................................................................................................................................................................ 20-572 Torque converter oil temperature sensor: Out of inputsignal range (KX) ..................... 20-611 20-502 (2) HD465-7............................................ 20-564 Shift lever: Disconnection (KA) ...................................................... 20-605 Disconnection in output circuit of 4th clutch solenoid: Disconnection (KA) ........................................................... 20-607 Fuel level gauge does not operate normally (It always indicates "FULL") .. 20-586 Transmission output shaft speed sensor: Disconnection (KA) ............................................. 20-563 4th clutch fill switch: Disconnection (KA) ....... 20-608 Abnormality in backup lamp and backup buzzer .............. the backup lamp and backup buzzer are not turned ON........... 20-575 Torque converter oil pressure sensor: See separate list (L6) ................................................................................................. 20-598 Short circuit in output circuit of 1st clutch solenoid: Short circuit (KB) ......................................................................................... 20-561 3rd clutch fill switch: Disconnection (KA).............................. 20-582 Transmission input shaft speed sensor: Disconnection (KA) ........................................ 20-591 Disconnection in output circuit of Hi clutch solenoid: Disconnection (KA) .................................. 20-600 Short circuit in output circuit of 2nd clutch solenoid: Short circuit (KB) .. 20-601 Disconnection in output circuit of 3rd clutch solenoid: Disconnection (KA) ............

HD605-7 20-503 (2) .TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL a For details of this page. HD465-7. see page 90-19.

• Ground fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. and handling of T-adapter indicate priority) Insert or connect T-adapter as explained below for troubleshooting. which do not 1) Method of indicating connector No. 5 • Connect negative (–) lead to pin No. 20-504 (10) HD465-7.TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. disconnect connector and insert T-adapters in both male side and female side. disconnect connector and connect T-adapter to only male side or female side. 1 2 Possible causes Possible causes of trouble and standard value (Given numbers are refer<Precautions for troubleshooting> 3 in normal state ence numbers. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting. • Short circuit Independent harnesses are in contact with each other abnormally. Before carrying out troubleshooting. 4 • If connector No. or harness entered on rear side. • If connector No. HD605-7 . • Connect positive (+) lead to pin No. has marks of "male" and "female". understand that information fully. unless otherwise specified. Action code Display on panel Failure code Controller code Display on panel Display on panel Trouble Trouble in machine Contents of trouble Contents of trouble detected by monitor panel or controller Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble Problem that Problem that appears on machine as result of action taken by monitor panel or controller (shown above) appears on machine Related information Information related to detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment <Troubles in harness> • Disconnection Connector is connected imperfectly or harness is broken. 2) Entry order of pin Nos. has no marks of "male" and "female". or harness entered on front side. • Short circuit with power source (Hot short) Harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. unless otherwise specified.

Analog signals in two systems are inconsistent. are inconsistent with operation state or stop state. PHENOMENON CODE TABLE a Regarding phenomenon code provided with instruction "Refer to table". Engine rotation signal.TROUBLESHOOTING PHENOMENON CODE TABLE Related electrical circuit diagram Part of electric circuit diagram related to trouble • Connector No. etc. ON and OFF signals at two systems are inconsistent. coolant temperature sensor signal.: Indicates (Model – Number of pins) and (Color). Phenomenon code KA KB KK KQ KR KT KX KY KZ MA MB MW NS ZG ZK Contents Disconnection in wiring Short circuit Source voltage reduction/ input Type select signal inconsistency Defective communication Abnormality in controller Outside input signal range Short circuit with power source (Hot short) Disconnection or short circuit Malfunction Performance reduction Sliding Overheat Oil pressure reduction Coolant level reduction Phenomenon code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents Fill signals at two or more channels which are not set as combination are turned ON at the same time. Fill signal is ON when command current to ECMV is OFF. Fill signal is OFF when command current to ECMV is ON. Object part is uncontrollable. rpm signals in two systems are inconsistent. Switch is pressed for usually unthinkable long time. oil pressure switch signal. Fuel pressure is above maxim specified value. terminal C signal. check it against table below. HD605-7 20-505 (10) . • Arrows ( ): Indicate rough location of connector in machine. HD465-7.

Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 31609. • If the shift lever is set in the "N" position. and DL**LC.3) Connect T-adapter. 31619). fill switch is ON. sensor 1) Turn the starting switch OFF. Action of controller • The lockup operation is reset and the gear cannot be shifted. Related information • If the electric system is normal. transmission intermediate shaft speed sensor. and transmission output shaft speed sensor is abnormal. the machine cannot start until it is stopped. 1 z CN20 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 2) Disconnect connector ATC2. Problem that appears on machine • If the shift lever is set in the "N" position. Lockup clutch ECMV defec. Disconnection in wiring har. Transmission controller de. the value calculated from the signals of the engine speed sensor. 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) – Resistance Max. 4 fective Wiring harness between ATC2 (female) (10) – Resistance 5 – 15 z ATC2 (female) (20) Related electrical circuit diagram 20-506 (10) HD465-7. transmission input shaft speed sensor. (2) – chassis ground Resistance Min. the controller keeps the gear in Neutral.3) Connect T-adapter. 2) Disconnect connector ATC2 and CN10.3) Connect T-adapter. and slip is sensed) • When a signal is output to the lockup clutch ECMV.TROUBLESHOOTING [1380MW] [1380MW] LOCKUP CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 1380MW TM Lockup clutch: Slip (MW) Trouble (Command is Holding pressure. 2) Disconnect connector CN20. check the hydraulic/mechanical system of the lockup clutch and pres- sure control valve for a defect. • This failure can be checked in the monitoring function (Code: 31519. • The controller keeps the current gear speed and turns the lockup operation OFF. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) – Resistance Max. 1 tive Between CN20 (male) (1) – (2) Resistance 5 – 15 z Between CN20 (male) (1). 1 Mz 1) Turn the starting switch OFF. HD605-7 .

fective HD465-7. in normal state Transmission controller de2 • Perform troubleshooting by the indicated failure code.TROUBLESHOOTING [1500L0] [1500L0] DETECTION OF DOUBLE ENGAGEMENT: *SEE SEPARATE LIST (L0) Action code E03 Contents of trouble Failure code Controller code 1500L0 TM Trouble Detection of double engagement: *See separate list (L0) • The fill switch signals of abnormally combined 2 clutches are input. Action of controller • The gear is set in Neutral during travel and the machine cannot start again. HD605-7 20-507 (10) . Cause Standard value in normal state/Remarks on troubleshooting Clutch pressure control Possible causes 1 valve system failure code • Perform troubleshooting by the indicated failure code. • The transmission cutout relay is turned OFF. Problem that appears on machine • The gear is set in Neutral. Related information • Another failure (Clutch pressure control valve system failure code: 15S*L1) occurs simultaneously with this failure. and standard value (15S*L1) is indicated.

TNF. 1 z (Disconnection or defective TMF (female) (1) contact) Wiring harness between CJH1 (female) (5) – Resistance Max. 2) Disconnect connectors ATC5A and ATC3A.3) Connect T-adapter. Action of controller • None in particular. 4 fective 5) Turn the starting switch ON. dust may enter the transmission circuit. 1 z Between TMF (male) Filter is normal. Related information • After repairing the failure and confirming resetting of the machine. appears on machine • This failure can be checked in the monitoring function (Code: 33300). (1) – (2) Filter is clogged. 1 Mz 1) Turn the starting switch OFF. 2 sensor defective Resistance Max. Filter is clogged. ter 1) Turn the starting switch OFF. HD605-7 . Voltage Voltage Max. Between ATC5A (6) – chassis ground Filter is normal. the signal circuit of the transmission clogging sensor is opened (disconnected from GND). 2) Disconnect connectors ATC5A. perform the initial learning of the transmission controller.TROUBLESHOOTING [15B0NX] [15B0NX] CLOGGING OF TRANSMISSION OIL FILTER: CLOGGING (NX) Action code E01 Contents of trouble Failure code Controller code 15B0NX TM Trouble Clogging of transmission oil filter: Clogging (NX) • When the torque converter oil temperature is above 50°C. 3) Insert T-adapter. and CN10. referring to TESTING AND ADJUSTING.4) Connect conector. and standard value ness 3 Wiring harness between ATC5A (female) (6) – in normal state Resistance Max. Resistance Min. "Inspection of machine monitor". Transmission controller de. 1 z TMF (female) (2) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A. Problem that • If the machine is used without repairing. Possible causes Disconnection in wiring har. 1 V 20 – 30 V Related electrical circuit diagram 20-508 (10) HD465-7. Cause Standard value in normal state/Remarks on troubleshooting Clogging of transmission fil1 • Clean or replace. Transmission filter clogging 3) Connect T-adapter. TMF and CN10.

Problem that appears on machine • The failure is only recorded in the failure history. HD465-7. • If the machine is used without repairing. 5 – 7 km/h). Related information • This failure can be checked in the monitoring function (Code: 31400). [15E7KM] R TO F GEAR SHIFT ABUSE 2: MISTAKE IN OPERATION OR SETTING (KM) Action code Not set Contents of trouble Failure code Controller code 15E7KM TM Trouble R to F gear shift abuse 2: Mistake in operation or setting (KM) • When the output shaft speed is above 300 rpm (approx. the gear is shifted from reverse to forward. Action of controller • None in particular. Possible causes and standard value 1 Abuse in normal state Cause Standard value in normal state/Remarks on troubleshooting • Change the travel direction after the machine is stopped perfectly. [15E7KM] [15E0KM] R TO F GEAR SHIFT ABUSE 1: MISTAKE IN OPERATION OR SETTING (KM) Action code Not set Contents of trouble Failure code Controller code 15E0KM TM Trouble R to F gear shift abuse 1: Mistake in operation or setting (KM) • When the output shaft speed is 200 rpm – 300 rpm (approx. it may be broken. the gear is shifted from reverse to forward. Action of controller • None in particular.TROUBLESHOOTING [15E0KM]. Problem that appears on machine • The failure is only recorded in the failure history. Related information • This failure can be checked in the monitoring function (Code: 31400). • If the machine is used without repairing. it may be broken. Possible causes and standard value 1 Abuse in normal state Cause Standard value in normal state/Remarks on troubleshooting • Change the travel direction after the machine is stopped perfectly. 7 km/h). HD605-7 20-509 (10) .

(2) – chassis ground Resistance Min. and DL**LC. 2) Disconnect connector ATC2 and CN10. fill switch is ON.3) Connect T-adapter. 2) Disconnect connector ATC2. 1 z CN10 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 1 z CN10 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) – Resistance Max. Between CN10 (male) (1) – (2) Resistance 5 – 15 z Between CN10 (male) (1). appears on machine • This failure can be checked in the monitoring function (Code: 31516. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN10. 4 fective Wiring harness between ATC2 (female) (5) – ATC2 (female) (15) Resistance 5 – 15 z Related electrical circuit diagram 20-510 (10) HD465-7. 1 Mz 1) Turn the starting switch OFF. Disconnection in wiring har. transmission intermediate shaft speed sensor. 3) Connect T-adapter. Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (5) – Resistance Max. Action of controller • The controller sets the gear in Neutral. 31606.3) Connect T-adapter. 31616).TROUBLESHOOTING [15G0MW] [15G0MW] R CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15G0MW TM R clutch: Slip (MW) Trouble (Command is Holding pressure. Related information • If the electric system is normal. HD605-7 . Transmission controller de. and transmission output shaft speed sensor is abnormal. the value calculated from the signals of the transmission input shaft speed sensor. and slip is sensed) • When a signal is output to the R clutch ECMV. sensor 1 R clutch ECMV defective 1) Turn the starting switch OFF. check the hydraulic/mechanical system of the R clutch and pressure control valve for a defect.

4 fective Wiring harness between ATC2 (female) (9) – ATC2 (female) (19) Resistance 5 – 15 z HD465-7. (2) – chassis ground Resistance Min. 3) Connect T-adapter. 1 z CN18 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 2) Disconnect connector CN18. Problem that • The gear is set in Neutral suddenly during travel. appears on machine • This failure can be checked in the monitoring function (Code: 31511. 31610). and slip is sensed) • When a signal is output to the Hi clutch ECMV.TROUBLESHOOTING [15H0MW] [15H0MW] HI CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15H0MW TM Hi clutch: Slip (MW) Trouble (Command is Holding pressure. Between CN18 (male) (1) – (2) Resistance 5 – 15 z Between CN18 (male) (1). Disconnection in wiring har. Action of controller • The controller sets the gear in Neutral. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (9) – Resistance Max. and DL**LC. Related information • If the electric system is normal. and transmission output shaft speed sensor is abnormal. the value calculated from the signals of the transmission input shaft speed sensor. transmission intermediate shaft speed sensor.3) Connect T-adapter. HD605-7 20-511 (10) . Transmission controller de.3) Connect T-adapter. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 z CN18 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (19) – Resistance Max. sensor 1 Hi clutch ECMV defective 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. 2) Disconnect connector ATC2 and CN18. 31600. fill switch is ON. 1 Mz 1) Turn the starting switch OFF. check the hydraulic/mechanical system of the Hi clutch and pressure control valve for a defect.

HD605-7 .TROUBLESHOOTING [15H0MW] Related electrical circuit diagram 20-512 (7) HD465-7.

1 z CN16 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (17) – Resistance Max. and transmission output shaft speed sensor is abnormal.3) Connect T-adapter. 1 Mz 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. 4 fective Wiring harness between ATC2 (female) (7) – ATC2 (female) (17) Resistance 5 – 15 z HD465-7. the value calculated from the signals of the transmission input shaft speed sensor.3) Connect T-adapter. fill switch is ON. (2) – chassis ground Resistance Min. and slip is sensed) • When a signal is output to the Lo clutch ECMV. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF.TROUBLESHOOTING [15J0MW] [15J0MW] LO CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15J0MW TM Lo clutch: Slip (MW) Trouble (Command is Holding pressure. 31611). transmission intermediate shaft speed sensor. Transmission controller de. 1 z CN16 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. Between CN16 (male) (1) – (2) Resistance 5 – 15 z Between CN16 (male) (1). 2) Disconnect connector ATC2 and CN16. appears on machine • This failure can be checked in the monitoring function (Code: 31510. HD605-7 20-513 (10) . 31601. 2) Disconnect connector CN16. sensor 1 Lo clutch ECMV defective 1) Turn the starting switch OFF. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (7) – Resistance Max. check the hydraulic/mechanical system of the Lo clutch and pressure control valve for a defect. and DL**LC. Disconnection in wiring har. Related information • If the electric system is normal. Action of controller • The controller sets the gear in Neutral. Problem that • The gear is set in Neutral suddenly during travel. 3) Connect T-adapter.

HD605-7 .TROUBLESHOOTING [15J0MW] Related electrical circuit diagram 20-514 (7) HD465-7.

Transmission controller de. fill switch is ON. HD605-7 20-515 (10) . 1 z CN6 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 1 Mz 1) Turn the starting switch OFF. and slip is sensed) • When a signal is output to the 1st clutch ECMV. 2) Disconnect connector ATC2 and CN6. transmission intermediate shaft speed sensor. and transmission output shaft speed sensor is abnormal. Disconnection in wiring har. 1 z CN6 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) – Resistance Max. and DL**LC. Problem that • The gear is set in Neutral suddenly during travel.3) Connect T-adapter.TROUBLESHOOTING [15K0MW] [15K0MW] 1ST CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15K0MW TM 1st clutch: Slip (MW) Trouble (Command is Holding pressure. appears on machine • This failure can be checked in the monitoring function (Code: 31512. Between CN6 (male) (1) – (2) Resistance 5 – 15 z Between CN6 (male) (1). Action of controller • The controller sets the gear in Neutral. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. 31612). sensor 1 1st clutch ECMV defective 1) Turn the starting switch OFF. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (2) – Resistance Max. check the hydraulic/mechanical system of the 1st clutch and pressure control valve for a defect. 4 fective Wiring harness between ATC2 (female) (2) – ATC2 (female) (13) Resistance 5 – 15 z Related electrical circuit diagram HD465-7. (2) – chassis ground Resistance Min. the value calculated from the signals of the transmission input shaft speed sensor. 2) Disconnect connector CN6. 31602.3) Connect T-adapter. 3) Connect T-adapter. Related information • If the electric system is normal.

TROUBLESHOOTING [15L0MW] [15L0MW] 2ND CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15L0MW TM 2nd clutch: Slip (MW) Trouble (Command is Holding pressure. (2) – chassis ground Resistance Min. the value calculated from the signals of the transmission input shaft speed sensor. 1 z CN8 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) – Resistance Max. and DL**LC. and slip is sensed) • When a signal is output to the 2nd clutch ECMV. 2) Disconnect connector ATC2 and CN8. check the hydraulic/mechanical system of the 2nd clutch and pressure control valve for a defect. sensor 1) Turn the starting switch OFF. appears on machine • This failure can be checked in the monitoring function (Code: 31513. 31603. 31613). 1 z CN8 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA.3) Connect T-adapter. 2) Disconnect connector ATC2. Disconnection in wiring har. 2) Disconnect connector CN8. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 2nd clutch ECMV defective 3) Connect T-adapter. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (4) – Resistance Max. Transmission controller de. transmission intermediate shaft speed sensor. and transmission output shaft speed sensor is abnormal. Problem that • The gear is set in Neutral suddenly during travel. Action of controller • The controller sets the gear in Neutral. Related information • If the electric system is normal. 4 fective Wiring harness between ATC2 (female) (4) – ATC2 (female) (15) Resistance 5 – 15 z Related electrical circuit diagram 20-516 (10) HD465-7. HD605-7 . Between CN8 (male) (1) – (2) Resistance 5 – 15 z Between CN8 (male) (1).3) Connect T-adapter. fill switch is ON. 1 Mz 1) Turn the starting switch OFF.

Problem that • The gear is set in Neutral suddenly during travel. (2) – chassis ground Resistance Min. and transmission output shaft speed sensor is abnormal. 31614). Between CN12 (male) (1) – (2) Resistance 5 – 15 z Between CN12 (male) (1). Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (8) – Resistance Max. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Disconnection in wiring har. sensor 1 3rd clutch ECMV defective 1) Turn the starting switch OFF. Related information • If the electric system is normal. appears on machine • This failure can be checked in the monitoring function (Code: 31514. Transmission controller de.3) Connect T-adapter.TROUBLESHOOTING [15M0MW] [15M0MW] 3RD CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15M0MW TM 3rd clutch: Slip (MW) Trouble (Command is Holding pressure. 1 z CN12 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. transmission intermediate shaft speed sensor. and slip is sensed) • When a signal is output to the 3rd clutch ECMV. 3) Connect T-adapter. 2) Disconnect connector CN12. 2) Disconnect connector ATC2. fill switch is ON.3) Connect T-adapter. 2) Disconnect connector ATC2 and CN12. 31604. 4 fective Wiring harness between ATC2 (female) (8) – ATC2 (female) (18) Resistance 5 – 15 z Related electrical circuit diagram HD465-7. 1 Mz 1) Turn the starting switch OFF. 1 z CN12 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (18) – Resistance Max. HD605-7 20-517 (10) . and DL**LC. check the hydraulic/mechanical system of the 3rd clutch and pressure control valve for a defect. Action of controller • The controller sets the gear in Neutral. the value calculated from the signals of the transmission input shaft speed sensor.

Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (3) – Resistance Max. transmission intermediate shaft speed sensor. Transmission controller de. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. appears on machine • This failure can be checked in the monitoring function (Code: 31515. 2) Disconnect connector ATC2 and CN14. 2) Disconnect connector CN14. Action of controller • The controller sets the gear in Neutral. HD605-7 . 1 z CN14 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. and transmission output shaft speed sensor is abnormal. Between CN14 (male) (1) – (2) Resistance 5 – 15 z Between CN14 (male) (1). sensor 1 4th clutch ECMV defective 1) Turn the starting switch OFF. (2) – chassis ground Resistance Min. 31605.TROUBLESHOOTING [15N0MW] [15N0MW] 4TH CLUTCH: SLIP (MW) Action code E03 Contents of trouble Failure code Controller code 15N0MW TM 4th clutch: Slip (MW) Trouble (Command is Holding pressure. the value calculated from the signals of the transmission input shaft speed sensor. fill switch is ON. Disconnection in wiring har. and slip is sensed) • When a signal is output to the 4th clutch ECMV. Related information • If the electric system is normal. Problem that • The gear is set in Neutral suddenly during travel. and DL**LC.3) Connect T-adapter. 1 Mz 1) Turn the starting switch OFF. 3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (3) – ATC2 (female) (13) Resistance 5 – 15 z Related electrical circuit diagram 20-518 (10) HD465-7. check the hydraulic/mechanical system of the 4th clutch and pressure control valve for a defect. 1 z CN14 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) – Resistance Max.3) Connect T-adapter. 31615).

31606. 3) Connect T-adapter. 3) Connect T-adapter.TROUBLESHOOTING [15SBL1] [15SBL1] R CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code 15SBL1 TM Trouble R clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON) • When the output to the R clutch ECMV is turned OFF. 1 Mz engaged When enResistance Max. Resistance between ATC5A (female) (16). 1 Mz 3 Transmission controller defective When disResistance Min. CN11 (female) (1) – chassis ground Min. Problem that • The gear is set in Neutral suddenly during travel. 1 Mz Between ATC5A (female) (16) – engaged chassis ground When enResistance Max. 1 R clutch fill switch defective Between CN11 (male) (1) – chassis ground When disResistance Min. Action of controller • The controller sets the gear in Neutral. 1 z gaged Related electrical circuit diagram HD465-7. Wiring harness between ATC5A (female) (16) – CN11 (female) (1) 1) Turn the starting switch OFF. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31516. 31616). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 2) Disconnect connector CN11. 1 z gaged Possible causes and standard value Ground fault in wiring har2 in normal state ness 1) Turn the starting switch OFF. the signal from the fill switch is kept ON and the clutch is not disengaged. HD605-7 20-519 (10) . 2) Disconnect connectors ATC5A and CN11. 3) Connect T-adapter.

HD605-7 . 1 Mz 1) Turn the starting switch OFF. Problem that • The gear is set in Neutral suddenly during travel.3) Connect T-adapter.3) Connect T-adapter. check the hydraulic/mechanical system of the R clutch and pressure control valve for a defect. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Related information • If the electric system is normal. appears on machine • This failure can be checked in the monitoring function (Code: 31516. 2) Disconnect connector ATC2. transmission intermediate shaft speed sensor. 2) Disconnect connector ATC2 and CN10.TROUBLESHOOTING [15SBMA] [15SBMA] R CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code 15SBMA TM R clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. Transmission controller de. 4 fective Wiring harness between ATC2 (female) (5) – Resistance 5 – 15 z ATC2 (female) (15) Related electrical circuit diagram 20-520 (10) HD465-7. Between CN10 (male) (1) – (2) Resistance 5 – 15 z Between CN10 (male) (1). 1 z CN10 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (5) – Resistance Max. sensor 1 R clutch ECMV defective 1) Turn the starting switch OFF. and DL**LC. the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor. 1 z CN10 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) – Resistance Max. 2) Disconnect connector CN10. Action of controller • The controller sets the gear in Neutral. and transmission output shaft speed sensor is abnormal. (2) – chassis ground Resistance Min. fill switch is ON. 3) Connect T-adapter. Disconnection in wiring har. and slip is sensed) • When a signal is output to the R clutch ECMV. 31616). 31606.

Problem that • The gear is set in Neutral suddenly during travel. 1 z gaged 1) Turn the starting switch OFF. Resistance between ATC5A (female) (12). 1 Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31511. 2) Disconnect connectors ATC5A and CN19. 2) Disconnect connector CN19. Wiring harness between ATC5A (female) (12) – CN19 (female) (1) CN19 (female) (1) – chassis ground 1) Turn the starting switch OFF. 31600. 1 Mz Between ATC5A (female) (12) – engaged chassis ground When enResistance Max. 3) Connect T-adapter. 1 Mz Between CN19 (male) (1) – chas. the signal from the fill switch is kept ON and the clutch is not disengaged.engaged sis ground When enResistance Max. 3) Connect T-adapter. When disResistance Min. Action of controller • The controller sets the gear in Neutral. 1 Mz 3 Transmission controller defective Related electrical circuit diagram HD465-7. 1 z gaged Cause Possible causes and standard value Ground fault in wiring har2 in normal state ness Min. 31610). 2) Disconnect connector ATC5A.TROUBLESHOOTING [15SCL1] [15SCL1] HI CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code Hi clutch solenoid: *See separate list (L1) Trouble (Command is OFF and fill switch is ON) 15SCL1 TM • When the output to the Hi clutch ECMV is turned OFF. 3) Connect T-adapter. HD605-7 20-521 (10) . Hi clutch fill switch defective When disResistance Min.

ness Wiring harness between ATC2 (female) (9) – Resistance Max. Hi clutch ECMV defective Resistance 5 – 15 z Between CN18 (male) (1) – (2) Between CN18 (male) (1). Action code Failure code Controller code Problem that • The gear is set in Neutral suddenly during travel. 1 z CN18 (female) (2) Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 2) Disconnect connector CN18. appears on machine • This failure can be checked in the monitoring function (Code: 31511.TROUBLESHOOTING [15SCMA] [15SCMA] HI CLUTCH SOLENOID: MALFUNCTION (MA) Hi clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. 3) Connect T-adapter. 31600. (2) – chassis ground Resistance Min. 1 Mz 1) Turn the starting switch OFF. fective Wiring harness between ATC2 (female) (9) – Resistance 5 – 15 z ATC2 (female) (19) Cause 1 Possible causes and standard value 2 in normal state 3 4 Related electrical circuit diagram 20-522 (10) HD465-7. Disconnection in wiring har. Related information • If the electric system is normal. 1 z (Disconnection or defective CN18 (female) (1) contact) Wiring harness between ATC2 (female) (19) – Resistance Max. 31610). and DL**LC. Action of controller • The controller sets the gear in Neutral. the signal from the fill switch is kept OFF and the value Contents of trouble calculated from the signals of the transmission input shaft speed sensor.3) Connect T-adapter. 2) Disconnect connector ATC2 and CN18. HD605-7 . transmission intermediate shaft speed sensor.3) Connect T-adapter. Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. check the hydraulic/mechanical system of the Hi clutch and pressure control valve for a defect. sensor 1) Turn the starting switch OFF. Transmission controller de. 2) Disconnect connector ATC2. and transmission output shaft speed sensor is abnormal. and slip is E03 15SCMA TM sensed) • When a signal is output to the Hi clutch ECMV. fill switch is ON.

Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Lo clutch fill switch defective Between CN17 (male) (1) – chassis ground When disResistance Min. 1 z gaged Related electrical circuit diagram HD465-7. 3) Connect T-adapter. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31510. (female) (10) – CN17 (female) (1) CN17 (female) (1) – chassis ground 1) Turn the starting switch OFF. HD605-7 20-523 (10) . 3) Connect T-adapter. 1 z gaged Possible causes and standard value Ground fault in wiring har2 in normal state ness 1) Turn the starting switch OFF.TROUBLESHOOTING [15SDL1] [15SDL1] LO CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code Lo clutch solenoid: *See separate list (L1) Trouble (Command is OFF and fill switch is ON) 15SDL1 TM • When the output to the Lo clutch ECMV is turned OFF. 2) Disconnect connector CN17. the signal from the fill switch is kept ON and the clutch is not disengaged. 1 Mz engaged When enResistance Max. 31611). 1 Mz Between ATC5A (female) (10) – engaged chassis ground When enResistance Max. 3) Connect T-adapter. 31601. Min. 2) Disconnect connectors ATC5A and CN17. Problem that • The gear is set in Neutral suddenly during travel. 2) Disconnect connector ATC5A. 1 Mz 3 Transmission controller defective When disResistance Min. Resistance between Wiring harness between ATC5A ATC5A (female) (10). Action of controller • The controller sets the gear in Neutral.

1 z CN16 (female) (2) Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 2) Disconnect connector ATC2 and CN16. Transmission controller de.TROUBLESHOOTING [15SDMA] [15SDMA] LO CLUTCH SOLENOID: MALFUNCTION (MA) Lo clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. and DL**LC. 31601. fective Wiring harness between ATC2 (female) (7) – Resistance 5 – 15 z ATC2 (female) (17) Cause 1 Possible causes and standard value 2 in normal state 3 4 Related electrical circuit diagram 20-524 (10) HD465-7. 3) Connect T-adapter. 2) Disconnect connector CN16. Related information • If the electric system is normal. fill switch is ON. sensor 1) Turn the starting switch OFF. 2) Disconnect connector ATC2.3) Connect T-adapter. and transmission output shaft speed sensor is abnormal. the signal from the fill switch is kept OFF and the value Contents of trouble calculated from the signals of the transmission input shaft speed sensor. 1 Mz 1) Turn the starting switch OFF. transmission intermediate shaft speed sensor. (2) – chassis ground Resistance Min. ness Wiring harness between ATC2 (female) (7) – Resistance Max. Action code Failure code Controller code Problem that • The gear is set in Neutral suddenly during travel. Lo clutch ECMV defective Resistance 5 – 15 z Between CN16 (male) (1) – (2) Between CN16 (male) (1). appears on machine • This failure can be checked in the monitoring function (Code: 31510. Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 31611).3) Connect T-adapter. HD605-7 . Action of controller • The controller sets the gear in Neutral. Disconnection in wiring har. check the hydraulic/mechanical system of the Lo clutch and pressure control valve for a defect. 1 z (Disconnection or defective CN16 (female) (1) contact) Wiring harness between ATC2 (female) (17) – Resistance Max. and slip is E03 15SDMA TM sensed) • When a signal is output to the Lo clutch ECMV.

1 Mz Between ATC5A (female) (13) – engaged chassis ground When enResistance Max. HD605-7 20-525 (10) . 3) Connect T-adapter. Action of controller • The controller sets the gear in Neutral. 3) Connect T-adapter. 2) Disconnect connector CN7.TROUBLESHOOTING [15SEL1] [15SEL1] 1ST CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code 15SEL1 TM Trouble 1st clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON) • When the output to the 1st clutch ECMV is turned OFF. Problem that • The gear is set in Neutral suddenly during travel. 1 z gaged 1) Turn the starting switch OFF. 1 Mz Possible causes and standard value Ground fault in wiring har2 in normal state ness 3 Transmission controller defective When disResistance Min. 1 Mz Between CN7 (male) (1) – chassis engaged ground When enResistance Max. the signal from the fill switch is kept ON and the clutch is not disengaged. 1 z gaged Related electrical circuit diagram HD465-7. 31602. CN7 (female) (1) – chassis ground Min. 2) Disconnect connectors ATC5A and CN7. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31512. 1 1st clutch fill switch defective When disResistance Min. Wiring harness between ATC5A (female) (13) – CN7 (female) (1) 1) Turn the starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 3) Connect T-adapter. 31612). Resistance between ATC5A (female) (13). 2) Disconnect connector ATC5A.

1 z CN6 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor. Disconnection in wiring har.3) Connect T-adapter. and slip is sensed) • When a signal is output to the 1st clutch ECMV. sensor 1 1st clutch ECMV defective 1) Turn the starting switch OFF. 2) Disconnect connector CN6. and DL**LC. 31612). Problem that • The gear is set in Neutral suddenly during travel. 1 Mz 1) Turn the starting switch OFF. Between CN6 (male) (1) – (2) Resistance 5 – 15 z Between CN6 (male) (1). HD605-7 . 3) Connect T-adapter. 1 z CN6 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) – Resistance Max. (2) – chassis ground Resistance Min. check the hydraulic/mechanical system of the 1st clutch and pressure control valve for a defect. 4 fective Wiring harness between ATC2 (female) (2) – Resistance 5 – 15 z ATC2 (female) (13) Related electrical circuit diagram 20-526 (10) HD465-7. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (2) – Resistance Max.3) Connect T-adapter. 31602. appears on machine • This failure can be checked in the monitoring function (Code: 31512. transmission intermediate shaft speed sensor. Action of controller • The controller sets the gear in Neutral. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF.TROUBLESHOOTING [15SEMA] [15SEMA] 1ST CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code 15SEMA TM 1st clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. Transmission controller de. Related information • If the electric system is normal. 2) Disconnect connector ATC2. and transmission output shaft speed sensor is abnormal. 2) Disconnect connector ATC2 – CN6. fill switch is ON.

3) Connect T-adapter. 2) Disconnect connector CN9. 1 Mz Possible causes and standard value Ground fault in wiring har2 in normal state ness 3 Transmission controller defective When disResistance Min.TROUBLESHOOTING [15SFL1] [15SFL1] 2ND CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code 15SFL1 TM Trouble 2nd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON) • When the output to the 2nd clutch ECMV is turned OFF. 2) Disconnect connectors ATC5A and CN9. 1 Mz Between CN9 (male) (1) – chassis engaged ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. Resistance between ATC5A (female) (14). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Action of controller • The controller sets the gear in Neutral. 3) Connect T-adapter. 31603. 3) Connect T-adapter. the signal from the fill switch is kept ON and the clutch is not disengaged. HD605-7 20-527 (10) . Problem that • The gear is set in Neutral suddenly during travel. Wiring harness between ATC5A (female) (14) – CN9 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 1 z gaged Related electrical circuit diagram HD465-7. 31613). CN9 (female) (1) – chassis ground Min. 1 2nd clutch fill switch defective When disResistance Min. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31513. 1 Mz Between ATC5A (female) (14) – engaged chassis ground When enResistance Max.

2) Disconnect connector ATC2 and CN8. transmission intermediate shaft speed sensor. (2) – chassis ground Resistance Min. 31603.3) Connect T-adapter. Transmission controller de. 4 fective Wiring harness between ATC2 (female) (4) – Resistance 5 – 15 z ATC2 (female) (15) Related electrical circuit diagram 20-528 (10) HD465-7. check the hydraulic/mechanical system of the 2nd clutch and pressure control valve for a defect.3) Connect T-adapter. 1 z CN8 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (15) – Resistance Max. and transmission output shaft speed sensor is abnormal. 2) Disconnect connector ATC2. 1 z CN8 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 1 Mz 1) Turn the starting switch OFF. and DL**LC. Related information • If the electric system is normal. Disconnection in wiring har. and slip is sensed) • When a signal is output to the 2nd clutch ECMV. fill switch is ON. the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor. Problem that • The gear is set in Neutral suddenly during travel. HD605-7 . Action of controller • The controller sets the gear in Neutral. sensor 1) Turn the starting switch OFF. 31613). appears on machine • This failure can be checked in the monitoring function (Code: 31513. 1 2nd clutch ECMV defective 3) Connect T-adapter. 2) Disconnect connector CN8.TROUBLESHOOTING [15SFMA] [15SFMA] 2ND CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code 15SFMA TM 2nd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (4) – Resistance Max. Between CN8 (male) (1) – (2) Resistance 5 – 15 z Between CN8 (male)(1) .

TROUBLESHOOTING [15SGL1] [15SGL1] 3RD CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code 15SGL1 TM Trouble 3rd clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON) • When the output to the 3rd clutch ECMV is turned OFF. (female) (15) – CN13 (female) (1) CN13 (female) (1) – chassis ground 1) Turn the starting switch OFF. 3) Connect T-adapter. 1 Mz 3 Transmission controller defective When disResistance Min. 2) Disconnect connector CN13. 1 z gaged Related electrical circuit diagram HD465-7. 3) Connect T-adapter. 1 3rd clutch fill switch defective Between CN13 (male) (1) – chassis ground When disResistance Min. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31514. Min. HD605-7 20-529 (10) . Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 31614). Problem that • The gear is set in Neutral suddenly during travel. 1 z gaged Possible causes and standard value Ground fault in wiring har2 in normal state ness 1) Turn the starting switch OFF. 1 Mz engaged When enResistance Max. 1 Mz Between ATC5A (female) (15) – engaged chassis ground When enResistance Max. Resistance between Wiring harness between ATC5A ATC5A (female) (15). the signal from the fill switch is kept ON and the clutch is not disengaged. Action of controller • The controller sets the gear in Neutral. 2) Disconnect connector ATC5A. 31604. 2) Disconnect connectors ATC5A and CN13. 3) Connect T-adapter.

transmission intermediate shaft speed sensor. and slip is sensed) • When a signal is output to the 3rd clutch ECMV. fill switch is ON. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (8) – Resistance Max. 1 z CN12 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (18) – Resistance Max. 3) Connect T-adapter. and transmission output shaft speed sensor is abnormal. 2) Disconnect connector CN12. Disconnection in wiring har. Related information • If the electric system is normal. check the hydraulic/mechanical system of the 3rd clutch and pressure control valve for a defect. Problem that • The gear is set in Neutral suddenly during travel. Transmission controller de. Action of controller • The controller sets the gear in Neutral. 1 Mz 1) Turn the starting switch OFF. 1 z CN12 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 2) Disconnect connector ATC2. HD605-7 . (2) – chassis ground Resistance Min.3) Connect T-adapter. 4 fective Wiring harness between ATC2 (female) (8) – Resistance 5 – 15 z ATC2 (female) (18) Related electrical circuit diagram 20-530 (10) HD465-7. sensor 1 3rd clutch ECMV defective 1) Turn the starting switch OFF. appears on machine • This failure can be checked in the monitoring function (Code: 31514.TROUBLESHOOTING [15SGMA] [15SGMA] 3RD CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code 15SGMA TM 3rd clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. and DL**LC. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 31604. Between CN12 (male) (1) – (2) Resistance 5 – 15 z Between CN12 (male) (1). the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor.3) Connect T-adapter. 2) Disconnect connector ATC2 and CN12. 31614).

1 4th clutch fill switch defective Between CN15 (male) (1) – chassis ground When disResistance Min. 2) Disconnect connectors ATC5A and CN15. 1 Mz engaged When enResistance Max. CN15 (female) (1) – chassis ground Min. 31605. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 z gaged Possible causes and standard value Ground fault in wiring har2 in normal state ness 1) Turn the starting switch OFF. appears on machine Related information • This failure can be checked in the monitoring function (Code: 31515. 2) Disconnect connector ATC5A. 2) Disconnect connector CN15. Wiring harness between ATC5A (female) (11) – CN15 (female) (1) 1) Turn the starting switch OFF. 1 Mz 3 Transmission controller defective When disResistance Min. 3) Connect T-adapter. HD605-7 20-531 (10) . 31615). Problem that • The gear is set in Neutral suddenly during travel. Action of controller • The controller sets the gear in Neutral. Resistance between ATC5A (female) (11). 1 z gaged Related electrical circuit diagram HD465-7. 1 Mz Between ATC5A (female) (11) – engaged chassis ground When enResistance Max. 3) Connect T-adapter.TROUBLESHOOTING [15SHL1] [15SHL1] 4TH CLUTCH SOLENOID: *SEE SEPARATE LIST (L1) Action code E03 Contents of trouble Failure code Controller code 15SHL1 TM Trouble 4th clutch solenoid: *See separate list (L1) (Command is OFF and fill switch is ON) • When the output to the 4th clutch ECMV is turned OFF. the signal from the fill switch is kept ON and the clutch is not disengaged. 3) Connect T-adapter.

31605. and slip is sensed) • When a signal is output to the 4th clutch ECMV. sensor 1 4th clutch ECMV defective 1) Turn the starting switch OFF. 2) Disconnect connector CN14. the signal from the fill switch is kept OFF and the value calculated from the signals of the transmission input shaft speed sensor. Related information • If the electric system is normal. 31615). Problem that • The gear is set in Neutral suddenly during travel. HD605-7 . Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC2. 1 Mz 1) Turn the starting switch OFF. and DL**LC.3) Connect T-adapter. 2) Disconnect connector ATC2 and CN14. transmission intermediate shaft speed sensor. Action of controller • The controller sets the gear in Neutral. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (3) – Resistance Max. 3) Connect T-adapter.TROUBLESHOOTING [15SHMA] [15SHMA] 4TH CLUTCH SOLENOID: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code 15SHMA TM 4th clutch solenoid: Malfunction (MA) Trouble (Command is Holding pressure. (2) – chassis ground Resistance Min. Between CN14 (male) (1) – (2) Resistance 5 – 15 z Between CN14 (male) (1). check the hydraulic/mechanical system of the 4th clutch and pressure control valve for a defect. Disconnection in wiring har.3) Connect T-adapter. and transmission output shaft speed sensor is abnormal. 4 fective Wiring harness between ATC2 (female) (3) – Resistance 5 – 15 z ATC2 (female) (13) Related electrical circuit diagram 20-532 (10) HD465-7. 1 z CN14 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (13) – Resistance Max. Transmission controller de. fill switch is ON. 1 z CN14 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. appears on machine • This failure can be checked in the monitoring function (Code: 31515.

• If the shift lever is set in the "N" position. the machine cannot start until it is stopped. 1 z gaged Possible causes and standard value Ground fault in wiring har2 in normal state ness 1) Turn the starting switch OFF. 2) Disconnect connector CN21. Problem that appears on machine • If the shift lever is set in the "N" position. the signal from the fill switch is kept ON and the clutch is not disengaged. 1 z gaged Related electrical circuit diagram HD465-7. Related information • This failure can be checked in the monitoring function (Code: 31519. the controller keeps the gear in neutral. Resistance between Wiring harness between ATC5A ATC5A (female) (17). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Mz engaged When enResistance Max. 2) Disconnect connectors ATC5A and CN21. 1 Mz 3 Transmission controller defective When disResistance Min. 1 Mz Between ATC5A (female) (17) – engaged chassis ground When enResistance Max. 1 Lockup clutch fill switch defective Between CN21 (male) (1) – chassis ground When disResistance Min. Min. 31609. Action of controller • The lockup operation is reset and the gear cannot be shifted. 3) Connect T-adapter. (female) (17) – CN21 (female) (1) CN21 (female) (1) – chassis ground 1) Turn the starting switch OFF.TROUBLESHOOTING [15SJL1] [15SJL1] LOCKUP CLUTCH SOLENOID: 15SJ (L1) Action code E03 Contents of trouble Failure code Controller code 15SJL1 TM Trouble Lockup clutch solenoid: 15SJ (L1) (Command is OFF and fill switch is ON) • When the output to the lockup clutch ECMV is turned OFF. 31619). • The controller keeps the current gear speed and turns the lockup operation OFF. HD605-7 20-533 (10) . 2) Disconnect connector ATC5A. 3) Connect T-adapter. 3) Connect T-adapter.

Transmission controller de. Disconnection in wiring har. HD605-7 . Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. • This failure can be checked in the monitoring function (Code: 31519. Possible causes ness and standard value 2 (Disconnection or defective Wiring harness between ATC2 (female) (10) – Resistance Max. (2) – chassis ground Resistance Min. 31609.3) Connect T-adapter. 2) Disconnect connector ATC5A and CN20. and DL**LC. the signal from the fill switch is kept OFF and the value calculated from the signals of the engine speed sensor. transmission intermediate shaft speed sensor. 2) Disconnect connector ATC2. sensor 1 Lockup clutch ECMV defective 1) Turn the starting switch OFF. and transmission output shaft speed sensor is abnormal. fill switch is ON. Between CN20 (male) (1) – (2) Resistance 5 – 15 z Between CN20 (male) (1). 1 z CN20 (female) (1) in normal state contact) Wiring harness between ATC2 (female) (20) – Resistance Max. the controller keeps the gear in Neutral. 2) Disconnect connector CN20. check the hydraulic/mechanical system of the lockup clutch and pres- sure control valve for a defect.3) Connect T-adapter. the machine cannot start until it is stopped. and slip is sensed) • When a signal is output to the lockup clutch ECMV. 3) Connect T-adapter. 31619).TROUBLESHOOTING [15SJMA] [15SJMA] LOCKUP CLUTCH SOLENOID: 15SJ (MA) Action code E03 Contents of trouble Failure code Controller code 15SJMA TM Trouble Lockup clutch solenoid: 15SJ (MA) (Command is OFF. 4 fective Wiring harness between ATC2 (female) (10) – Resistance 5 – 15 z ATC2 (female) (20) Related electrical circuit diagram 20-534 (10) HD465-7. Action of controller • The lockup operation is reset and the gear cannot be shifted. • If the shift lever is set in the "N" position. Related information • If the electric system is normal. • The controller keeps the current gear speed and turns the lockup operation OFF. 1 z CN20 (female) (2) 3 Defective sensing by speed • Troubleshooting by the failure codes of DL**KA. 1 Mz 1) Turn the starting switch OFF. Problem that appears on machine • If the shift lever is set in the "N" position.

and then set the emergency brake switch in the FREE position and start the machine. HD605-7 20-535 (10) . appears on machine Related information • This failure can be checked in the monitoring function (Code: 31400). it may be broken. 1 z Mistake in operation of emergency brake 4 (Operation of emergency brake during travel) • Operate the emergency brake only when necessary. Resistance Min. the parking brake or emergency brake is operated. 4) Start the engine. When the parking brake relay (R03) is replaced. 1) Turn the starting switch OFF. 3) Connect T-adapter. (3) – (6) Do not apply 24 V beResistance Max. 2) Disconnect connector R03. 1 Mz Resistance 200 – 400 z Yes No Relay (R03) Relay (R03) 2 Parking brake relay (R03) defective Possible causes and standard value in normal state Resistance Max. 1 z tween (1) – (2). Between R03 (male) (1) – (2) 1) Turn the starting switch OFF. Apply 24 V between Resistance Min. Problem that • If the machine is used without repairing. (1) – (2) Set parking brake switch in PARK position. HD465-7. 1 Mz Between R03 (male) (1) – (2). 3) Check the relay. 5 km/h). Action of controller • None in particular. 1 ing brake switch • Stop the machine perfectly. Cause Standard value in normal state/Remarks on troubleshooting • Set the parking brake switch in the FREE position and then start the Mistake in operation of park. 3) Check the relay. 4) Apply voltage between R03 (male) (1) – (2). is failure repaired? 1) Turn the starting switch OFF.machine. 2) Replace R03 with normal one. 3 Parking brake oil pressure switch defective Set parking brake switch in FREE posiBetween PSW (male) position.TROUBLESHOOTING [2F00KM] [2F00KM] PARKING BRAKE: MISTAKE IN OPERATION OR SETTING (KM) Action code Not set Contents of trouble Failure code Controller code 2F00KM TM Trouble Parking brake: Mistake in operation or setting (KM) (Parking brake drags) • When the output shaft speed is above 200 rpm (approx. 2) Disconnect connector PSW. 1) Turn the starting switch OFF. 2) Disconnect connector R03.

4) Connect connector BRC5A 5) Start the engine. 2) Disconnect connector R03. 3) Connect T-adapter. ness 5 (Disconnection or defective 2) Disconnect connectors R03. Wiring harness between R03 (female) (2). R03 (female) (3) – Resistance Min. 7 Retarder controller defective Set parking brake switch in FREE posiBetween BRC5A (5) – tion. 1 V 6 Ground fault of wiring harness Voltage 20 – 30 V Related electrical circuit diagram 20-536 (10) HD465-7. 3) Connect T-adapter.chassis ground 1) Turn the starting switch OFF. chassis ground Set parking brake switch in PARK position. Voltage Max. and PSW. 1 Mz chassis ground 1) Turn the starting switch OFF. Between BRC5A (female). contact) Wiring harness between fuse BT3 (16) – PSW Resistance Max. 1 z (female) (1) Wiring harness between R03 (female) (1) – Resistance Max. (6) – Resistance Max. 1 z PSW (female) (2) Possible causes and standard value in normal state 1) Turn the starting switch OFF. HD605-7 .TROUBLESHOOTING [2F00KM] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 3) Connect T-adapter. 1 z Disconnection in wiring har. 3) Connect T-adapter. BT3. 2) Disconnect connectors BRC5A and R03. 2) Disconnect connector BRC5A.

TROUBLESHOOTING [989A00] [989A00] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: OPERATION (00) Action code E02 Contents of trouble Failure code Controller code 989A00 TM Trouble Engine overrun prevention command signal: Operation (00) • When the gear speed is not in neutral.600 rpm. Problem that • The brake operates and the travel speed lowers. in normal state • If the machine is not traveling under the condition where the transmisTransmission controller de2 sion input shaft speed signal rises higher than 2.600 rpm.600 rpm. HD605-7 20-537 (10) . Cause Standard value in normal state/Remarks on troubleshooting aIf the machine is traveling under the condition where the transmission Possible causes 1 Overrun of engine input shaft speed signal rises higher than 2. HD465-7. the engine is and standard value overrunning. Action of controller • The controller sends a command signal to the retarder controller to apply the brake. appears on machine Related information • This failure can be checked in the monitoring function (Code: 35000). the transmission input shaft speed signal rises higher than 2. the transfective mission controller is defective.

Action of controller • The controller continues the control with the S-NET signal. 2) Disconnect connectors ATC1 – BRC5B. fective 5) Start the engine. 4 Retarder controller defective 4) Connect the connector. appears on machine Related information • None in particular. grounding fault. 1 V Related electrical circuit diagram 20-538 (10) HD465-7. Min. 2) Disconnect connector BRC5B. ness 1 Wiring harness between ATC1 (female) (13) – Resistance Max.ATC1 (female) (13). Problem that • This failure does not have a serious effect on the machine. 1 V Voltage Max. 1 V 2 Ground fault of wiring harness Possible causes and standard value in normal state 1) Turn the starting switch OFF. 3) Connect T-adapter. 2) Disconnect connectors ATC1 – BRC5B. Transmission controller de. 1 z (Disconnection or defective BRC5B (female) (5) contact) Wiring harness between fuse BT3 Voltage between ATC1 20 – 30 V terminal (14) – ATC1 (female) (4) (4) – chassis ground 1) Turn the starting switch OFF. BRC5B (female) (5) – chassis ground Max. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Mz male) (13) – BRC5B (female) (5) BRC5B (female) (5) – chassis ground 1) Turn the starting switch OFF.TROUBLESHOOTING [989AKZ] [989AKZ] ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E01 Contents of trouble Failure code Controller code 989AKZ TM Trouble Engine overrun prevention command signal: Disconnection or short circuit (KZ) • There is disconnection.3) Connect T-adapter. 2) Disconnect connectors ATC1 and BRC5B. 3) Connect T-adapter. Disconnection in wiring har.3) Connect T-adapter. Between BRC5B (5) – chassis ground 1) Turn the starting switch OFF. 3 Hot short in wiring harness Wiring harness between ATC1 (female) (13) – BRC5B (female) (5) Voltage between ATC1 (female) (13). Resistance between Wiring harness between ATC1 (fe. 2) Disconnect connector ATC1. or short circuit with power source in the engine overrun prevention command signal circuit. Between ATC1 (13) – chassis ground Voltage Max. 5) Start the engine. 3) Connect T-adapter. 5 4) Connect the connector. HD605-7 .

Between ATC3A (19) Air cleaner is normal.4) Connect connector. and standard value Air cleaner clogging sensor 3) Connect T-adapter. 3) Check the relay. 1) Turn the starting switch OFF. 1 z – R32 (female) (3) 1) Turn the starting switch OFF. 1 z tween (1) – (2). 2 Dust indicator relay (R32) defective 1) Turn the starting switch OFF. When the dust indicator relay (R32) is replaced. – (16) Air cleaner is clogged. Resistance 200 – 400 z No Yes Relay (R32) is normal. 2) Disconnect connectors ATC3A and R32. Transmission controller de. Disconnection in wiring har. 6 fective 5) Turn the starting switch ON. FR01 (female) (1)– chassis ground Min. Wiring harness between R32 (female) (2) – FR01 (female) (1) Resistance between R32 (female) (2). 3) Connect T-adapter. 3) Turn the starting switch ON. Resistance Max. The dust indicator is red. Relay (R32) is defective. 2) Disconnect connectors ATC3A. 2) Disconnect connector R32. 2) Replace R32 with normal one. 3) Insert T-adapter. 1 z – R32 (female) (6) contact) Wiring harness between ATC3A (female) (19) Resistance Max. 1 V HD465-7. 4) Apply voltage between R32 (male) (1) – (2). ness 4 Wiring harness between ATC3A (female) (16) (Disconnection or defective Resistance Max. Action of controller • None in particular. the suction performance of the engine may be lowered. Cause 1 Clogging of air cleaner Standard value in normal state/Remarks on troubleshooting The dust indicator is not red. Problem that • If the machine is used without repairing. 1 Mz 1) Turn the starting switch OFF. 3 in normal state defective Between FR01 (male) Air cleaner is normal.TROUBLESHOOTING [AA10NX] [AA10NX] AIR CLEANER ELEMENT: CLOGGING (NX) Action code E01 Contents of trouble Failure code Controller code AA10NX TM Trouble Air cleaner element: Clogging (NX) • The air cleaner clogging signal circuit is opened (disconnected from GND). appears on machine Related information • This failure can be checked in the monitoring function (Code: 33200). 2) Disconnect connector R32 and FR01. Air cleaner is normal. Resistance Min. 1 z (1) – (2) Air cleaner is clogged. Between R32 (male) (1) – (2) 1) Turn the starting switch OFF. (3) – (6) Do not apply 24 V beResistance Max. Air cleaner is clogged. Voltage Voltage 20 – 30 V Max. is failure repaired? 1) Turn the starting switch OFF. Apply 24 V between Resistance Min.3) Connect T-adapter. 3) Check the relay. Possible causes 2) Disconnect connectors FR01. 1 Mz Between R32 (male) (1) – (2). 2) Disconnect connector R32. 1 Mz 5 Ground fault of wiring harness 1) Turn the starting switch OFF. HD605-7 20-539 (10) .

HD605-7 .TROUBLESHOOTING [AA10NX] Related electrical circuit diagram 20-540 (1) HD465-7.

1 z aIf the battery is deteriorated or used in a cold district. 2) Disconnect connector alternator terminal R. Transmission controller de. 1 Alternator defective Between alternator R – E Voltage 20 – 30 V aIf the battery is deteriorated or used in a cold district. 1) Turn the starting switch OFF. Action of controller • None in particular. 3) Start the engine. Wiring harness between battery relay terminal Resistance Max.TROUBLESHOOTING [AB00MA] [AB00MA] ALTERNATOR: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code AB00MA TM Trouble Alternator: Malfunction (MA) (Failure in battery charging circuit) • A generation signal is not input from the alternator while the engine is running. • If the machine is used without repairing. 3) Connect T-adapter. fective Between ATC3B (1) – chassis ground Voltage 20 – 30 V aIf the battery is deteriorated or used in a cold district. the voltage may not rise for a while after the engine is started. Disconnection in wiring harPossible causes ness and standard value 2 (Disconnection or defective in normal state contact) Wiring harness between ATC3B (female) (1) – alternator terminal R Voltage between ATC3B (fe20 – 30 V male) (1) – chassis ground Resistance Max. Related information • This failure can be checked in the monitoring function (Code: 04301). the voltage may not rise for a while after the engine is started. 3 5) Start the engine. 2) Disconnect connector ATC3B. HD465-7. 1 z M – alternator terminal R 1) Turn the starting switch OFF. 3) Connect T-adapter. HD605-7 20-541 (10) . the source voltage may lower so much that the machine cannot Problem that appears on machine travel. 2) Disconnect connector ATC3B.4) Connect the connector. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. the voltage may not rise for a while after the engine is started.

TROUBLESHOOTING [AB00MA] Related electrical circuit diagram 20-542 (1) HD465-7. HD605-7 .

ness 3 Wiring harness between ATC5A (female) (3) – Resistance Max. 1 V 20 – 30 V Related electrical circuit diagram HD465-7. Problem that • If the machine is used without repairing. 3 fective Radiator coolant level Between ATC5A (fe. 3) Insert T-adapter.TROUBLESHOOTING [B@BCZK] [B@BCZK] LOWERING OF RADIATOR WATER: LOWERING OF LEVEL (ZK) Action code E01 Contents of trouble Failure code Controller code B@BCZK TM Trouble Lowering of radiator coolant: Lowering of level (ZK) • The radiator coolant level switch signal circuit is opened (disconnected from GND). Disconnection in wiring har. male) (3) – chassis Radiator coolant level ground is low. Lowering of radiator coolant aIf the radiator coolant level is low. 2 Radiator coolant level switch defective Radiator coolant level Resistance Max. Transmission controller de. 2) Disconnect connector ATC5A. 1 z chassis ground 1) Turn the starting switch OFF. 4) Connect the connector.is normal. check around the engine and ralevel diator for coolant leakage before adding coolant . appears on machine Related information • This failure can be checked in the monitoring function (Code: 33100). Action of controller • None in particular. 1) Turn the starting switch OFF. HD605-7 20-543 (10) . 2) Disconnect connectors ATC5A and FL01.5) Turn the starting switch ON. 1 Mz is low. 2) Disconnect connector FL01. the engine may overheat. Possible causes and standard value in normal state 1) Turn the starting switch OFF. 1 z (Disconnection or defective FL01 (female) (1) contact) Wiring harness between FL01 (female) (2) – Resistance Max. Cause 1 Standard value in normal state/Remarks on troubleshooting • The radiator coolant level is normal. (1) – (2) Radiator coolant level Resistance Min. Voltage Voltage Max. 1 z Between FL01 (male) is normal. 3) Connect T-adapter.3) Connect T-adapter.

Resistance between Wiring harness between ATC1 (fe. 1) Turn the starting switch OFF. Transmission controller cut. 3) Turn the starting switch ON. Do not apply voltage between (1) – (2). 4 fective When failure code to turn transmisBetween sion cutout relay OFF is displayed ATC1 (14) (Example: 1500LO) – (8). When transmission cutout relay (R15) is replaced. is failure repaired? No Yes Relay (R15) is normal. 2) Disconnect connector ATC1. HD605-7 .ATC1 (female) (14). appears on machine Related information • None in particular. 4) Apply voltage between R15 (male) (1) – (2). 3) Connect T-adapter. 1 z Resistance Min. • The controller sets the gear in Neutral.3) Check the relay. 2) Disconnect connector R15. 3) Check the relay.TROUBLESHOOTING [D1B0KZ] [D1B0KZ] TRANSMISSION CONTROLLER CUTOUT: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E03 Contents of trouble Failure code Controller code D1B0KZ TM Transmission controller cutout relay: Disconnection or short cirTrouble cuit (KZ) (Disconnection or short circuit) • Abnormal voltage is generated in the transmission cutout relay circuit. 1 z 2 (Disconnection or defective R15 (female) (1) contact) Between R15 (female) (2) – chassis ground Resistance Max. 1 Mz 1) Turn the starting switch OFF. • The controller turns the transmission cutout relay OFF. 1 V 20 – 30 V 20-544 (10) HD465-7. 3) Connect T-adapter. (16) When failure code is not displayed Voltage Voltage Max. 2) Disconnect connector R15. 1 z Wiring harness between fuse BT2 Voltage between ATC1 20 – 30 V terminal (22) – ATC1 (female) (5) (5) – chassis ground 1) Turn the starting switch OFF. 3 Ground fault in wiring harness 1) Turn the starting switch OFF. Transmission controller de. Resistance 200 – 400 z Resistance Max. 2) Disconnect connectors ATC1 and R15.4) Turn the starting switch ON. 2) Disconnect connectors ATC1 and R15. Action of controller Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. male) (14) – R15 (female) (1) R15 (female) (1) – chassis ground Min. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Mz Disconnection in wiring harWiring harness between ATC1 (female) (14) – ness Resistance Max. 2) Replace R15 with normal one. Relay (R15) is defective. 1 out relay (R15) defective Between R15 (male) (1) – (2) 1) Turn the starting switch OFF. Between R15 (male) (3) – (5) Possible causes and standard value in normal state Apply 24 V between (1) – (2). 3) Insert T-adapter.

TROUBLESHOOTING [D1BOKZ] Related electrical circuit diagram HD465-7. HD605-7 20-545 (1) .

2) Disconnect connector ECMB. 4) Connect the connector. Problem that • This failure does not have a serious effect on the machine. 5 fective 5) Start the engine. 3) Connect T-adapter.4 V Voltage Voltage 9. or short circuit in engine output mode command line: Disconnection or short circuit (KZ) • Disconnection. 2) Disconnect connectors ATC5A and BRC5B. Action of controller • The controller controls in the power mode (The machine is fixed to the power mode). grounding fault. 1 z ECMB (female) (19) 1) Turn the starting switch OFF. ECMB (female) (19) – chassis ground 1) Turn the starting switch OFF. ness 3) Connect T-adapter. 3) Connect T-adapter. 2) Disconnect connector ATC1. Between ATC1 (female) (15). grounding fault. OR SHORT CIRCUIT IN ENGINE OUTPUT MODE COMMAND LINE: DISCONNECTION OR SHORT CIRCUIT (KZ) Action code E01 Contents of trouble Failure code Controller code D5ZMKZ TM Trouble Disconnection.4 – 12 V 0 – 2. Wiring harness between Resistance between ATC1 ATC1 (female) (15) – ECMB (female) (15). or short circuit occurs in engine output mode command line. GROUNDING FAULT.4) Disconnect the connector. 3) Connect T-adapter. HD605-7 .TROUBLESHOOTING [D5ZMKZ] [D5ZMKZ] DISCONNECTION. 2) Disconnect connectors ATC1 and ECMB. 1 V 2 Ground fault in wiring harness 3 Hot short in wiring harness Possible causes and standard value in normal state 4 Engine controller defective Related electrical circuit diagram 20-546 (10) HD465-7. appears on machine Related information • None in particular. ECMB (feMin. Between ATC1 (15) – In power mode chassis ground In economy mode Voltage Voltage 9. Between ECMB (19) – In power mode chassis ground In economy mode 1) Turn the starting switch OFF.4 V Voltage Max. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF.4 – 12 V 0 – 2. Transmission controller de. Disconnection in wiring har. 3) Connect T-adapter.2) Disconnect connectors ATC1 – ECMB. 1 Mz (female) (19) male) (19) – chassis ground 1) Turn the starting switch OFF. 5) Start the engine. 1 (Disconnection or defective Wiring harness between ATC1 (female) (15) – contact) Resistance Max.

1. ness 2 (Disconnection or defective Wiring harness between battery. Disconnection in wiring har. 2) Disconnect connector ATC1. (16) Voltage 20 – 30 V Voltage 20 – 30 V HD465-7. 24 V Min. (16) – chassis ground Resistance Max. perform troubleshooting for it first. 4) Connect the connector.3) Connect T-adapter. 20 – 30 V Wiring harness between battery re. 2) Disconnect connector ATC1 3) Insert T-adapter. (16) Transmission controller de1) Turn the starting switch OFF. 2) Disconnect connector ATC1. (17) – (8). Voltage between ATC1 contact) battery relay terminal B. 4) Connect the connector.TROUBLESHOOTING [DAQ0KK] [DAQ0KK] TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code E03 Contents of trouble Failure code Controller code DAQ0KK TM Trouble Transmission controller: Lowering of source/input voltage (KK) • While the engine is running. 3 Between ATC1 (7) – (8). Between ATC1 (9). (16) 1) Turn the starting switch OFF. 5) Turn the starting switch ON. 4) Connect the connector. (17) – (8). Related information • If the fuse is broken. (17) (9). fective 2) Disconnect connector ATC1 3) Insert T-adapter. 1 z Voltage Specific gravity Min. 1 Battery defective Battery voltage Specific gravity of battery fluid 1) Turn the starting switch OFF. 3) Connect T-adapter. (16) 1) Turn the starting switch OFF. 4) Connect the connector. (9). • The gear is set in Neutral suddenly during travel and the machine cannot start again until the voltage Problem that appears on machine rises to the normal level. – ATC1 (7) (7) – (8).Voltage between ATC1 20 – 30 V lay terminal M – ATC1 (9). Action of controller • The controller sets the gear in Neutral. Cause Standard value in normal state/Remarks on troubleshooting 1) Test the battery voltage and specific gravity of the battery fluid. 3) Insert T-adapter. 2) Disconnect connector ATC1. check the line between the fuse and BRC1 (female) (7).26 Possible causes and standard value in normal state 1) Turn the starting switch OFF. Wiring harness between ATC1 (female) (8). the voltages of both main power source voltage circuit and direct power source voltage circuit lower below 18 V. HD605-7 20-547 (10) . and (17) for grounding fault. • If failure code "ABOOMA" (Malfunction of alternator) is indicated. 5) Turn the starting switch ON.

HD605-7 .TROUBLESHOOTING [DAQ0KK] Related electrical circuit diagram 20-548 (1) HD465-7.

Between ATC1 (9). check the line between the fuse – ATC1 (female) (9) and (17) for grounding fault. (16) 1) Turn the starting switch OFF. appears on machine Related information • If the fuse is broken. 2) Disconnect connector ATC1. 3) Connect T-adapter. 1 z Possible causes and standard value in normal state 1) Turn the starting switch OFF. (17) (9).3) Insert T-adapter. (16) – chassis ground Resistance Max. Disconnection in wiring har. fective 5) Turn the starting switch ON. 4) Connect the connector. (17) – (8). 2) Disconnect connector ATC1. 2) Disconnect connector ATC1. HD605-7 20-549 (10) .4) Connect the connector. 2) Disconnect connector ATC1. ness 1 (Disconnection or defective Wiring harness between battery – Voltage between battery relay terminal B – 20 – 30 V contact) battery relay terminal B chassis ground 1) Turn the starting switch OFF. Transmission controller de. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. Wiring harness between ATC1 (female) (8). Wiring harness between battery re.Voltage between ATC1 20 – 30 V lay terminal M – ATC1 (9).TROUBLESHOOTING [DAQ1KK] [DAQ1KK] MAIN POWER LINE OF TRANSMISSION CONTROLLER: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code E03 Contents of trouble Failure code Controller code DAQ1KK TM Trouble Main power line of transmission controller: Lowering of source/input voltage (KK) • The main power source voltage is lower than the direct power source voltage by 5 V or more. Problem that • The condition before the failure is kept. (17) – (8). Action of controller • The controller prohibits updating of information about input. 3) Insert T-adapter. (16) Voltage 20 – 30 V HD465-7. 2 4) Connect the connector. 5) Turn the starting switch ON. 3) Connect T-adapter.

HD605-7 .TROUBLESHOOTING [DAQ1KK] Related electrical circuit diagram 20-550 (1) HD465-7.

3) Turn the starting switch ON When transmission cutout relay (R15) is replaced. 2) Disconnect connectors ATC2 and R15. 3) Insert T-adapter. 2) Replace R15 with normal one. Relay (R15) is defective. 1 z Resistance Min. Between R15 (male) (3) – (5) Apply 24 V between (1) – (2).TROUBLESHOOTING [DAQ2KK] [DAQ2KK] TRANSMISSION CONTROLLER LOAD POWER LINE: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code E03 Contents of trouble Failure code Controller code DAQ2KK TM Trouble Transmission controller load power line: Lowering of source/input voltage (KK) • While the transmission controller source voltage is normal. check the line between the fuse and ATC1 (female) (9) and (17) for grounding fault. is failure repaired? No Yes Relay (R15) is normal. 2) Disconnect connector ATC2. 1 z (female) (3) 1) Turn the starting switch OFF. HD605-7 20-551 (10) . 2) Disconnect connector R15. Between ATC2 (1). 1) Turn the starting switch OFF. Action of controller Problem that • The gear is set in Neutral suddenly during travel and the machine cannot start again. Disconnection in wiring har. Transmission controller de. 4) Connect the connector. 3) Check the relay.3) Check the relay. 2) Disconnect connector R15. 1 out relay (R15) defective Between R15 (male) (1) – (2) 1) Turn the starting switch OFF. appears on machine Related information • If the fuse is broken.Wiring harness between fuse BT3 Voltage between R15 (female) (3) – chassis ness to 14 – R15 (female) (3) 2 ground (Disconnection or defective contact) 1) Turn the starting switch OFF. (12) – chassis ground Voltage 20 – 30 V HD465-7. 3) Connect T-adapter. Do not apply voltage between (1) – (2). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 3 4) Connect the connector. 2) Disconnect connectors R15. fective 5) Turn the starting switch ON. (12) – R15 Resistance Max. Transmission controller cut. the solenoid source voltage is below 18 V. Resistance 200 – 400 z Resistance Max. • The controller turns the transmission cutout relay OFF. 4) Apply voltage between R15 (male) (1) – (2). • The controller sets the gear in Neutral. 20 – 30 V Wiring harness between ATC2 (1). 1 Mz Possible causes and standard value in normal state 1) Turn the starting switch OFF.3) Insert T-adapter.

HD605-7 .TROUBLESHOOTING [DAQ2KK] Related electrical circuit diagram 20-552 (1) HD465-7.

TROUBLESHOOTING [DAQ3KK] [DAQ3KK] DIRECT LINE OF TRANSMISSION CONTROLLER BATTERY: LOWERING OF SOURCE/INPUT VOLTAGE (KK) Action code E03 Contents of trouble Failure code Controller code DAQ3KK TM Trouble Direct line of transmission controller battery: Lowering of source/ input voltage (KK) • The direct power source voltage is below 5 V. Voltage between ATC1 20 – 30 V battery relay terminal B. contact) Possible causes 3) Insert T-adapter. and standard value 4) Connect the connector. check the line between the fuse and ATC1 (female) (7) for grounding fault. 3) Connect T-adapter. Between ATC1 (7) – (8). Problem that • This failure does not have a serious effect on the machine. appears on machine Related information • If the fuse is broken. Action of controller • None in particular. – ATC1 (7) (7) – (8). Wiring harness between ATC1 (female) (8). 2) Disconnect connector ATC1. in normal state Wiring harness between battery. 2) Disconnect connector ATC1. (16) 1) Turn the starting switch OFF. (16) Voltage 20 – 30 V Related electrical circuit diagram HD465-7. HD605-7 20-553 (10) . Resistance Max.(16) – chassis ground ness 1 (Disconnection or defective 1) Turn the starting switch OFF. 2) Disconnect connector ATC1. fective 5) Turn the starting switch ON.3) Insert T-adapter. 2 4) Connect the connector. Transmission controller de. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 z Disconnection in wiring har.

does not Contents of trouble agree with setting in the controller. ness 3) Connect T-adapter. 2 (Disconnection or defective Wiring harness between ATC5A (female) (1) – contact) Resistance Max.3) Connect T-adapter.2) Disconnect connector ATC5A. Transmission controller de. Problem that • When the starting operation is performed. 1 Mz Related electrical circuit diagram 20-554 (10) HD465-7. 2) Disconnect connector ATC5A. Disconnection in wiring har. Cause 1 Wrong connection of connector Standard value in normal state/Remarks on troubleshooting The connector of the connector check signal is connected normally. appears on machine Related information • None in particular. • This failure is not recorded in the fault history. 4 fective Wiring harness between ATC5A (female) (1) – Resistance Max. aConnector check signal connector: ATC3A (1) (OPEN). • The controller turns the transmission cutout relay OFF. that is input when the starting switch is turned to the ON position. Wiring harness between ATC3A (female) (1) – chassis ground Resistance between ATC3A (female) (1) – chassis ground Min. 1 Mz 3 Ground fault in wiring harness 1) Turn the starting switch OFF. 1 z chassis ground Possible causes and standard value in normal state 1) Turn the starting switch OFF. HD605-7 . 2) Disconnect connector ATC3A. 1 z chassis ground Between ATC3A (female) (1) – chassis ground Resistance Min. 3) Connect T-adapter. the machine does not start.TROUBLESHOOTING [DAQ9KM] [DAQ9KM] TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKE IN OPERATION OR SETTING (KM) Action code E03 Failure code Controller code DAQ9KM TM Trouble Transmission controller wiring harness: Mistake in operation or setting (KM) • The connector check signal. Action of controller • The controller keeps the gear speed in neutral. ATC5A (1) (CLOSE) 1) Turn the starting switch OFF.

Disconnection in wiring har. Min. 1 z chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 1) Turn the starting switch OFF. • The controller turns the transmission cutout relay OFF. 02702. Problem that • When the starting operation is performed. 2) Disconnect connector ATC5B. appears on machine Related information • This failure can be checked in the monitoring function (Code: 02701. Action of controller • The controller sets the gear speed in neutral. 1 Mz MS21 (female) – chassis ground Possible causes Ground fault in wiring harand standard value 2 ness in normal state 3 Wrong setting of rotary switch • For setting of the rotary switch.TROUBLESHOOTING [DAQ9KQ] [DAQ9KQ] TRANSMISSION CONTROLLER WIRING HARNESS: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code E03 Contents of trouble Failure code Controller code DAQ9KQ TM Trouble Transmission controller wiring harness: Disagreement of model selection signals (KQ) • The model selection signal input when the starting switch is turned ON is different from the setting of the controller. 1 z 4 Wrong setting of rotary switch Related electrical circuit diagram HD465-7. the machine does not start. • This failure is not recorded in the fault history. HD605-7 20-555 (10) . see ADJUSTING TRANSMISSION CONTROLLER. 02703). Wiring harness between ATC5A (female) (15) – MS21 (female) Resistance between ATC5A (female) (15). 3) Connect T-adapter.3) Connect T-adapter. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 1 Mz Between ATC5A (female) (16) – chassis ground Resistance Max. ness 1 Wiring harness between ATC5A (female) (14) – Resistance Max. 2) Disconnect connector ATC5B. 3) Connect T-adapter. 1 z Between ATC5A (female) (15) – chassis ground Resistance Min. Between ATC5A (female) (14) – chassis ground Resistance Max. 1 z (Disconnection or defective chassis ground contact) Wiring harness between ATC5A (female) (16) – Resistance Max.

appears on machine Related information • This failure can be checked in the monitoring function (Code: 30801). [DAQSMA] TRANSMISSION CONTROLLER: MALFUNCTION (MA) Action code E03 Contents of trouble Failure code Controller code DAQSMA TM Trouble Transmission controller: Malfunction (MA) • Communication with the machine monitor (S-NET) is defective and the optional items cannot be set. [DAQSMA] [DAQAKQ] TRANSMISSION CONTROLLER ROTARY SWITCH: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ) Action code E03 Contents of trouble Failure code Controller code DAQAKQ TM Trouble Transmission controller wiring harness: Disagreement of model selection signals (KQ) • Setting of the model by the rotary switch does not agree with setting in the controller.TROUBLESHOOTING [DAQAKQ]. the machine does not start. Cause Standard value in normal state/Remarks on troubleshooting Wrong setting of rotary • For setting of the rotary switch. perform troubleshooting for it first. and standard value • For setting of the rotary switch. HD605-7 . Problem that • When the starting operation is performed. the machine does not start.aIf the failure is repaired by replacing the transmission controller. in normal state Transmission controller de. appears on machine • If failure code "DAQSKR" of the machine monitor system is indicated. see ADJUSTING TRANSMISSION Possible causes 1 switch CONTROLLER. Cause Standard value in normal state/Remarks on troubleshooting Possible causes aIf the failure is not repaired by replacing the transmission controller. • The controller turns the transmission cutout relay OFF. the transmission controller is defective. the starting switch does not need to be turned to the left). Action of controller • The controller sets the gear speed in neutral. 20-556 (10) HD465-7. Action of controller • The controller sets the gear speed in Neutral. 1 Machine monitor defective and standard value the machine monitor is defective. the 2 fective transmission controller is defective. Related information • Do not turn the starting switch to the left before starting the engine (Since the engine preheating system is automatic. Problem that • When the starting operation is performed. see ADJUSTING TRANSMISSION in normal state Transmission controller de2 CONTROLLER. fective aIf setting is normal. • This failure is not recorded in the fault history.

1 z – CN21 (female) (1) 1) Turn the starting switch OFF. and standard value ness 3) Connect T-adapter. • If the shift lever is set in the "N" position. Action of controller Problem that • If the shift lever is set in the "N" position. 31609. 3 Transmission controller defective When disResistance Min. 31619). the machine cannot start until it is stopped. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 1 Lockup clutch fill switch defective Between CN21 (male) (1) – chassis ground When disResistance Min. Related information • This failure can be checked in the monitoring function (Code: 31519. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (17) contact) Resistance Max. 1 Mz engaged When enResistance Max. • The controller keeps the current gear speed. 3) Connect T-adapter. Possible causes Disconnection in wiring har. HD605-7 20-557 (10) . 1 z gaged Related electrical circuit diagram HD465-7. 3) Connect T-adapter. fill switch is OFF.TROUBLESHOOTING [DDTGKA] [DDTGKA] LOCKUP CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTGKA TM Lockup clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. 1 Mz Between ATC5A (female) (17) – engaged chassis ground When enResistance Max. • The gear cannot be shifted. the clutch is engaged but the signal from the fill switch is not turned ON. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF.2) Disconnect connectors ATC5A and CN21. appears on machine • The lockup pilot lamp does not light up. the controller keeps the gear in Neutral. 2) Disconnect connector CN21. and slip is not sensed) • When the output to the lockup clutch ECMV is turned ON.

3) Connect T-adapter. 31610). • If the shift lever is set in the "N" position. 31600. 3 Transmission controller defective When disResistance Min. and slip is not sensed) • When the output to the Hi clutch ECMV is turned ON. the controller keeps the gear in Neutral. 3) Connect T-adapter. 1 z CN19 (female) (1) 1) Turn the starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. the machine cannot start until it is stopped. • The controller keeps the current gear speed.TROUBLESHOOTING [DDTHKA] [DDTHKA] HI CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTHKA TM Hi clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. 1 Mz Between ATC5A (female) (12) – engaged chassis ground When enResistance Max. 1 z gaged Related electrical circuit diagram 20-558 (10) HD465-7. appears on machine • If the shift lever is set in the "N" position. 2) Disconnect connector ATC5A. Related information • This failure can be checked in the monitoring function (Code: 31511. 1 Mz engaged When enResistance Max. fill switch is OFF. 1 z gaged 1) Turn the starting switch OFF. 2) Disconnect connectors ATC5A and CN19. HD605-7 . 3) Connect T-adapter. 2) Disconnect connector CN19. the clutch is engaged but the signal from the fill switch is not turned ON. Action of controller Problem that • The gear cannot be shifted. Wiring harness between ATC5A (female) (12) – Resistance Max. 1 Hi clutch fill switch defective Between CN19 (male) (1) – chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact) When disResistance Min.

1 Mz Between ATC5A (female) (10) – engaged chassis ground When enResistance Max. 1 z gaged 1) Turn the starting switch OFF. 1 Mz engaged When enResistance Max. 2) Disconnect connector CN17. 3 Transmission controller defective When disResistance Min. 31601. the clutch is engaged but the signal from the fill switch is not turned ON. 3) Connect T-adapter. 3) Connect T-adapter. 31611). Related information • This failure can be checked in the monitoring function (Code: 31510. 2) Disconnect connectors ATC5A and CN17. fill switch is OFF. the machine cannot start until it is stopped. Action of controller Problem that • The gear cannot be shifted. 3) Connect T-adapter. • If the shift lever is set in the "N" position. appears on machine • If the shift lever is set in the "N" position. 1 Lo clutch fill switch defective Between CN17 (male) (1) – chassis ground Possible causes Disconnection in wiring harand standard value ness 2 in normal state (Disconnection or defective contact) When disResistance Min.TROUBLESHOOTING [DDTJKA] [DDTJKA] LO CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTJKA TM Lo clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. the controller keeps the gear in Neutral. Wiring harness between ATC5A (female) (10) Resistance Max. • The controller keeps the current gear speed. 2) Disconnect connector ATC5A. 1 z gaged Related electrical circuit diagram HD465-7. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. and slip is not sensed) • When the output to the Lo clutch ECMV is turned ON. 1 z – CN17 (female) (1) 1) Turn the starting switch OFF. HD605-7 20-559 (10) .

Possible causes Disconnection in wiring har. Related information • This failure can be checked in the monitoring function (Code: 31512. 3 Transmission controller defective When disResistance Min. 1 z gaged Related electrical circuit diagram 20-560 (10) HD465-7. and slip is not sensed) • When the output to the 1st clutch ECMV is turned ON. the machine cannot start until it is stopped. fill switch is OFF. 2) Disconnect connector CN7. 1 z – CN7 (female) (1) 1) Turn the starting switch OFF. 3) Connect T-adapter. the clutch is engaged but the signal from the fill switch is not turned ON. HD605-7 . Problem that appears on machine • If the shift lever is set in the "N" position. • The controller keeps the current gear speed. and standard value ness 3) Connect T-adapter. 1 Mz Between ATC5A (female) (13) – engaged chassis ground When enResistance Max. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. • If the shift lever is set in the "N" position. the controller keeps the gear in neutral. 31612). Action of controller • The gear cannot be shifted.TROUBLESHOOTING [DDTKKA] [DDTKKA] 1ST CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTKKA TM 1st clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. 1 1st clutch fill switch defective When disResistance Min. 31602. 2) Disconnect connector ATC5A. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (13) contact) Resistance Max. 1 z gaged 1) Turn the starting switch OFF.2) Disconnect connectors ATC5A and CN7. 3) Connect T-adapter. 1 Mz Between CN7 (male) (1) – chassis engaged ground When enResistance Max.

2) Disconnect connector ATC5A. the clutch is engaged but the signal from the fill switch is not turned ON.2) Disconnect connectors ATC5A and CN9. the machine cannot start until it is stopped. • If the shift lever is set in the "N" position. 1 Mz Between CN9 (male) (1) – chassis engaged ground When enResistance Max. and slip is not sensed) • When the output to the 2nd clutch ECMV is turned ON. 1 z CN9 (female) (1) 1) Turn the starting switch OFF. Action of controller • The gear cannot be shifted. Related information • This failure can be checked in the monitoring function (Code: 31513. Possible causes Disconnection in wiring har. • The controller keeps the current gear speed. 1 Mz Between ATC5A (female) (14) – engaged chassis ground When enResistance Max. 31603. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (14) – contact) Resistance Max. 1 z gaged 1) Turn the starting switch OFF. 3 Transmission controller defective When disResistance Min.TROUBLESHOOTING [DDTLKA] [DDTLKA] 2ND CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTLKA TM 2nd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. the controller keeps the gear in neutral. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 3) Connect T-adapter. 31613). HD605-7 20-561 (10) . fill switch is OFF. 3) Connect T-adapter. 1 2nd clutch fill switch defective When disResistance Min. Problem that appears on machine • If the shift lever is set in the "N" position. 1 z gaged Related electrical circuit diagram HD465-7. and standard value ness 3) Connect T-adapter. 2) Disconnect connector CN9.

3 Transmission controller defective When disResistance Min.TROUBLESHOOTING [DDTMKA] [DDTMKA] 3RD CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTMKA TM 3rd clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure.2) Disconnect connectors ATC5A and CN13. 1 Mz engaged When enResistance Max. and standard value ness 3) Connect T-adapter. 31614). HD605-7 . 3) Connect T-adapter. 2) Disconnect connector CN13. 1 z CN13 (female) (1) 1) Turn the starting switch OFF. Possible causes Disconnection in wiring har. Problem that appears on machine • If the shift lever is set in the "N" position. and slip is not sensed) • When the output to the 3rd clutch ECMV is turned ON. the controller keeps the gear in Neutral. 3) Connect T-adapter. 1 z gaged Related electrical circuit diagram 20-562 (10) HD465-7. • The controller keeps the current gear speed. 31604. 1 3rd clutch fill switch defective Between CN13 (male) (1) – chassis ground When disResistance Min. Action of controller • The gear cannot be shifted. 1 z gaged 1) Turn the starting switch OFF. 1 Mz Between ATC5A (female) (15) – engaged chassis ground When enResistance Max. fill switch is OFF. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (15) – contact) Resistance Max. Related information • This failure can be checked in the monitoring function (Code: 31514. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. the machine cannot start until it is stopped. • If the shift lever is set in the "N" position. 2) Disconnect connector ATC5A. the clutch is engaged but the signal from the fill switch is not turned ON.

1 z gaged 1) Turn the starting switch OFF. the machine cannot start until it is stopped. • The controller keeps the current gear speed. Possible causes Disconnection in wiring har. 1 z gaged Related electrical circuit diagram HD465-7. 1 Mz engaged When enResistance Max. the clutch is engaged but the signal from the fill switch is not turned ON. • If the shift lever is set in the "N" position. 1 z CN11 (female) (1) 1) Turn the starting switch OFF. 1 R clutch fill switch defective Between CN11 (male) (1) – chassis ground When disResistance Min. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (16) – contact) Resistance Max. 3 Transmission controller defective When disResistance Min. Action of controller • The gear cannot be shifted.TROUBLESHOOTING [DDTNKA] [DDTNKA] R CLUTCH FILL SWITCH: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTNKA TM R clutch fill switch: Disconnection (KA) Trouble (Command is Holding pressure. 3) Connect T-adapter. and slip is not sensed) • When the output to the R clutch ECMV is turned ON. 3) Connect T-adapter. HD605-7 20-563 (10) . 2) Disconnect connector CN11. fill switch is OFF. Related information • This failure can be checked in the monitoring function (Code: 31516.2) Disconnect connectors ATC5A and CN11. Problem that appears on machine • If the shift lever is set in the "N" position. the controller keeps the gear in Neutral. 31616). 31606. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector ATC5A. 1 Mz Between ATC5A (female) (16) – engaged chassis ground When enResistance Max. and standard value ness 3) Connect T-adapter.

2) Disconnect connector ATC5A. 2 in normal state (Disconnection or defective Wiring harness between ATC5A (female) (11) – contact) Resistance Max. Related information • This failure can be checked in the monitoring function (Code: 31515. and slip is not sensed) • When the output to the 4th clutch ECMV is turned ON. 1 Mz Between ATC5A (female) (11) – engaged chassis ground When enResistance Max. the machine cannot start until it is stopped. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 31615). 1 z gaged Related electrical circuit diagram 20-564 (10) HD465-7.2) Disconnect connectors ATC5A and CN15. 2) Disconnect connector CN15. 3 Transmission controller defective When disResistance Min. Possible causes Disconnection in wiring har. 3) Connect T-adapter. • The controller keeps the current gear speed. HD605-7 . 1 Mz engaged When enResistance Max. and standard value ness 3) Connect T-adapter. 1 z CN15 (female) (1) 1) Turn the starting switch OFF. 1 4th clutch fill switch defective Between CN15 (male) (1) – chassis ground When disResistance Min. 1 z gaged 1) Turn the starting switch OFF. • If the shift lever is set in the "N" position. the clutch is engaged but the signal from the fill switch is not turned ON. 3) Connect T-adapter. Problem that appears on machine • If the shift lever is set in the "N" position. the controller keeps the gear in Neutral. Action of controller • The gear cannot be shifted.TROUBLESHOOTING [DDTPKA] [DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DDTPKA TM 4th clutch fill switch : Disconnection (KA) Trouble (Command is Holding pressure. 31605. fill switch is OFF.

1 z SF1 (female) (6) Possible causes and standard value in normal state Wiring harness between ATC5B (female) (6) – Resistance Max. 1 z SF1 (female) (3) Resistance Max. 2) Disconnect connector SF1. • The gear may be shifted up above the gear speed set with the shift lever. Problem that • The gear is kept in neutral and the machine cannot start.. 1 z SF1 (female) (10) Wiring harness between ATC5B (female) (10) – Resistance Max. SF1 (female) (3) – chassis ground Resistance between ATC5B (female) (3). 2) Disconnect connectors ATC5B and SF1. 2) Disconnect connectors ATC5B and SF1. HD605-7 20-565 (10) . appears on machine • The travel direction cannot be changed. 1 Mz Min. 3) Connect T-adapter. Wiring harness between ATC5B (female) (2) – SF1 (female) (3) 3 Hot short in wiring harness Wiring harness between ATC5B (female) (3) – SF1 (female) (4) Resistance between ATC5B (female) (2). 1 Mz Wiring harness between ATC5B (female) (4) – SF1 (female) (5) Min. 1 z SF1 (female) (9) Wiring harness between ATC5B (female) (9) – Resistance Max. 3) Connect T-adapter. 1 Mz HD465-7. Cause 1 Wrong operation Standard value in normal state/Remarks on troubleshooting • The shift lever is pressed by some force while it is not operated. • The shift lever is stopped between 2 positions. 1 z 2 (Disconnection or defective SF1 (female) (5) contact of connector) Wiring harness between ATC5B (female) (5) – Resistance Max. 3) Insert T-adapter. SF1 (female) (5) – chassis ground Min. Wiring harness between BT3 (10) – SF1 (female) (1) 1) Turn the starting switch OFF.SF1 (female) (4) ness Wiring harness between ATC5B (female) (4) – Resistance Max. Action of controller • The controller keeps the condition before occurrence of the failure. 1 z SF1 (female) (11) 1) Turn the starting switch OFF. 1 z SF1 (female) (8) Wiring harness between ATC5B (female) (8) – Resistance Max. 1) Turn the starting switch OFF. Wiring harness between ATC5B (female) (2) – Resistance Max. Related information • None in particular. 1 z SF1 (female) (7) Wiring harness between ATC5B (female) (7) – Resistance Max. • All the shift lever position lamps go off.TROUBLESHOOTING [DF10KA] [DF10KA] SHIFT LEVER: DISCONNECTION (KA) Action code E03 Contents of trouble Failure code Controller code DF10KA TM Trouble Shift lever: Disconnection (KA) • The shift lever signal is not input at all. SF1 (female) (4) – chassis ground Resistance between ATC5B (female) (4). 1 z Wiring harness between ATC5B (female) (3) – Resistance Max. 1 z Disconnection in wiring har.

4) Connect the connector. 1 Mz Min. SF1 (female) (9) – chassis ground Resistance between ATC5B (female) (9). 3) Insert T-adapter. 1 V 20 – 30 V Max. 1 Mz Wiring harness between ATC5B (female) (6) – SF1 (female) (7) Min. SF1 (female) (7) – chassis ground Resistance between ATC5B (female) (7). 1 Mz Wiring harness between ATC5B (female) (9) – SF1 (female) (10) Min. SF1 (female) (10) – chassis ground Resistance between ATC5B (female) (10). 5) Turn the starting switch ON. SF1 (female) (11) – chassis ground Min. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. Between SF1 (3) – chassis ground Between SF1 (4) – chassis ground Between SF1 (5) – chassis ground Between SF1 (6) – chassis ground Between SF1 (7) – chassis ground Between SF1 (8) – chassis ground Between SF1 (9) – chassis ground Between SF1 (10) – chassis ground Between SF1 (11) – chassis ground Min. 1 V 20 – 30 V Max. 2) Disconnect connector SF1.TROUBLESHOOTING [DF10KA] Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between ATC5B (female) (5) – SF1 (female) (6) Resistance between ATC5B (female) (5). SF1 (female) (8) – chassis ground Resistance between ATC5B (female) (8). HD605-7 . 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. 1 V 4 Gearshift lever defective 20-566 (10) HD465-7. 1 Mz Wiring harness between ATC5B (female) (10) – SF1 (female) (11) 1) Turn the starting switch OFF. 1 Mz Possible causes and standard value in normal state When shift range is "R" When shift range is not "R" When shift range is "N" When shift range is not "N" When shift range is "D" When shift range is not "D" When shift range is "6" When shift range is not "6" When shift range is "5" When shift range is not "5" When shift range is "4" When shift range is not "4" When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2" When shift range is "1" When shift range is not "1" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 – 30 V Max. SF1 (female) (6) – chassis ground Resistance between ATC5B (female) (6). 1 V 20 – 30 V Max. 1 Mz Wiring harness between ATC5B (female) (7) – SF1 (female) (8) 3 Hot short in wiring harness Wiring harness between ATC5B (female) (8) – SF1 (female) (9) Min.

1 V 20 – 30 V Max. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. 2) Disconnect connector ATC5B. 1 V 20 – 30 V Max. 3) Insert T-adapter.chassis ground 5 "6" in normal state fective When shift range is "5" Between ATC5B (6) – When shift range is not chassis ground "5" When shift range is "4" Between ATC5B (7) – When shift range is not chassis ground "4" When shift range is "3" Between ATC5B (8) – When shift range is not chassis ground "3" When shift range is "2" Between ATC5B (9) – When shift range is not chassis ground "2" When shift range is "1" Between ATC5B (10) – When shift range is not chassis ground "1" HD465-7. 1 V When shift range is "6" Possible causes Between ATC5B (5) – When shift range is not and standard value Transmission controller de. 5) Turn the starting switch ON. 1 z 20 – 30 V Max. 1 V 20 – 30 V Max. 4) Connect the connector. When shift range is "R" Between ATC5B (2) – When shift range is not chassis ground "R" When shift range is "N" Between ATC5B (3) – When shift range is not chassis ground "N" When shift range is "D" Between ATC5B (4) – When shift range is not chassis ground "D" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 – 30 V Max.TROUBLESHOOTING [DF10KA] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. HD605-7 20-567 (10) . 1 V 20 – 30 V Max. 1 V 20 – 30 V Max.

TROUBLESHOOTING [DF10KA] Related electrical circuit diagram 20-568 (1) HD465-7. HD605-7 .

1 V Wiring harness between ATC5B (female) (9) – SF1 (female) (10) Max. 1 V Wiring harness between ATC5B (female) (10) – SF1 (female) (11) Max. (1): N > D > 6 > 5 > 4 > 3 > 2 > 1. SF1 (female) (11) – chassis ground Max. SF1 (female) (9) – chassis ground Voltage between ATC5B (female) (9). 1 V Wiring harness between ATC5B (female) (7) – SF1 (female) (8) Max. 1 V Max. SF1 (female) (8) – chassis ground Voltage between ATC5B (female) (8). 1 V Possible causes Short circuit in wiring harand standard value 1 ness in normal state (Hot short in wiring harness) Wiring harness between ATC5B (female) (6) – SF1 (female) (7) Wiring harness between ATC5B (female) (5) – SF1 (female) (6) Max. • The gear may be shifted up above the gear speed set with the shift lever. 3) Insert T-adapter. HD605-7 20-569 (10) .TROUBLESHOOTING [DF10KB] [DF10KB] SHIFT LEVER: SHORT CIRCUIT (KB) Action code E03 Contents of trouble Failure code Controller code DF10KB TM Trouble Shift lever: Short circuit (KB) • The shift lever signals are input from 2 or more systems. SF1 (female) (6) – chassis ground Voltage between ATC5B (female) (6). Problem that • The gear is kept in neutral and the machine cannot start. • The controller controls with the signal having higher priority. 1 V Wiring harness between ATC5B (female) (3) – SF1 (female) (4) Max. the controller sets the gear in neutral. SF1 (female) (10) – chassis ground Voltage between ATC5B (female) (10). Action of controller (2): N > R • If the signals of systems (1) and (2) are input simultaneously. 2) Disconnect connectors ATC5B and SF1. SF1 (female) (4) – chassis ground Voltage between ATC5B (female) (4). SF1 (female) (3) – chassis ground Voltage between ATC5B (female) (3). appears on machine Related information • None in particular. 1 V Wiring harness between ATC5B (female) (8) – SF1 (female) (9) Max. SF1 (female) (5) – chassis ground Voltage between ATC5B (female) (5). Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. SF1 (female) (7) – chassis ground Voltage between ATC5B (female) (7). Wiring harness between ATC5B (female) (2) – SF1 (female) (3) Voltage between ATC5B (female) (2). 1 V Wiring harness between ATC5B (female) (4) – SF1 (female) (5) Max. 1 V HD465-7. • The shift lever position lamp is different from the shift lever position.

1 z 20 – 30 V Max. 1 V 20 – 30 V Max. 1 z 20 – 30 V Max. 1 V 20 – 30 V Max. 3) Insert T-adapter. 1 V 20 – 30 V Max. 1 V 2 Gearshift lever defective Between SF1 (6) – chassis ground Between SF1 (7) – chassis ground Between SF1 (8) – chassis ground Possible causes and standard value in normal state Between SF1 (9) – chassis ground Between SF1 (10) – chassis ground Between SF1 (11) – chassis ground 1) Turn the starting switch OFF. 2) Disconnect connector ATC5B. 1 V 20 – 30 V Max. 5) Turn the starting switch ON. 1 V 20 – 30 V Max. 2) Disconnect connector SF1.TROUBLESHOOTING [DF10KB] Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 4) Connect the connector. 1 V 20 – 30 V Max. HD605-7 . 4) Connect the connector. When the right FNR switch is installed (Turn the right FNR switch ON) When shift range is "R" Between ATC5B (2) – When shift range is not chassis ground "R" When shift range is "N" Transmission controller de. 5) Turn the starting switch ON.Between ATC5B (3) – When shift range is not 3 chassis ground fective "N" When shift range is "D" Between ATC5B (4) – When shift range is not chassis ground "D" Between ATC5B (5) – When shift range is "6" chassis ground When shift range is not "6" When shift range is "5" Between ATC5B (6) – When shift range is not chassis ground "5" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 – 30 V Max. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. Between SF1 (3) – chassis ground Between SF1 (4) – chassis ground Between SF1 (5) – chassis ground When shift range is "R" When shift range is not "R" When shift range is "N" When shift range is not "N" When shift range is "D" When shift range is not "D" When shift range is "6" When shift range is not "6" When shift range is "5" When shift range is not "5" When shift range is "4" When shift range is not "4" When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2" When shift range is "1" When shift range is not "1" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 – 30 V Max. 3) Insert T-adapter. 1 V 20-570 (10) HD465-7. 1 V 20 – 30 V Max.

1 V 20 – 30 V Max.TROUBLESHOOTING [DF10KB] Cause Standard value in normal state/Remarks on troubleshooting When shift range is "4" Between ATC5B (7) – When shift range is not chassis ground "4" Voltage Voltage Voltage Voltage Voltage Voltage Voltage Voltage 20 – 30 V Max. 1 V Between ATC5B (8) – chassis ground Possible causes Transmission controller deand standard value 3 fective in normal state Between ATC5B (9) – chassis ground When shift range is "3" When shift range is not "3" When shift range is "2" When shift range is not "2" When shift range is "1" Between ATC5B (10) – When shift range is not chassis ground "1" Related electrical circuit diagram - HD465-7. 1 V 20 – 30 V Max. 1 V 20 – 30 V Max. HD605-7 20-571 (10) .

Disconnection in wiring har. Wiring harness between ATC3B (female) (9) – CN24 (female) (2) Voltage between ATC3B (female) (9). 1 z CN24 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A.3) Connect T-adapter. 3) Insert T-adapter.Oil temperature: 25°C Resistance 37 – 50 kz male) (9) – ATC3A (feOil temperature: 100°C Resistance 3. CN24 (female) (2) – chassis ground Max. ness 2 Wiring harness between ATC3B (female) (9) – Resistance Max. fixing the sensed oil temperature high. ATC3B. HD605-7 . Transmission controller de. appears on machine • This failure can be checked in the monitoring function (Code: 32500). 1 Mz Ground fault in wiring har3 Possible causes ness and standard value in normal state 4 Hot short in wiring harness 1) Turn the starting switch OFF. referring to TESTING AND ADJUSTING. Wiring harness between ATC3B (female) (9) – CN24 (female) (2) Resistance between ATC3B (female) (9). Between CN24 (male) Oil temperature: 25°C Resistance 37 – 50 kz (1) – (2) Oil temperature: 100°C Resistance 3. Cause Standard value in normal state/Remarks on troubleshooting 1) Turn the starting switch OFF. 2) Disconnect connector CN24. 2) Disconnect connectors ATC3B and CN24. CN24 (female) (2) – chassis ground Min.0 kz 1 Transmission oil temperature sensor defective 1) Turn the starting switch OFF.5 – 4. fective Between ATC3B (fe. 1 V 1) Turn the starting switch OFF. 5 5) Turn the starting switch ON. 1 z (Disconnection or defective CN24 (female) (2) contact) Wiring harness between ATC3A (female) (16) – Resistance Max. 3) Connect T-adapter. 3) Insert T-adapter. 2) Disconnect connectors ATC3B and CN24. 4) Turn the starting switch ON. perform the initial learning of the transmission controller. Related information • After repairing the failure and confirming resetting of the machine. "Inspection of machine monitor".TROUBLESHOOTING [DGF1KX] [DGF1KX] TRANSMISSION VALVE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX) Action code E03 Failure code Controller code DGF1KX TM Trouble Transmission valve oil temperature sensor: Out of input signal range (KX) • The voltage of the signal circuit of the transmission valve oil temperature sensor is below 0. 3) Connect T-adapter. Problem that • Gear shift shocks become large. Action of controller • The controller controls the clutch oil pressure.0 kz male) (16) 20-572 (10) HD465-7.97 V (above Contents of trouble 150°C) or very different from the torque converter oil temperature signal.5 – 4. and CN24.4) Connect the connector. 2) Disconnect connectors ATC3A and ATC3B.

HD605-7 20-573 (1) .TROUBLESHOOTING [GDF1KX] Related electrical circuit diagram HD465-7.

4) Connect the connector. 1 z TC-SE (female) (2) contact) Wiring harness between ATC3A (female) (16) – Resistance Max. 2) Disconnect connectors ATC3A. 4) Turn the starting switch ON. 3) Insert T-adapter. Disconnection in wiring har.3) Connect T-adapter. 3) Connect T-adapter.5 – 4. appears on machine Related information • This failure can be checked in the monitoring function (Code: 30100). 2) Disconnect connector CN23. 2) Disconnect connectors ATC3B and CN23. Torque converter oil temper.0 kz 1) Turn the starting switch OFF. Action of controller • None in particular. 1 ature sensor defective Between CN23 (T/C-T) Oil temperature: 25°C Resistance 37 – 50 kz (male) (1) – (2) Oil temperature: 100°C Resistance 3. Wiring harness between ATC3B (female) (7) – CN23 (female) (2) Resistance between ATC3B (female) (7). CN23 (female) (2) – chassis ground Max. 1 z CN23 (female) (1) 1) Turn the starting switch OFF. 2) Disconnect connectors ATC3A and ATC3B. Wiring harness between ATC3B (female) (7) – CN23 (female) (2) Voltage between ATC3B (female) (7). 2) Disconnect connectors ATC3B and CN23.TROUBLESHOOTING [DGT1KX] [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUTSIGNAL RANGE (KX) Action code E01 Contents of trouble Failure code Controller code DGT1KX TM Trouble Torque converter oil temperature sensor: Out of input signal range (KX) • The voltage of the signal circuit of the torque converter oil temperature sensor is below 0. Cause Standard value in normal state/Re