HD465-7 Shop Manual PDF

SEBM027607
MACHINE MODEL SERIAL NUMBER
HD465-7 7001 and up

HD605-7 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 mounts the SAA6D170E-3 engine.

For details of the engine, see the 170-3 Series Engine Shop Manual.
© 2003
All Rights Reserved
Printed in Japan 03-03(02) 00-1
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CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD ................................................................. 10-1
20 TESTING AND ADJUSTING ............................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1
90 OTHERS ............................................................................................................................... 90-1
00-2 HD465-7, HD605-7

➂
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the ! Page to be newly added Add
table below.
" Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-1 (7) 10-3 10-46 10-90 (6) 10-131
00-2 (3) 10-4 10-48 (6) 10-91 (6) 10-132 (6)
q 00-2-1 (7) 10-5 10-49 (6) 10-92 10-133 (6)
q 00-2-2 (7) 10-6 10-50 (6) 10-93 10-134
q 00-2-3 (7) 10-7 10-51 (6) 10-94 10-135
q 00-2-4 (7) 10-7-1 (6) 10-52 (6) 10-95 10-136
q 00-2-5 (7) 10-8 10-53 (6) 10-96 10-137
00-3 10-9 10-54 (6) 10-97 10-138
00-4 10-10 10-55 (6) 10-98 10-139
00-5 10-11 10-56 (6) 10-99 10-140
00-6 10-12 10-57 (6) 10-100 10-141
00-7 10-13 10-58 (6) 10-101 10-142
00-8 10-14 10-59 (6) 10-102 10-143
00-9 10-15 10-60 (6) 10-103 10-144
00-10 10-16 10-61 (6) 10-104 10-145
00-11 10-18 10-62 (6) 10-105 10-146
00-12 10-19 10-63 (6) 10-106 10-147
00-13 10-20 10-64 (6) 10-107 10-151 (6)
00-14 10-21 10-65 (6) 10-108 10-151-1 (6)
00-15 10-22 10-66 (6) 10-109 10-152 (6)
00-16 10-23 10-67 (6) 10-110 10-153 (6)
00-17 10-24 10-68 (6) 10-111 10-154 (6)
00-18 10-25 10-69 (6) 10-112 10-155 (6)
00-19 10-26 10-71 (6) 10-113 10-156 (6)
00-20 10-27 10-72 (6) 10-114 10-157 (6)
00-21 10-28 10-73 (6) 10-115 10-158 (6)
00-22 10-29 10-74 (6) 10-116 10-159 (6)
10-30 10-75 (6) 10-117 10-160 (6)
01-1 10-31 10-76 (6) 10-118 10-161 (6)
01-2 10-32 10-77 (6) 10-119 (6) 10-162 (6)
01-3 10-33 10-78 (6) 10-120 (6) 10-163 (6)
01-4 10-34 10-79 (6) 10-121 10-164 (6)
01-5 10-35 10-80 (6) 10-122 10-165 (6)
01-6 10-36 10-81 (6) 10-123 10-166 (6)
01-7 10-37 10-82 (6) 10-124 10-167 (6)
01-8 10-38 (6) 10-83 (6) 10-125 10-168 (6)
01-9 10-41 10-84 (6) 10-126 10-169
01-10 10-42 10-86 10-127 10-170
01-11 10-43 10-87 10-128 10-171
10-44 10-88 (6) 10-129 10-172 (6)
10-1 (6) 10-45 10-89 (6) 10-130 10-173 (6)
HD465-7, HD605-7 00-2-1

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Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
10-174 (6) 10-226 (6) 20-120 (4) 20-168 (5) 20-203-4 (2)
10-175 (6) 10-227 (6) 20-121 (1) 20-169 (5) 20-203-5 (2)
10-176 (6) 10-228 (6) 20-122 (1) 20-170 (5) 20-203-6 (2)
10-177 (6) 10-229 (6) 20-123 (1) 20-171 (5) 20-203-7 (2)
10-178 (6) 10-230 (6) 20-124 (1) 20-172 (5) 20-203-8 (2)
10-179 10-231 (6) 20-125 (1) 20-173 (5) 20-203-9 (2)
10-180 (6) 10-232 (6) 20-126 (1) 20-174 (5) 20-203-10 (2)
10-181 10-233 (6) 20-127 (1) 20-175 (1) 20-203-11 (2)
10-182 (6) 10-234 (6) 20-128 (1) 20-176 (1) 20-203-12 (2)
10-183 (6) 10-235 (6) 20-129 (1) 20-177 (5) 20-203-13 (5)
10-184 10-236 (6) 20-130 (1) 20-178 (1) 20-203-14 (2)
10-185 10-237 (6) 20-131 (1) 20-179 (5) 20-203-15 (2)
10-186 10-238 (6) 20-132 (1) 20-180 (1) 20-203-16 (2)
10-187 (6) 10-239 (6) 20-133 (1) 20-181 (5) 20-203-17 (5)
10-188 (6) 10-240 (6) 20-134 (1) 20-182 (1) 20-203-18 (5)
10-189 (6) 10-241 (6) 20-135 (1) 20-183 (1) q 20-203-19 (7)
10-190 (6) 10-242 (6) 20-136 (1) 20-184 (1) 20-203-20 (5)
10-191 (6) 10-243 (6) 20-137 (1) 20-185 (1) 20-203-21 (5)
10-192 (6) 20-138 (1) 20-186 (1) q 20-203-22 (7)
10-193 (6) 20-1 (1) 20-139 (1) 20-187 (1) 20-204 (2)
10-194 (6) 20-2 (1) 20-140 (1) 20-188 (1) 20-204-1 (5)
10-195 (6) 20-3 (1) 20-141 (1) 20-189 (2) 20-204-2 (2)
10-196 (6) 20-4 (1) 20-142 (1) 20-190 (5) 20-204-3 (5)
10-197 (6) 20-5 (1) 20-143 (1) 20-190-1 (2) 20-205 (5)
10-198 (6) 20-6 (1) 20-144 (1) 20-191 (5) 20-206 (5)
10-199 (6) 20-7 (1) 20-145 (5) q 20-192 (7) 20-207 (5)
10-200 (6) q 20-101 (7) 20-146 (5) q 20-193 (7) q 20-301 (7)
10-201 (6) q 20-101-1 (7) 20-147 (5) 20-194 (1) 20-302 (1)
10-202 (6) q 20-101-2 (7) 20-148 (5) q 20-195 (7) 20-303 (2)
10-204 (6) q 20-101-3 (7) 20-149 (1) Q 20-195-1 (7) 20-304 (1)
10-205 (6) Q 20-101-4 (7) 20-150 (5) Q 20-195-2 (7) 20-305 (1)
10-206 (6) 20-102 (1) q 20-151 (7) Q 20-195-3 (7) 20-306 (1)
10-207 (6) 20-103 (1) 20-152 (1) q 20-196 (5) 20-307 (1)
10-208 (6) q 20-104 (7) 20-153 (1) 20-197 (1) 20-308 (6)
10-209 (6) 20-105 (1) 20-154 (1) 20-197-1 (5) 20-309 (1)
10-210 (6) 20-106 (1) 20-155 (1) 20-197-2 (5) 20-310 (1)
10-211 (6) 20-107 (1) 20-156 (1) 20-197-3 (5) 20-311 (1)
10-212 (6) q 20-108 (7) 20-157 (5) 20-197-4 (5) 20-312 (2)
10-213 (6) q 20-109 (7) 20-158 (1) 20-197-5 (5) 20-312-1 (2)
10-214 (6) 20-110 (2) 20-159 (1) 20-197-6 (5) 20-313 (5)
10-215 (6) 20-111 (4) q 20-160 (7) 20-197-7 (5) 20-314 (2)
10-216 (6) Q 20-111-1 (7) 20-160-1 (5) 20-197-8 (5) 20-315 (2)
10-217 (6) Q 20-111-2 (7) 20-161 (2) 20-198 (5) 20-316 (2)
10-218 (6) q 20-112 (7) 20-162 (2) 20-199 (1) 20-317 (5)
10-219 (6) 20-113 (1) 20-163 (2) 20-200 (1) 20-317-1 (5)
10-220 (6) 20-114 (4) 20-163-1 (5) 20-201 (5) 20-318 (1)
10-221 (6) q 20-115 (7) 20-163-2 (5) 20-202 (5) 20-319 (1)
10-222 (6) 20-116 (4) q 20-164 (7) 20-203 (5) 20-320 (1)
10-223 (6) 20-117 (1) 20-165 (1) 20-203-1 (2) q 20-321 (7)
10-224 (6) 20-118 (1) 20-166 (5) 20-203-2 (2) 20-322 (1)
10-225 (6) 20-119 (1) 20-167 (5) 20-203-3 (2) 20-323 (1)
00-2-2 HD465-7, HD605-7

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q 20-324 (7) 20-411 (1) 20-462 (2) 20-547 (1) q 20-598 (7)
20-325 (1) 20-412 (1) 20-463 (1) 20-548 (1) q 20-599 (7)
20-326 (1) 20-413 (1) 20-464 (1) 20-549 (1) q 20-600 (7)
20-327 (1) 20-414 (1) 20-465 (1) 20-550 (1) q 20-601 (7)
20-328 (1) 20-415 (1) 20-466 (1) 20-551 (1) q 20-602 (7)
20-329 (1) 20-416 (1) q 20-501 (7) 20-552 (1) q 20-603 (7)
20-330 (1) 20-417 (1) 20-502 (2) 20-553 (1) q 20-604 (7)
20-331 (1) 20-418 (1) 20-503 (2) 20-554 (1) q 20-605 (7)
20-332 (1) 20-419 (1) 20-504 (1) 20-555 (1) q 20-606 (7)
20-333 (1) 20-420 (2) 20-505 (1) 20-556 (1) q 20-607 (7)
20-334 (1) 20-421 (2) q 20-506 (7) 20-557 (1) 20-608 (1)
20-335 (1) 20-422 (1) 20-507 (1) 20-558 (1) 20-609 (1)
20-336 (1) 20-423 (1) q 20-508 (7) 20-559 (1) 20-610 (1)
20-337 (1) 20-424 (1) 20-509 (1) 20-560 (1) 20-611 (1)
20-338 (1) 20-425 (2) q 20-510 (7) 20-561 (1) 20-612 (1)
q 20-339 (7) 20-426 (1) q 20-511 (7) 20-562 (1) 20-701 (5)
20-340 (5) 20-427 (1) q 20-512 (7) 20-563 (1) 20-702 (5)
20-341 (1) 20-428 (1) q 20-513 (7) 20-564 (2) 20-704 (2)
20-342 (1) 20-429 (1) q 20-514 (7) 20-565 (1) 20-705 (5)
q 20-343 (7) 20-430 (1) q 20-515 (7) 20-566 (1) 20-706 (1)
20-344 (5) 20-431 (1) q 20-516 (7) 20-567 (1) 20-707 (1)
20-345 (5) 20-432 (1) q 20-517 (7) 20-568 (1) 20-708 (1)
20-346 (5) 20-433 (1) q 20-518 (7) 20-569 (1) 20-709 (1)
20-347 (5) 20-434 (1) q 20-519 (7) 20-570 (1) 20-710 (1)
20-348 (5) 20-435 (1) q 20-520 (7) 20-571 (1) 20-711 (1)
20-349 (5) 20-436 (1) q 20-521 (7) 20-572 (1) 20-712 (1)
20-350 (5) 20-437 (1) q 20-522 (7) 20-573 (1) 20-713 (1)
20-351 (5) 20-438 (1) q 20-523 (7) 20-574 (1) 20-714 (1)
20-352 (5) 20-439 (1) q 20-524 (7) 20-575 (1) 20-715 (1)
20-353 (5) 20-440 (1) q 20-525 (7) 20-576 (1) 20-716 (1)
20-354 (5) 20-441 (1) q 20-526 (7) 20-577 (1) 20-717 (1)
20-355 (5) 20-442 (1) q 20-527 (7) 20-578 (1) 20-718 (1)
20-355-1 (5) 20-443 (1) q 20-528 (7) 20-579 (1) 20-719 (1)
20-355-2 (5) 20-444 (1) q 20-529 (7) 20-580 (1) 20-720 (1)
20-356 (5) 20-445 (1) q 20-530 (7) 20-581 (1) 20-721 (1)
20-357 (5) 20-446 (1) q 20-531 (7) 20-582 (1) 20-722 (1)
20-358 (1) 20-447 (1) q 20-532 (7) 20-583 (1) 20-723 (1)
20-359 (1) 20-448 (1) q 20-533 (7) 20-584 (1) 20-724 (1)
20-360 (1) 20-449 (1) q 20-534 (7) 20-585 (1) 20-725 (1)
20-361 (1) 20-450 (1) 20-535 (1) 20-586 (1) 20-726 (1)
20-362 (2) 20-451 (1) 20-536 (1) 20-587 (1) 20-727 (1)
20-363 (2) 20-452 (1) 20-537 (1) 20-588 (1) 20-728 (5)
20-401 (2) 20-453 (1) 20-538 (1) 20-589 (1) 20-729 (5)
20-402 (2) 20-454 (1) q 20-539 (7) q 20-590 (7) 20-730 (5)
20-404 (2) 20-455 (1) 20-540 (1) q 20-591 (7) 20-731 (5)
20-405 (2) 20-456 (1) 20-541 (2) q 20-592 (7) 20-732 (5)
20-406 (1) 20-457 (1) 20-542 (1) q 20-593 (7) 20-733 (5)
20-407 (1) 20-458 (1) 20-543 (1) q 20-594 (7) 20-734 (5)
20-408 (1) 20-459 (1) 20-544 (1) q 20-595 (7) 20-735 (5)
20-409 (1) 20-460 (1) 20-545 (1) q 20-596 (7) 20-736 (1)
20-410 (1) 20-461 (1) 20-546 (1) q 20-597 (7) 20-737 (1)
HD465-7, HD605-7 00-2-3

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20-738 (1) 20-812 (1) 20-920 (2) 20-1003-1 (5) 20-1036 (5)
20-739 (1) 20-813 (1) 20-921 (1) 20-1004 (2) 20-1051 (5)
20-740 (1) 20-814 (1) 20-922 (1) 20-1005 (2) 20-1052 (5)
20-741 (1) 20-815 (1) 20-923 (1) 20-1006 (2) 20-1053 (5)
20-742 (1) 20-816 (1) 20-924 (1) 20-1006-1 (5) 20-1054 (5)
20-743 (1) 20-817 (1) 20-925 (1) 20-1006-2 (5) 20-1055 (5)
20-744 (1) 20-818 (1) 20-926 (1) 20-1006-3 (5) 20-1056 (5)
20-745 (1) 20-819 (1) 20-927 (1) 20-1006-4 (5) 20-1057 (5)
20-746 (1) 20-820 (1) 20-928 (1) 20-1006-5 (5) 20-1058 (5)
20-747 (1) 20-821 (1) 20-929 (1) 20-1006-6 (5) 20-1059 (5)
20-748 (1) 20-822 (1) 20-930 (1) 20-1006-7 (5) 20-1060 (5)
20-749 (1) 20-823 (1) 20-931 (1) 20-1006-8 (5) 20-1061 (5)
20-750 (1) 20-824 (1) 20-932 (1) 20-1007 (2) 20-1062 (5)
20-751 (1) 20-825 (1) 20-933 (1) 20-1008 (2) 20-1063 (5)
20-752 (1) 20-826 (1) 20-934 (1) 20-1009 (2) 20-1064 (5)
20-753 (1) 20-827 (1) 20-935 (1) 20-1010 (2) 20-1065 (5)
20-754 (5) 20-828 (1) 20-936 (1) 20-1011 (2) 20-1066 (5)
20-755 (5) 20-829 (1) 20-937 (1) 20-1012 (2) 20-1067 (5)
20-756 (1) 20-830 (1) 20-938 (1) 20-1013 (2) 20-1068 (5)
20-757 (1) 20-831 (1) 20-939 (1) 20-1014 (2) 20-1069 (5)
20-758 (1) 20-832 (1) 20-940 (1) 20-1015 (2) 20-1070 (5)
20-759 (1) 20-833 (1) 20-941 (1) 20-1016 (2) 20-1071 (5)
20-759-1 (5) 20-834 (1) 20-942 (1) 20-1017 (2) 20-1072 (5)
20-759-2 (5) 20-835 (1) 20-943 (1) 20-1018 (2) 20-1073 (5)
20-760 (5) 20-836 (1) 20-944 (1) 20-1019 (2) 20-1074 (5)
20-761 (5) 20-837 (1) 20-945 (1) 20-1020 (2) 20-1075 (5)
20-762 (5) 20-838 (1) 20-946 (1) 20-1021 (2) 20-1076 (5)
20-762-1 (5) 20-839 (1) 20-947 (1) 20-1022 (2) 20-1077 (5)
20-763 (5) 20-840 (1) 20-948 (1) 20-1023 (2) 20-1078 (5)
20-764 (5) 20-841 (1) 20-949 (2) q 20-1023-1 (7) 20-1079 (5)
20-765 (5) 20-842 (1) 20-950 (2) 20-1023-2 (5) 20-1080 (5)
20-766 (1) 20-843 (1) 20-951 (2) q 20-1023-3 (7) 20-1081 (5)
20-767 (1) 20-844 (1) 20-952 (2) 20-1023-4 (5) 20-1082 (5)
20-768 (1) 20-901 (2) 20-953 (2) 20-1023-5 (5) 20-1101 (2)
20-769 (1) 20-902 (5) 20-954 (2) 20-1023-6 (5) q 20-1102 (7)
20-770 (1) 20-904 (2) 20-955 (2) 20-1023-7 (5) 20-1103 (2)
20-771 (1) 20-905 (1) 20-956 (2) 20-1023-8 (5) q 20-1104 (7)
20-772 (1) 20-906 (1) 20-957 (5) q 20-1023-9 (7) q 20-1105 (7)
20-773 (1) 20-907 (1) 20-958 (5) 20-1023-10 (6) 20-1106 (2)
20-774 (1) 20-908 (1) 20-959 (5) 20-1024 (2) q 20-1107 (7)
20-801 (2) 20-909 (1) 20-960 (5) 20-1025 (2) q 20-1108 (7)
20-802 (2) 20-910 (1) 20-961 (5) 20-1026 (2) q 20-1109 (7)
20-803 (2) 20-911 (1) 20-962 (5) 20-1027 (2) 20-1110 (2)
20-804 (1) 20-912 (1) 20-963 (5) 20-1028 (2) q 20-1111 (7)
20-805 (1) 20-913 (1) 20-964 (5) 20-1029 (5) 20-1112 (2)
20-806 (1) 20-914 (1) 20-965 (5) 20-1030 (5) 20-1113 (2)
20-807 (1) 20-915 (2) 20-966 (5) 20-1031 (5) 20-1114 (2)
20-808 (1) 20-916 (1) 20-967 (5) 20-1032 (5) 20-1115 (2)
20-809 (1) 20-917 (1) 20-1001 (5) 20-1033 (5) 20-1116 (2)
20-810 (1) 20-918 (1) 20-1002 (5) 20-1034 (5) 20-1117 (2)
20-811 (1) 20-919 (1) 20-1003 (5) 20-1035 (5) 20-1118 (2)
00-2-4 HD465-7, HD605-7

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20-1119 (2) 30-15 (3) 30-66 (3) 30-117 (3)
20-1120 (2) 30-16 (3) 30-67 (3) 30-118 (3)
Q 20-1151 (7) 30-17 (3) 30-68 (3) 30-119 (3)
Q 20-1152 (7) 30-18 (3) 30-69 (3) 30-120 (3)
Q 20-1153 (7) 30-19 (3) 30-70 (3) 30-121 (3)
Q 20-1154 (7) 30-20 (3) 30-71 (3) 30-122 (3)
Q 20-1155 (7) 30-21 (3) 30-72 (3) 30-123 (3)
Q 20-1156 (7) 30-22 (3) 30-73 (3) 30-124 (3)
Q 20-1157 (7) 30-23 (3) 30-74 (3) 30-125 (3)
Q 20-1159 (7) 30-24 (3) 30-75 (3) 30-126 (3)
Q 20-1160 (7) 30-25 (3) 30-76 (3) 30-127 (3)
Q 20-1161 (7) 30-26 (3) 30-77 (3) 30-128 (3)
Q 20-1162 (7) 30-27 (3) 30-78 (3) 30-129 (3)
Q 20-1163 (7) 30-28 (3) 30-79 (3) 30-130 (3)
Q 20-1164 (7) 30-29 (3) 30-80 (3) 30-131 (3)
Q 20-1165 (7) 30-30 (3) 30-81 (3) 30-132 (3)
Q 20-1166 (7) 30-31 (3) 30-82 (3) 30-133 (3)
Q 20-1167 (7) 30-32 (3) 30-83 (3) 30-134 (3)
Q 20-1168 (7) 30-33 (3) 30-84 (4) 30-135 (4)
Q 20-1169 (7) 30-34 (3) 30-85 (3) 30-136 (3)
Q 20-1170 (7) 30-35 (3) 30-86 (4) 30-137 (3)
Q 20-1171 (7) 30-36 (3) 30-87 (4) 30-138 (3)
Q 20-1172 (7) 30-37 (3) 30-88 (3) 30-139 (3)
Q 20-1173 (7) 30-38 (3) 30-89 (3) 30-140 (3)
Q 20-1175 (7) 30-39 (3) 30-90 (3) 30-141 (3)
Q 20-1176 (7) 30-40 (3) 30-91 (3) 30-142 (3)
Q 20-1177 (7) 30-41 (3) 30-92 (3) 30-143 (3)
Q 20-1178 (7) 30-42 (3) 30-93 (3) q 30-144 (7)
Q 20-1179 (7) 30-43 (3) 30-94 (3) 30-145 (4)
Q 20-1180 (7) 30-44 (3) 30-95 (3) 30-146 (4)
Q 20-1181 (7) 30-45 (3) 30-96 (3) 30-147 (4)
Q 20-1182 (7) 30-46 (3) 30-97 (3) 30-148 (4)
Q 20-1183 (7) 30-47 (3) 30-98 (3) 30-149 (4)
30-48 (3) 30-99 (3) 30-150 (4)
30-1 (4) 30-49 (3) 30-100 (3) 30-151 (4)
30-2 (4) 30-50 (3) 30-101 (3) 30-152 (4)
30-3 (3) 30-51 (3) 30-102 (3)
30-4 (3) 30-52 (3) 30-103 (3) 90-1 (2)
30-5 (3) 30-53 (3) 30-104 (3) 90-2
30-5-1 (4) 30-54 (3) 30-105 (3) 90-3
30-5-2 (4) 30-55 (3) 30-106 (3) 90-5
30-5-3 (4) 30-56 (3) 30-107 (3) 90-7
30-6 (3) 30-57 (3) 30-108 (3) 90-9
30-7 (3) 30-58 (3) 30-109 (3) 90-11
30-8 (3) 30-59 (3) 30-110 (3) 90-13
30-9 (3) 30-60 (3) 30-111 (3) 90-15
30-10 (3) 30-61 (3) 30-112 (3) 90-17
30-11 (3) 30-62 (3) 30-113 (3) q 90-19 (7)
30-12 (3) 30-63 (3) 30-114 (3) q 90-21 (7)
30-13 (3) 30-64 (3) 30-115 (3)
30-14 (3) 30-65 (3) 30-116 (3)
HD465-7, HD605-7 00-2-5

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

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

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

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

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

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

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

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

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

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
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.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
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
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
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.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 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.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Radiator, torque converter oil cooler, after cooler, Steering and hoist hydraulic system
work equipment oil cooler, fuel cooler ......... 10- 3 diagram...................................................... 10-88
Brake oil cooler............................................ 10- 4 Dump body control ...................................... 10-90
Power train skeleton.................................... 10- 5 Hydraulic tank ............................................. 10-91
Output shaft................................................. 10- 6 Steering control valve .................................. 10-92
Drive shaft .................................................. 10-7-1 Crossover relief valve .................................. 10-96
Torque converter and transmission hydraulic Steering cylinder .......................................... 10-97
piping......................................................... 10- 8 Demand valve.............................................. 10-98
Torque converter ......................................... 10-10 Hoist valve ................................................. 10-102
Transmission ............................................... 10-18 EPC valve.................................................. 10-108
Transmission valve...................................... 10-27 Hoist cylinder ............................................. 10-109
E-POCV ...................................................... 10-28 Hydraulic pump.......................................... 10-110
Axle ............................................................. 10-38 Air conditioner............................................ 10-114
Differential ................................................... 10-42 Machine monitor system............................ 10-119
Final drive.................................................... 10-44 Engine control system ............................... 10-134
Wheels ........................................................ 10-46 Automatic shift control system ................... 10-136
Suspension.................................................. 10-48 Payload meter (card type)...................... 10-151
Suspension cylinder .................................... 10-50 Automatic emergency steering system...... 10-184
Rear axle support ........................................ 10-56 Automatic suspension system ................... 10-188
Steering column........................................... 10-58 Retarder control system ............................ 10-192
Steering linkage........................................... 10-59 Sensors, switches...................................... 10-204
Brake piping ................................................ 10-62 Dump control lever .................................... 10-212
Brake valve.................................................. 10-64
Emergency brake valve............................... 10-67 [Related to VHMS controller]
Relay valve.................................................. 10-68 VHMS controller ........................................ 10-216
Front brake off valve.................................... 10-69 BLOW-BY pressure sensor ....................... 10-216
Accumulator charge valve ........................... 10-71 Engine oil pressure sensor ........................ 10-217
Accumulator ................................................ 10-75 Exhaust temperature sensor/amp ............. 10-218
Slack adjuster.............................................. 10-76 Ambient temperature sensor...................... 10-218
Brake ........................................................... 10-78 Communications (orb•••orbcomm)
Proportional reducing valve......................... 10-83 controller/antenna...................................... 10-219
Parking brake solenoid valve ...................... 10-84 Payload meter (Having VHMS) ................. 10-220
Steering and hoist hydraulic piping.............. 10-86
For details of VHMS, see TESTING AND

ADJUSTING.
HD465-7, HD605-7 10-1

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft Outline

2. Rear drive shaft • The power from the engine is transmitted
through the output shaft, the front drive shaft (1)
and the transmission, to the rear drive shaft (2).
10-7-1 HD465-7, HD605-7

(6)
TORQUE CONVERTER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
10-8 HD465-7, HD605-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT
1. Wheel hub
Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit
Repair or
2 Wear of oil seal sliding surface 0
280 — replace
–0.130
10-38 HD465-7, HD605-7

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION
SUSPENSION
1. Front suspension cylinder

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION
Function
1. Front suspension
The front suspension cylinder functions as a
shock absorber and spring, and is connected by
spherical bearings to the lower arm (A-frame)
and main frame. 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 sta-
bility of the machine.
2. Rear suspension
The differential housing is supported by the
frame and two radius rods at the bottom, and at
the top by two inverted-V-shaped rods and two
suspension cylinders. It is connected to these at
both ends by spherical bearings. It transmits the
load and motive force through the top and bot-
tom rods.
The inverted-V-shaped rods at the top also func-
tion to maintain the center of the machine (axle).
Employment of the inverted-V-shaped link im-
proves the rolling steering characteristics.
HD465-7, HD605-7 10-49

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER
SUSPENSION CYLINDER
FRONT
1. Feed valve 7. Air cylinder

2. Cylinder (with axle) 8. Valve assembly
3. Rod 9. Damping force selector valve
4. Valve (for bleeding air and mounting 10. Damping force selector valve lever
pressure sensor)
5. Air bleeding valve A : Port
6. Tube B : Port
10-50 HD465-7, HD605-7

(6)
Unit: mm

Tolerance Standard
Standard size Clearance limit
Clearance between piston rod Shaft Hole clearance Replace
11
and bushing bushing
–0.043 +0.240 0.043 –
160 0.4
–0.106 0 0.346
Clearance between piston rod –0.043 +0.540 0.403 – Replace

12 160 0.7
and bushing –0.106 +0.360 0.646 bushing
Clearance between cylinder –0.05 +0.115 0.05 – Replace

13 200 0.8
and wear ring –0.26 0 0.375 wear ring
Repair limit
14 Elasticity of leaf spring

Max. 0.3 mm
Replace
Measuring method:
Measure protrusion and elongation stopper.
All the conditions below must be fulfilled.
Elongation :
Max. 5 mm
15 Deformation of stopper Protrusion:
Max. 2 mm
No cracks
HD465-7, HD605-7 10-51

(6)
Structure and operation

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

(6)
c. Variable shaft mechanism

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

(6)
REAR
1. Feed valve
2. Cylinder
3. Rod
4. Air bleeding valve
5. Ball
10-54 HD465-7, HD605-7

(6)
Unit: mm

Tolerance Standard
Crearance between piston rod Shaft Hole clearance
1
and bushing
–0.043 +0.246 0.043 –
180 0.4
–0.106 0 0.352
Replace
Crearance between piston rod –0.043 +0.246 0.043 –
2 180 0.4
and bushing –0.106 0 0.352
Crearance between cylinder –0.050 +0.115 0.05 –

3 220 0.8
and wear ring –0.260 –0.008 0.375
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(6) through orifices (4) and (5) to cavity (2), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
a) Retracting action
When the machine is traveling and it hits a bump
or object on the road, the wheels are pushed up,
and the cylinder rod is pushed inside the cylin-
der.
When this happens, the nitrogen gas inside
chamber (7) is compressed, the oil in chamber
(6) is sent through both orifices (4) and (5) to
cavity (2), and cavity (2) is filled more quickly
than when extending.
b) Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(7).
As a result, the amount of oil in cavity (2) is
reduced, and pressure is applied to the oil
remaining in cavity (2).
This pressurized oil closes orifice (4) with check
ball (3), and is sent to chamber (6) through only
orifice (5), so the flow of oil passing through the
orifice is controlled so that it is less than during
retraction. 1. Air bleed 8. Cylinder rod
In this way, the amount of oil returning to cham- 2. Cavity 9. Cylinder
ber (6) is restricted to provide a shock absorbing 3. Check ball 10. Feed valve
effect. 4. Orifice
5. Orifice a : When extending
6. Oil chamber b : When retracting
7. Nitrogen gas chamber
HD465-7, HD605-7 10-55

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD REAR AXLE SUPPORT
Unit: mm

Tolerance Standard
Clearance between rod Shaft Hole clearance
5
mounting pin and bushing
–0.030 +0.046 0.030 –
70 0.3
–0.076 0 0.122
Clearance between inner and 0.110 –

6 100 0.5 Replace
outer for bushing 0.180
Clearance between suspen-

–0.030 +0.046 0.030 –
7 sion cylinder mounting pin and 70 0.3
–0.076 0 0.122
frame or axle

8 100 0.5
HD465-7, HD605-7 10-57

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

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

(6)
10-60 HD465-7, HD605-7

(6)
Unit: mm

Tolerance Standard
Clearance between inner and Shaft Hole clearance
5
outer for knuckle arm bushing
0.150 –
165 0.7
0.300
Clearance between bushing 0 +0.054 0–

6 85 0.3
and pin –0.035 0 0.089
Clearance between steering

–0.025 +0.069 0.055 –
7 cylinder mounting pin and 45 0.3
–0.064 +0.030 0.133
bushing

8 80 0.4
Clearance between tie rod –0.025 +0.069 0.055 –

9 40 0.3
mounting pin and bushing –0.064 +0.030 0.133

10 110 0.4
Replace
Clearance between arm –0.030 +0.076 0.060 –
11 55 0.3

12 100 0.5
Clearance between arm –0.030 +0.091 0.075 –

13 70 0.3
Clearance between center

–0.030 +0.197 0.167 –
14 lever mounting pin and bush- 55 1.0
–0.076 +0.137 0.273
ing

15 80 0.4
Clearance between tie rod –0.025 +0.069 0.055 –

16 40 0.3
Clearance between suspen-

–0.030 +0.046 0.030 –
17 sion cylinder mounting pin and 60 0.3
–0.076 0 0.122
bushing
HD465-7, HD605-7 10-61

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-62 HD465-7, HD605-7

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
1. Front brake cut valve

2. Relay valve
3. Slack adjuster
4. Emergency brake valve
5. Brake valve
6. Parking brake valve
7. Accumulator charge valve
8. Accumulator (parking brake)
9. Accumulator (rear brake)
10. Accumulator (front brake)
11. Proportional reducing valve (for retarder)
HD465-7, HD605-7 10-63

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Pilot piston A : To rear brake

2. Rod B : To front brake
3. Lower cylinder C : To transmission oil pan
4. Spool D : From front accumulator
5. Upper cylinder E : From rear accumulator
6. Spool
10-64 HD465-7, HD605-7

(6)
Operation Applying brake when upper valve fails

Upper portion • Even if there is leakage of oil in the upper piping,
• When brake pedal (1) is depressed, the operat- spool (5) is moved down mechanically when
ing force is transmitted to spool (3) through rod pedal (1) is depressed, and the lower portion is
(2) and spring (4). When spool (3) goes down, actuated normally.
drain port a is closed, and the oil from the pump The upper brake is not actuated.
and accumulator flows from port A to port C and
actuates the rear brake cylinders. Applying brake when lower valve fails
• Even if there is leakage of oil in the lower piping,
Lower portion the upper portion is actuated normally.
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the rear brake cylinders and the
pressure between port A and port C becomes
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes up
spool (3) and shuts off the circuit between port A
and port C. When this happens, drain port a
stays closed, so the oil entering the brake cylin-
der is held and the brake remains applied.
HD465-7, HD605-7 10-65

(6)
Lower portion Brake released

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY BRAKE VALVE
EMERGENCY BRAKE VALVE
HD465-7, HD605-7 10-67

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RELAY VALVE
RELAY VALVE
1. Spool Function
2. Upper cylinder • This valve operates the brake depending on the
3. Lower cylinder parking brake release pressure controlled by the
4. Spool emergency brake pedal.
A : To front brake
P : From accumulator
Pp: From emergency brake valve
T : To transmission oil pan
10-68 HD465-7, HD605-7

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
ACC : To accumulator Specification

P : From hydraulic pump • Cut in pressure : 14.2 MPa {14.5 kg/cm2}
PP : From accumulator • Cut out pressure: 20.6 MPa {210 kg/cm2}
T : To transmission oil pan
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 accumu-
lator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
HD465-7, HD605-7 10-71

(6)
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-72 HD465-7, HD605-7

(6)
Operation 2. When oil supplied to accumulator

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

(6)
2) When cut-out pressure is reached 3. Main relief valve (R3)

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (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.
Specifications
Front brake
Gas used : Nitrogen gas
Charge amount : 3,500 cc
Charging pressure: 11.8 MPa {120 kg/cm2}
Rear brake, Parking brake

Gas used : Nitrogen gas
Charge amount : 4,000 cc
Charging pressure: 6.9 MPa {70 kg/cm2}
HD465-7, HD605-7 10-75

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
1. Cylinder
2. Check valve
3. Piston
A : Inlet port
B : Outlet port
Unit: mm

Tolerance Standard
Clearance between body and Shaft Hole clearance
4
piston
–0.030 +0.074 0.030 –
55 0.25
–0.076 0 0.150
Standard size Repair limit Replace
Spring Installed
Installed load Free length Installed load
5 Slack adjuster spring coefficient length
0.45 N/mm 45.6 N

97 – –
{0.046 kg/mm} {4.7 kg}
10-76 HD465-7, HD605-7

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
Function
• The slack adjuster is installed in the brake oil line • If the brake pedal is depressed further, and the
from the brake valve to the brake piston. It acts oil pressure discharged from the brake valve
to keep the clearance between the brake piston goes above to set pressure, check valve (3)
and discs constant even when the brake discs opens and the pressure is applied to port C to
are worn. in this way it acts to keep a constant act as the braking force.
time lag when the brake is operated. Therefore, when the brake is applied, the time
lag is a fixed value.
Operation
1. When brake pedal is depressed

• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port P
of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
2. When brake pedal is released

• When the brake is released, piston (4) is
returned by brake return spring (8) by an amount
equivalent to the oil for the stroke S, and the
brake is released.
In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke
S of the slack adjuster. The time lag of the brake
is always kept constant regardless of the wear of
the brake disc.
• When this is done, brake piston (7) moves by a

distance of stroke S. In this condition, the closer
the clearance between the brake piston and dics
is to 0, the greater the braking force becomes.
HD465-7, HD605-7 10-77

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

(6)
Unit: mm

Standard size Repair limit
Wear of pad (remaining thick-
4
ness of wear material) 19.5 3.0
Replace
5 Missing portion of pad – Ratio of surface: 10%
Correct of
6 Face runout of disc (Note 1) 0.15 0.50
replace
Wear of disc
7 30 Less than 27
(thickness of disc)
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, check the front wheel bearing also.
Note 2: • If the depth of the scratch exceeds 1.5 mm.
• If the whole pad is worn, the disc has been rubbed by mistake by the pad rear plate, the rear plate metal is melted to the disc, or
there is protrusion.
• If there are vertical scratches other than concentric scratches.
HD465-7, HD605-7 10-79

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

(6)
Unit: mm
Backlash between outer gear Standard size Repair limit

11
and plate 0.21 – 0.64 2.2
Backlash between inner gear

12 0.21 – 0.64 2.2
and disc
Standard size Repair limit

13 Thickness of plate
2.4 2.15
14 Thickness of disc 5.1 4.6
15 Thickness of damper 6.9 5.1 Replace
16 Thickness of damper 3.4 3.0
Warping of disc friction Standard warping Repair limit

17
surface Max. 0.45 0.7
Warping of plate and damper

18 Max. 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit

19
and disc 93.9 86.2
HD465-7, HD605-7 10-81

(6)
Function Operation of parking brake

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
slack adjuster and the transmission oil pan in the
A : From slack adjuster brake circuit.
P : From slack adjuster It varies the discharge pressure of the pressure
T : To transmission oil pan oil in accordance with the turning angle of the
retarder control lever, so the retarder control can
be carried out as desired.
HD465-7, HD605-7 10-83

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
2. Solenoid • The parking brake solenoid is installed in the
brake oil circuit between the emergency brake
B : To parking brake valve and the rear brake. When the parking
P : From emergency brake valve brake switch is set to PARK, the solenoid valve is
T : To transmission oil pan demagnetized and cut off the parking brake
release oil pressure. Then, the spring force will
operate the parking brake.
10-84 HD465-7, HD605-7

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

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

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP BODY CONTROL
DUMP BODY CONTROL
1. Dump control lever Function

2. Hydraulic pump (SAR(3)80+80+(1)6) • The positioner sensor senses the body opera-
3. Hoist valve tion, and from this data the retarder controller
4. EPC valve controls output to the EPC valve..
5. Body positioner sensor • The signal from the dump control lever is con-
6. Hoist cylinder trolled by the retarder controller, and actuates
the EPC valve. The pilot pressure generated by
the EPC valve moves the spool of the hoist valve
and controls the hoist cylinder.
10-90 HD465-7, HD605-7

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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
HD465-7, HD605-7 10-119

(6)
Outline
• With the machine monitor system, the controllers 4. E-POCV compensation
on the network use the data from the sensors This is used for the initial adjustment of the
installed to all parts of the machine to observe transmission.
and control the condition of the machine and 5. Changing replacement time for filter, oil. This
transmit that data as network data to the changes the original setting for the replace-
machine monitor. ment interval.
• The machine monitor is a system to display 6. Snapshot
these data and inform the operator of the condi- For details, see "TESTING AND ADJUST-
tion of the machine. ING, Execution of Pm Clinic with Manual
• There are two types of display on the machine Snapshot (another name: Quick PM)".
monitor: the normal mode and the service mode. 7. Controller initialize
• The items that are always displayed for the oper- This function is used to set the machine
ator are the normal mode items. Their main con- monitor when the machine is shipped from
tent is as follows. the factory.
1. Normal display items
• Meters (speedometer, tachometer) The service mode has the following functions.
• Gauges (engine water temperature, Setting service meter
torque converter oil temperature, retarder • This can set service meter values recorded
oil temperature, fuel level) in machine monitor memory
• Pilot display • However, values can only be increased from
• Service meter, odometer (character dis- present value (they cannot be decreased).
play)
2. Items displayed when there is abnormality Setting total travel distance
Caution, action code display (if an action code • This can set travel distance values recorded
is being displayed, press machine monitor in machine monitor memory
mode selector switch (2), then release it. A • However, values can only be increased from
failure code (6-digit) is then displayed.) present value (they cannot be decreased).
3. When the filter, oil replacement interval is
reached, the item needing replacement is Setting distance traveled in reverse
displayed in the character display. • This can set values for distance traveled in
4. Other functions using the character display reverse recorded in machine monitor mem-
and the machine monitor mode selector ory.
switch to operate include the following: Total • However, values can only be increased from
reverse distance traveled display, filter, oil present value (they cannot be decreased).
replacement interval reset, telephone num-
ber input, and language selection. • The machine monitor system consists of the
monitor panel, buzzer, and switches, network,
• To make it easier to carry out troubleshooting of controllers on the network, and the sensors
the controllers (including the monitor panel inputting data to the monitor panel.
itself), a service mode function is provided. Its
main content is as follows.
1. Displaying trouble data for electrical compo- • If the payload meter (having VHMS) is set
nents, deleting from memory optionally, execute display of load mass and set-
• Displays electrical components failure ting of items related to the payload meter, too.
data from each controller that is saved in For details, see "OPERATION MANUAL" and
machine monitor "STRUCTURE, OPERATION, and MAINTE-
• Deletes data from memory NANCE STANDARD, Payload meter (having
2. Trouble data for machine VHMS)".
• Displays machine failure data from each
controller that is saved in machine moni-
tor
3. Real-time monitor
• Takes input and output signal values rec-
ognized by each controller on network
and displays in real time.
10-120 HD465-7, HD605-7

(6)
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 charac-
ter display is as shown below.
*** : 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 below.
##### : Displays specified ID No.
%%% : Displays data. If units are used, the-
unit is displayed on the right side of
the data
4) ECMV compensation
For details of this function, see TESTING
AND ADJUSTING, Adjusting transmission, 2.
ECMV compensation.
5) Changing filter, oil replacement time
For details of this function, see the Operation
and Maintenance Manual, OPERATION,
Character display portion, Filter, oil replace-
ment time display. This is used when chang-
ing the replacement interval.
6) Snapshot function
When the VHMS controller is installed, this
menu is displayed.
For details, see "TESTING AND ADJUST-
ING, [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, OPERA-
TION, and MAINTENANCE STANDARD,
Payload meter (having VHMS)".
8) Controller initialize
This function is used only at the factory, so
do not touch it.
9) Setting service meter
This is used when replacing the machine
monitor with a new part, and setting the
appropriate service meter reading for the
machine. For details of the method of opera-
tion, see TESTING AND ADJUSTING, Adjust-
ing machine monitor.
10) Setting travel distance total
appropriate travel distance total value for the
machine. For details of the method of opera-
tion, see TESTING AND ADJUSTING, Adjust-
ing machine monitor.
11) Setting reverse travel distance total
appropriate reverse travel distance total
value for the machine. For details of the
method of operation, see TESTING AND
ADJUSTING, Adjusting machine monitor.
10-132 HD465-7, HD605-7

(6)
2. Method of operation
For details of the method of operating each ser distance total, see TESTING AND ADJUSTING.
vice mode function, see TROUBLESHOOTING. REMARK : When the starting switch is turned
For details of the method for setting the service OFF, it returns to the normal mode.
meter, travel distance total, and reverse travel
HD465-7, HD605-7 10-133

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
Safety functions 6) Speed range limit function when dump body is

1) Down-shift inhibition function raised.
If gearshift lever is operated D → 6-L, 6 → 5-L, 5 After dumping the load, if the body is not com-
→ 4-L, 4 → 3-L, 3 → 2-L, 2 → L pletely lowered, shifting up is limited.
For example, when traveling in D (F6), even if If the gearshift lever is at D, the machine starts in
the gearshift lever is operated to 4, the transmis- F2, and if it is at positions 6 to L, the machine
sion does not shift directly F6 → F4. It shifts starts in F1. The transmission does not shift up
down F6 → F5 → F4 in turn according to the until the body is completely lowered.
travel speed.
(The transmission does not jump two speed Self-diagnostic function
ranges if the operator makes a mistake when The controller carries out self-diagnosis of the sys-
operating the gearshift lever. This is to prevent tem and displays any abnormalities.
the engine from overrunning.) If any abnormality is detected by the self-diagnosis
2) Neutral safety function function, the abnormality data is transmitted to the
This circuit prevents the engine from starting if network and is displayed as an action code on the
the gearshift lever is not at the N position, even if machine monitor. The transmission system caution,
the starting switch is turned to the START posi- warning lamp, or alarm buzzer may also be actu-
tion. ated.
(This is a safety circuit to prevent the machine
from moving unexpectedly when the engine is
started.)
3) Directional inhibition function
When traveling forward at a speed of more than
4 km/h, even if the gearshift lever is operated to
positions R, the transmission will not be shifted
immediately to travel in reverse. The speed
range is shifted to N and the engine speed is
lowered to reduce the travel speed. When the
travel speed goes below 4 km/h, the transmis-
sion is shifted to REVERSE.
(To prevent overload on power train, to improve
durability and reliability)
4) Power train overrun prevention rear brake func-
tion
When the engine speed exceeds 2,500 rpm in
high-speed mode or 2,400 rpm in low-speed
mode, the central warning lamp flashes and the
warning buzzer sounds.
When the engine speed exceeds 2,600 rpm in
high-speed mode or 2,450 rpm in low-speed
mode, the rear brake is activated automatically.
(To prevent overrun of engine, torque converter,
and transmission, to improve durability and reli-
ability)
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, N, 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.
(Turnover prevention function)
HD465-7, HD605-7 10-147

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER (CARD TYPE)
PAYLOAD METER (CARD TYPE)

STRUCTURE OF SYSTEM
1. Shift lever neutral detection switch (relay) Outline

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

(6)
BLOCK DIAGRAM OF PAYLOAD METER
• If a dump truck having the VHMS controller is

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

(6)
PRINCIPLE OF CALCULATION
1. Outline
A dump truck is supported by 4 suspension cylin-
ders. By measuring the total of the loads on
each cylinder, it is possible to know the load
mass on the springs of the dump truck.
The measurement of the load mass is obtained
by calculating the difference between the mass
when empty and the mass when full.
The load on each cylinder can be calculated
from the internal pressure and sectional area of
the suspension cylinder.
[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 cylin-

der,
PB PT
Therefore, the load can be calculated as follows.
W = PBST
10-152 HD465-7, HD605-7

(6)
2. Measurement of mass when empty

(Calibration)
Drive the empty dump truck at a speed of about
10 km/h for about 30 seconds, and then mea-
sure the average load and use it as the mass
when empty.
The reason why the mass is measured while the
dump truck is traveling is that the sliding resis-
tance of the suspension cylinders must be aver-
aged by extracting and retracting the cylinders
by changing the condition of the dump truck.
The measured mass when empty is saved as a
calibration data in the memory in the controller.
3. Measurement of mass when full

Load the dump truck and measure the mass at
that time. When loading for this purpose, 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°.
4. Correction on slope
If the dump truck is loaded on a slope, the mea-
sured mass is different from the mass measured
on a level ground. To solve this problem, the lon-
gitudinal inclination of the dump truck is mea-
sured and the measured mass is corrected
according to the inclination angle. (Correction
range of inclination angle: ± 5°)
5. Detecting distance, travel speed

(payload meter )
The travel speed and distance are detected from
the travel signal sensor on the truck.
★ Travel signal sensor:
Transmission output speed sensor
HD465-7, HD605-7 10-153

(6)
FEATURES OF EACH DEVICE

1. Payload meter
Payload meter receives signals from the pres-
sure sensors, clinometer, body float sensor,
gearshift lever (neutral sensor switch on Payload
meter ), etc., calculates the load mass with the
microcomputer in it, displays the calculation
result on the panel, and indicates the load level
on the external indicator lamps.
1) General locations of payload

1. Display
2. Communication "receiving" lamp
(Rx busy)
3. Communication "transmitting" lamp
(Tx busy)
4. Memory card access lamp
(CARD busy)
5. Mode switch
6. Calibration/clear switch
7. Total/shift switch
8. Light/increment switch
9. Memory card
10. Cover
★ Communication "transmitting" lamp (3)
lights up even when the communication
cable is not connected to a PC or when
there is defective connection.
★ When not inserting or removing memory
card (9), always keep cover (10) closed.
10-154 HD465-7, HD605-7

(6)
LEFT FACE
• Details of switches on left face
No. Name Type Remarks
–20% – +20%
1. Load mass compensation trimmer Rotary volume (Counterclockwise) (Clockwise)
2. Speed compensation trimmer 0 – F rotary selector switch 0 : 107% –7 : 107% – F : 92%
3. Distance compensation trimmer 0 – F rotary selector switch 0 : 107% –7 : 107% – F : 92%
4. Model selector switch 0 – F rotary selector switch According to model selector code table
5. Memory card use switch 2-stage selector switch Up : Not used Down : Used
6. Clinometer use switch 2-stage selector switch Up : Not used Down : Used
7. Mass unit setting switch 2-stage selector switch Up: t (Metric ton), Down: US ton (Short ton)
Switch forcible prohibition setting Up : Permitted Down : Prohibited

8. switch 2-stage selector switch According to Permitted/prohibited setting
table for switches
Turn CLOCKWISE to DECREASE volume
B. Buzzer volume adjustment Rotatory volume Turn COUNTERCLOCKWISE to INCREASE
volume
★ The switches are adjusted before the machine is If it should become necessary to adjust any switch
shipped. Only No. 7 and No. B can be adjusted. except No. 7 or No. B (for example, when compen-
For this reason, do not touch any other switch. sating the speed or distance calculation or the pay-
load value), please contact your Komatsu distributor
to have the switch adjusted.
HD465-7, HD605-7 10-155

(6)
• Table of model selector code
No. of model selector switches Model

0 (*1) HD1200-1 STD Large-tire Cummins engine
1 HD785-3 STD Large-tire Komatsu engine
2 HD465-5 STD Small-tire Komatsu engine
6 HD785-3 STD Small-tire Komatsu engine
7 HD465-5,7 STD Large-tire Komatsu engine
9 HD985-3 STD 30:00-51 Komatsu engine
A HD605-5,7 STD Large-tire Komatsu engine
B HD785-5 STD Large-tire Komatsu engine
*1. The PLM on HD1200-1 has a different part No.
• Permitted/prohibited setting table for switches
Left side switch No. 8
Top (prohibited) Bottom (permitted)
Top Permitted Permitted

Left (memory card not used) (1) (2)
side
switch
No. 5 Bottom
(3) (4)
(memory card used)
(1) Left side switch No. 5 (top), No. 8 (top)

All switches can be operated.
(2) Left side switch No. 5 (top), No. 8 (bottom)
Calibration, data all clear, time, date setting opera-
tions only are possible.
(3) Left side switch No. 5 (bottom), No. 8 (top)
All switches can be operated.
(4) Left side switch No. 5 (bottom), No. 8 (bottom)
Calibration, data all clear, card dump, time, date
setting operations only are possible.
10-156 HD465-7, HD605-7

(6)
Payload meter has the following basic functions.

i) Power ON (reset)
When the power is turned ON, all functions are checked and displayed.
★ If the engine is started during the flow for this display, even there are items left to display, the display will
switch after several seconds to iii) Normal operation display.
HD465-7, HD605-7 10-157

(6)
ii) Measuring empty mass (calibration)

The mass of the machine when empty is measured
and this is used as the calibration data.
These data are retained even when the power is
turned OFF.
iii) Normal operation display (for details, see the Opera-
tion and Maintenance Manual)
See the Normal operation display.
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.
The estimated display shows the estimation of the total
mass when one more load is added. The applicable
lamp flashes to prevent overload.
Normal operation display
Shift lever Dump lever

Condition of the machine Payload meter display External display lamps
position position
Stopped N FLOAT Mass display (*1) Mass display

Empty
Traveling Except N FLOAT Time display OFF
During load- Mass display and esti-

Stopped N FLOAT Mass display
ing, before mated display
reaching 50%
of correct
Traveling Except N FLOAT Mass display OFF
mass
During load- Mass display and esti-

Stopped N FLOAT Mass display
ing, after mated display
reaching 50%
of correct Travel distance displayed
Traveling Except N FLOAT in units of m from 0 – 160 OFF
mass
m (each 5 m)
Traveling Except N FLOAT after completion, changes OFF

to time display
Loaded
Stopped N FLOAT Mass display Mass display
FLOAT→ Aggregate mass display

When dumping (*2) N RAISE → LOWER OFF
→ FLOAT (*3)
Abnormality, warning (Error code displayed in See Operation and Main-

generated
— — order of priority) tenance Manual
(*1) When load is less than 50% of correct mass, display shows 0 t.
(*2) For details of conditions taken as dumping, see v) Content of memory (1).
(*3) The aggregate mass display is shown in units of 100 t. (Rounded to the nearest 100)
10-158 HD465-7, HD605-7

(6)
V) Content of memory (for details, see Operation and

Maintenance Manual)
Cycle data
★ The period between one dumping operation and
the next dumping operation is taken as one cycle
and the data are recorded.
★ The cycle data are recorded when the dumping
conditions are fulfilled (see right).
★ The maximum limit for cycle data in memory is
2900 cycles.
Item Unit Range
Engine operation number Integer 1-65535 

Month Month 1-12 
Day Day 1-31 
Time Hour Hour Displayed as 0-23  Displays value and set value at time of
Time Minute Minute 0-59 dumping

Machine ID Integer 0-200
Open ID Integer 0-200

Load mass t (Metric ton) or 0-6553.5

US ton (Short ton)
Empty travel time min 0-6553.5
Empty travel distance km 0-25.5
Empty max. travel speed km/h 0-99
Empty average travel speed km/h 0-99
Empty stopped time min 0-6553.5
Loading stopped time min 0-6553.5
Loaded travel time min 0-6553.5
Loaded travel distance km 0-25.5
Loaded max. travel speed km/h 0-99
Loaded average travel km/h 0-99
speed
Loaded stopped time min 0-6553.5
Dumping time min 0-25.5 Displays set value at time of dumping
Limit speed km/h 0-99
Warning items/cycle
Analog spare 1
 MAX electric potential V 0-4.0 
 MIN electric potential V 0-4.0 
 Average electric potential V 0-4.0 
Analog spare 2  Data processing on PC
 MAX electric potential V 0-4.0  Data inside cycle are handled
 MIN electric potential V 0-4.0  separately as spare signal input data.
 Average electric potential V 0-4.0 
Digital spare 1 
Lo frequency Times 0-255 
Digital spare 2 
Lo frequency Times 0-255 
HD465-7, HD605-7 10-159

(6)
Engine ON/OFF data

★ Each time the engine was stopped and started is recorded.
★ The maximum limit in memory for engine ON/OFF data is 115 ON/OFF sets.
Item Unit Range
Engine operation number Integer 1-65535 Consecutive number for operation of engine
Year (last 2 digits) Year 0-99 
Day Day 1-31  Shows when engine was switched ON
Time Hour Hour Displayed as 0-23 
Time Minute Minute 0-59 
Year (last 2 digits) Year 0-99

Month Month 1-12

Day Day 1-31
 Shows when engine was switched OFF
Time Hour Hour Displayed as 0-23

Time Minute Minute 0-59

Aggregate load mass t (Metric ton) or 0-9999000  Total value between engine ON and engine
US ton (Short ton) 
Total number of cycles Times 0-9999  OFF
Abnormality, warning data

★ Each time a payload meter abnormality or warning is generated or cancelled is recorded.
★ The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets
Item Unit Range
Engine operation number when According to

error code was generated Integer 1-65535
Frequency of generation Times 1-255
after engine is switched ON
Month Month 1-12  Shows when error code was
Day Day 1-31  generated
Time Hour Hour (0 – 23) Displayed as 0-23 
Engine operation number Integer 0-65535
when cancelled
Month Month 1-12  Shows when error code was
Day Day 1-31  cancelled
Time Hour Hour (0 – 23) Displayed as 0-23 
10-160 HD465-7, HD605-7

(6)
Data for aggregate load mass, total number of cycles

★ 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.
★ The calculation is started again for both values when the data for aggregate load mass and total number
of cycles are cleared.
★ The maximum limit in memory for aggregate load mass and total number of cycles is 999900.0 t (Metric
ton) or US ton (Short ton) and 9999 cycles respectively.
Item Unit Range
Aggregate load mass t (Metric ton) or 0-999900.0 Shows aggregate from time when data were
US ton (Short ton) cleared
Total number of cycles Times 0-9999
Year (last 2 digits) Year 0-99

Month Month 1-12  Shows date and time when data were
Day Day 1-31  cleared
Time Hour Hour Displayed as 0-23 
Other data
Content Item Unit Range
Operator check Machine ID Integer 0-200

mode set data Open ID Integer 0-200 Operator check mode set in input oper-
Limit speed km/h 0-99 ation
Option code Integer 0-11
Calibration Year (last 2 digits) Year 0-99
performance Month Month 1-12
Date and time when calibration was
data Day Day 1-31
performed
Time Hour Hour Displayed as 0-23
User write data Data 1 20 Characters Comments that can be written freely
Data 2 20 Characters into payload meter.
Data 3 20 Characters Note: Input and settings are possible
Data 4 20 Characters only from PC through cable communi-
cations.
(For details, see software manual.)
HD465-7, HD605-7 10-161

(6)
Calibration data
★ These are saved in RAM each time calibration is performed.
★ The maximum limit in memory for calibration data is 15 sets.
Item Unit Range
Year Year (last 2 digits) 00-99 

Day Day 1-31  Shows values and settings when cali-
Time Hour Hour 0-23  bration was performed
Time Minute Minute 0-59 

Model selection code Integer 0-F 
Suspension pressure (front left) x 98 kPa 0-6553.5 
Suspension pressure (front right) x 98 kPa 0-6553.5 
Suspension pressure (rear left) x 98 kPa 0-6553.5 
 Shows values before compensation
Suspension pressure (rear right) x 98 kPa 0-6553.5 
Mass on spring (front) t (Metric ton) 0-6553.5  factor was calculated
Mass on spring (rear) t (Metric ton) 0-6553.5 
Tilt angle x 180 rad –9.99 – +9.99
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Mass on spring (empty) t (Metric ton)
Load mass calculation data (analog data)

★ These are saved in RAM when the load mass calculation data are required.
★ The maximum limit in memory for load mass calculation data is 180 sets.
Item Unit Range
Year Year (last 2 digits) 00-99

Month Month 1-12
Day Day 1-31
Time Hour Hour 0-23
Suspension pressure (front left) x 98 kPa 0-6553.5
Suspension pressure (front right) x 98 kPa 0-6553.5
Suspension pressure (rear left) x 98 kPa 0-6553.5
Suspension pressure (rear right) x 98 kPa 0-6553.5
Mass on spring (front) t (Metric ton) 0-6553.5
Mass on spring (rear) t (Metric ton) 0-6553.5
Tilt angle x 180 rad –9.99 – +9.99
0-9.99999
Front wheel tilt compensation factor Integer
0-9.99999
Rear wheel tilt compensation factor Integer
0-9.99999
Front wheel link factor Integer
0-9.99999
Rear wheel link factor Integer
0-6553.5
Mass on spring (empty) t (Metric ton)
(Calibration value)
0.7500 –1.2500
Trimmer gain value Integer
0-6553.5
Load mass t (Metric ton)
0-25.5
Backup battery voltage V
The above data items – are retained even when the power is switched OFF.
10-162 HD465-7, HD605-7

(6)
vi) Forced display of aggregate load mass, total x) Service check mode
number of cycles By operating the switches of payload meter , it
Forced display of existing abnormalities and is possible to forcibly carry out display, setting,
warnings and correction of the following items.
By operating the switch of payload Detailed calibration data display

The display shows the date, suspension
meter II, it is possible to carry out forcible display
pressure, etc. when the latest calibration was
of these items.
carried out.
For details, see the Operation and Maintenance
Manual.
Detailed load mass calculation data display
(analog data)
vii) Operator check mode
The display shows the suspension pressure
By operating the switch of payload meter , it is
and machine angle used when calculating
possible to carry out the following items.
the present load mass.
For details, see the Operation and Maintenance
Manual.
Memory card dump (service area)
Memory card dump
This writes all the data displayed for Items 6-
Data all clear
6 and 6-7 to the memory card inserted in the
Abnormality, warning exists/cancelled, input
machine.
signal condition display
Machine ID setting
★ This function is available only when the No. 5
Open ID setting
switch on the left side of the controller (mem-
Limit speed setting
ory card use switches) is set for "Use"
Option code setting
Time, date correction
Data all clear (service area)
This forcibly deletes all the calibration data
viii) Dimming of display portion
and analog data, except for the latest calibra-
It is possible to adjust the brightness of the pay-
tion data.
load meter II display portion to 10 levels with the
switch. ★ Before clearing the data, always download

the data to a PC or carry out Card dump.
ix) Downloading saved data Input signal condition display

It is possible to download any data recorded in This displays some of the signal conditions
payload meter to a PC through a cable (ANSI/ for the sensors input to payload meter and
E1A RS-232C). the present recognition condition of the pay-
For details, see the PC software manual pro- load meter.
vided by Komatsu.
Forced initialization
This forcibly deletes all the data in payload
meter .
★ Before carrying out this operation, check the

time and date. Always carry out the opera-
tion with the machine unloaded. Do not carry
out the operation unless necessary.
Extra load mass setting when loading

The extra load can be forcibly input or cor-
rected to set the load mass when loading.
Available range for setting: –9 – +9 (%)
HD465-7, HD605-7 10-163

(6)
Load mass fixed display and cycle data recording,

load mass value setting
1) Load mass fixed display
When displaying the load mass in the range
shown in the table below, 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), not the real-time
load mass.
Setting Range Payload fixed display
The time that machine is Load mass when stopped in
stopped when loading at least previous cycle
TALKS not set
50% of set load mass and
(option codes 0 – 3, 10, 11 set)
traveling 160 m and starting
to dump
When there is per- The time that machine is Load mass last displayed in
mission to start stopped from permission to previous cycle
move off to starting to dump (Final radio transmission
TALKS set value)
 option codes 
The time that machine is Load mass last displayed in
 4 – 9 set  When disconnection
stopped from disconnection previous cycle
of line from payload
of line to starting to dump
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, 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: 00, 01, 10
Possible set value table
Display Load mass fixed display Recorded load mass value
00 Yes Load mass fixed display value
01 Yes Value when dumping load
10 No Value when dumping load
Loading completion recognition travel distance set-

ting
This is used to input and correct the values to set
the travel distance recognized as completion of
loading by payload meter .
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 .
Possible set range:
HD325-6 
 1
480 – 1,480 [ x 100 t]
HD405-6 
HD465-7 
 690 – 1,690 [ x 1
100
t]
HD605-7 
HD785-5 
 1,000 – 2,000 [ x 1
100
t]
HD985-3 
10-164 HD465-7, HD605-7

(6)
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.
Possible set range: 5 – 10
[%: ratio of correct load mass]
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.
Possible set range:
Lamp 1 (green) A : 510 – 255
Lamp 2 (yellow) B : A – 255
Lamp 3 (red) C : B – 255
The set value is displayed as a propor-

tion (%) of the correct load mass.
■ Of the service check mode functions, the fol-

lowing functions can be downloaded to a PC
using the PC downloading software provided
by Komatsu.
• Calibration data
• Load mass calculation data (analog data)
For details, see the software manual.
(1) Method of operation
ALways actuate the service check mode
Note, and are actuated on the HD1200-
1 when the parking brake is ON or when the
brake lock is ON, 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.
is actuated only when the power is ON.
★ When the service mode is working, on
the HD1200-1, set the parking brake to
ON or the brake lock to ON, and on
machines other than the HD1200-1, set
the shift lever to the N position and the
dump lever to FLOAT. If they are oper-
ated to other positions, the payload
meter will return to the normal operation
display, but in this case, the data set and
input in the service check mode may not
be processed correctly.
HD465-7, HD605-7 10-165

(6)
10-166 HD465-7, HD605-7

(6)
(a) Operation for calibration data display
Set to CHEC display, then press

From CALO flashing
switch for at least 2 seconds. Last 2 digits of year for date

when CAL was carried out
Display: CALO Month and day for date when
CAL was carried out
Hour and minute for date
when CAL was carried out
Model selection switch (decimal
Every time the switch is pressed, value) when CAL was carried out
x 98kPa P'FL (Front left)

the display changes in the order
Suspension
shown on the right. x 98kPa P'FR (Front right) pressure less than
100 x 98 kPa: XX.X
x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
If switch is pressed at any time XXX.X
during the display in Steps or , the display x 98kPa P'RR (Rear right)
will return to CHEC. (End) t Mass on front axle

π
Less than 100 t:
(= – 2 (P'FL+P'RL)) XX.X
4 D–
F
t Mass on rear axle More than 100 t:

(= –π4 D R
2 (P'RL+P'RR))
– XXX.X
Angle of tilt when CAL was Appears when value is

x 180 rad carried out negative
↓
(–) X.XX
Front axle tilt coefficient
Rear axle tilt coefficient

X.XXX
Front axle link coefficient
Rear axle link coefficient
Spring-up mass calculated Same number of digits as

according to calibration and
CALO flashes
Returns to and
repeats sequence
All displayed values are rounded to

the value given.
HD465-7, HD605-7 10-167

(6)
(b) Operation for payload calculation data (analog data) display
Set to CHEC display, then press From ALLO flashing or A.FUL

flashing
Hour, minute
switch for at least 2 seconds.
x 98kPa P'FL (Front left)
Display: ALLO (when data in memory is Suspension
x 98kPa P'FR (Front right) pressure less than
less than 170 cycles) 100 x 98 kPa: XX.X
A.FUL (when data in memory is x 98kPa P'RL (Rear left) More than 100 x 98 kPa:
XXX.X
more than 170 cycles)
x 98kPa P'RR (Rear right)
A.FUL (when data in memory is
more than 180 cycles) t Mass on front axle Less than 100 t:
π 2
(= –
4
D–
F
(P'FL+P'RL)) XX.X
t Mass on rear axle More than 100 t:
π 2 XXX.X
(= –
4
D–
R
(P'RL+P'RR))
Every time the switch is pressed, Angle of tilt when CAL was Appears when value is
x 180 rad carried out negative
the display changes in the order ↓
(–) X.XX
shown on the right. Front axle tilt coefficient
Rear axle tilt coefficient

If switch is pressed at any time X.XXX
Front axle link coefficient
during the display in Steps or , the display
will return to CHEC. (End) Rear axle link coefficient
Spring-up mass calculated

t
according to calibration Same as and
— GT
→ Gain trimmer
t Present load mass

Same as and
V Backup battery
X.X
Voltage
ALLO flashing
Returns to (1) and

repeats sequence
All displayed values are rounded to

the value given.
10-168 HD465-7, HD605-7

(6)
( f ) Operation for performing forced initialization (g) Operation for setting extra load mass when loading
Set to CHEC display, then press Set to CHEC display, then press
switch and at the same time for

switches , , and at the same at least 2 seconds.
time for at least 2 seconds.
Display: S.5EL
Display: :
Press switch .
Display UP : XX present set value: for + : X 

Press switch for at least 2 seconds.  for – : – X 
If it is necessary to correct the setting, press
The display becomes : (lighted up) (2
seconds), switch and correct.
and when all the data is completely cleared, it
automatically displays F.CAL. (End)
When the correction operation from Step is
After that, it carries out the process from 10. .
completed, press switch at any time
If it is desired to stop the forced initialization to return to the CHEC display. (End)
operation when the display is : ,
press switch (4), and the display will
return to CHEC without performing the forced ini-
tialization operation.
10-172 HD465-7, HD605-7

(6)
(h) Operation for setting load mass fixed display and cycle data record value
Set to UP : XX display, then press
switch
Display: PL : XX (present set value)
switch and correct.
When the correction operation is completed,

press switch at any time to return to
the CHEC display. (End)
HD465-7, HD605-7 10-173

(6)
( i ) Operation for setting loading completion recognition travel distance

When the correction operation from Step is
completed, press switch (1) at any time
to return to the CHEC display after displaying
O.XXX (input value). (End)
If it is impossible to set the input values even
when switch is pressed, it displays
O.XXX (input value) and returns to Step .
Set to PL : XX display, then press

switch
Display: O.SEL
Press switch .
Display: XXX
If it is necessary to correct the setting
for the units, press switch

and correct.
Press switch .
Display: XXX
for the tens, press switch

and correct.
Press switch again.
Display: XXX
for the hundreds, press switch
and correct.
If switch is pressed again, the dis-
play will return to XXX, so it is possible to correct

the units again.
10-174 HD465-7, HD605-7

(6)
( j) Operation for setting loading start recognition When the correction operation from Step is
load mass completed, press switch at any time
to return to the CHEC display. (End)

when switch is pressed, it returns to
Step .
Set to O.SEL display, then press

switch
Display: P.SEL
Press switch .
Display: XXXX
for the tens, press switch

and correct.
Press switch .
Display: XXXX
for the hundreds, press
switch and correct.
Press switch again.
Display: XXXX
for the thousands, press
switch and correct.
If switch is pressed again, the dis-
play will return to Step , so it is possible to cor-

rect again.
HD465-7, HD605-7 10-175

(6)
(k) Operation for setting 0 ton display range
Set to P.SEL display, then press

switch
Display: H.SEL
Press switch .
Display: – – XX (present value)

switch and correct.
When the correction operation from Step is com-

pleted, press switch at any time to return
to the CHEC display. (End)
10-176 HD465-7, HD605-7

(6)
( l) Operation for setting display range of external

display lamps Press switch again.
Display: d.XXX
(present value of lamp 4)
If it is necessary to correct the display
range for lamp 4, press
switch and correct.
Press switch again.
Display: E.XXX
Set to H.SEL display, then press range for lamp 5, press
switch and correct.

switch
Display: E.SEL When the correction operation from Step is

completed, press switch at any time
to return to the CHEC display. (End)
Press switch .
Display: A.XXX
when switch is pressed, it displays
(present value of lamp 1) d.FAL (input value) and returns to Step .
switch and correct.
Press switch .
Display: b.XXX
switch and correct.
Press switch again.
Display: C.XXX
switch and correct.
HD465-7, HD605-7 10-177

(6)
2. Pressure sensor
The pressure sensor is installed at the bottom
end of the suspension cylinder and acts to mea-
sure the pressure at the cylinder bottom.
When replacing pressure sensor (1), leave the

valve (2) installed to the suspension and remove
only pressure sensor (1).
When removing or installing pressure sensor (1),
be careful not to let valve (2) rotate.
When removing pressure sensor (1), the action
of valve core (3) prevents the suspension pres-
sure from going down.
The output characteristics of the sensor are as

shown in the diagram on the right.
 Voltage between pin (1) (GND) and pin (3) 
 (output) of each pressure sensor connector 
 or voltage of output (pins (4), (5), (6), (7)) of 
 each sensor when pin (3) of payload meter 
 controller connector (PM6) is grounded 
Pressure sensor
1. Sensor
2. Tube
3. Connector
10-178 HD465-7, HD605-7

(6)
5. Self-diagnostic function
The controller always observes the condition of the sensors and outputs, and if any abnormality occurs, it
displays an error message.
Error message display
Order Error code display

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
1 Dump lever at position — b-FL ON All flash When [for HD1200-1]
other than FLOAT removed When parking
(except when dumping) brake or brake
lock is ON
b-FL ON — When [for HD1200-1]
removed When parking
brake or brake
lock is OFF
2 Memory card — Cd flashes — When Removal detec-
removed removed tion only for card
dump
3 Drop in backup battery Defective contact F-09 flashes — When Except during
voltage or voltage below removed loading
2.7 V
4 Cycle data memory See (*1) See (*1) — See (*1) Except during
FULL loading
Engine ON/OFF data
memory FULL
Abnormality, warning
data memory FULL
Aggregate load mass,
number of cycles data
memory FULL
5 Disconnection in Output below 2 V F-18 flashes All flash When When engine is
terminal R when engine is removed running
running
6 Abnormality in sensor Output is less than F-20 flashes All flash When Any time
power source (18 V) 15 V and power removed
source voltage is
more than 20 V
7 Short circuit with Suspension pres- F-21 flashes All flash When Any time
ground, disconnection sure sensor input removed
in front left suspension signal is 0 kPa or
pressure sensor system below
8 Short circuit with F-22 flashes
ground, disconnection
in front right suspen-
sion pressure sensor
system
in rear left suspension
pressure sensor system
in rear right suspension
pressure sensor system
10-180 HD465-7, HD605-7

(6)
Order Error code display

of Judgement
display Content Controller External lamp Cancellation Timing for display
standard
priority display display of display
11 Short circuit with Suspension pres- F-25 flashes All flash When Any time
power source in front sure sensor input removed
left suspension pres- signal is 220 x 98
sure sensor system kPa or more
power source in front
right suspension pres-
sure sensor system
power source in rear left
suspension pressure
sensor system
power source in rear
right suspension pres-
sure sensor system
15 Short circuit with Clinometer input F-31 flashes All flash When Any time
ground, disconnection signal above + 10 removed
in clinometer system
x 180 rad
16 Short circuit with power Clinometer input F-32 flashes
source in clinometer signal above – 10
system
x 180 rad
17 Calibration not per- Calibration data in F • CAL All flash When Any time
formed or abnormality in memory damaged flashes removed
RAM
18 Short circuit in external When coil is con- F-41 flashes See When Except when load-
display lamp No. 1 relay ducting electricity, Remarks removed ing (for external
relay coil short cir- column display lamps, see
19 Short circuit in external F-42 flashes
cuits with power Remarks column)
display lamp No. 2 relay
source
23 Defective cycle data See (*2) L.bad — Start of Start of dumping -
payload (*2) flashes empty travel start of empty
travel
24 Over speed limit Travel speed is SP:SP — Set value When problem
over set speed flashes – 2km/h occurs
limit
25 Defective communica- F-71 — When —
tions or defective setting F-73 removed
of option code F-80
F-81
F-91
F-92
F-93
F-94
F-95
F-96
F-97
F-98
F-99
10-182 HD465-7, HD605-7

(6)
Saving abnormality,
warning data (PC soft- Remarks
ware display code)
Records Calibration cannot be
(000-025) performed when there is
abnormality
(000-026)
(000-027)
(000-028)
Records Applicable only when

(000-031) clinometer "use" switch
is at "use"
Calibration cannot be
(000-032) performed when there is
abnormality
Records Load mass calculation

(000-019) stopped while problem
occurs
Records External display lamps
(000-041) actuated as follows
Applicable lamp
(000-042)
Machine stopped:
Always ON
(000-043) Machine traveling: OFF
Other lamps during load-
ing: Specified actuation
(000-044) Other than loading
Machine stopped: Flashes
Machine traveling: OFF
(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

(6)
AUTOMATIC EMERGENCY
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING SYSTEM
RELAY TIMER
1. Dial Outline
2. Lock The relay timer is a delay timer to prevent the emer-
3. Pin gency steering system from being actuated when the
flow switch is acuated mistakenly by the pulse of the
oil ro fluttering of the flow switch.
Set time: 1 seconds With this relay timer, the relay points are switched
after electric current is passed through the coil for
the time set by the timer.
HD465-7, HD605-7 10-187

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SUSPENSION SYSTEM
AUTOMATIC SUSPENSION SYSTEM
1. Dump control lever Outline

2. Retarder controller The front suspension mode (damper force) is auto-
3. Suspension cylinder matically switched according to the travel condition
4. Solenoid valve and load condition to give a more comfortable ride to
5. Hydraulic cylinder the operator and to improve the travel stability.
For details of the internal mechanism of the sus-
pension, see SUSPENSION
10-188 HD465-7, HD605-7

(6)
AUTOMATIC SUSPENSION MODE SELECTION CONTROL

With the front suspension, the mode (damping force) When a liner has been installed to the body for
is automatically changed according to the travel con- HD465 to make it equivalent to the rock body,
ditions and load conditions to ensure a comfortable the increased load on the springs will affect the
ride and to improve the travel stability of the loaded/unloaded judgement in the table below.
machine. The control patterns and functions of the In this case. Select the machine model to HD605
modes (damping force) are as shown in the table by the switch for the transmission control sys-
below. tem.
S:Soft
M:Medium
H:Heard
Set mode
Control pattern Function Content of control Empty Loaded
S M H S M H
Distinguishing To set damping force Internal pressure of front suspen-
empty/loaded according to load on sion cylinder is measured and
machine compared with standard valve
Anti-roll To prevent the chas- This detects the travel speed
sis from rolling when and steering angle, and switches
turning at high speed the mode according to certain (When
turning)
conditions.
(Not controlled when traveling
empty)
Anti-dive To prevent nose-div- The damping force is made

ing when braking stronger when the brakes are
(Brake (Brake (Brake (Brake
applied. OFF) ON) OFF) ON)
Anti-lift To prevent the front The damping force is made
from lifting up when stronger when the dump body
dumping control lever is at any position (Float) (Other (Float) (Other
than than
except FLOAT. Float) Flot)
High speed To improve stability Detects travel speed and selects
stability when traveling at damping force. (No control when
high speed traveling empty)
HD465-7, HD605-7 10-189

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

(6)
STEERING ANGLE SENSOR
1. Body Function
2. Tube • A round disc with teeth like a comb is installed to
3. Connector the steering column, and as this passes through
the slit in the sensor, the sensor outputs a pulse
signal. The suspension controller can obtain the
steering speed from the number of pulses per
unit of time.
STEERING ANGLE SENSOR
1. Body Function
2. Tube • A round disc with teeth like a comb is installed to
3. Connector the steering column, and as this passes through
the slit in the sensor, the sensor outputs a pulse
signal. The suspension controller can obtain the
steering speed from the number of pulses per
unit of time.
HD465-7, HD605-7 10-191

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

(6)
RETARDER CONTROLLER
1. Self-diagnostic display window 4. Automatic retarder speed control

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

(6)
7. Transmission of network data

1) Retarder actuation, float caution, parking
brake actuation, accumulator oil pressure
drop warning, and other data are transmitted
to the monitor panel.
2) The overrun prevention, retarder command
when there is abuse, and other data sent
from the transmission controller are received.
3) The reverse inhibit, and other data are trans-
mitted to the transmission controller.
10-194 HD465-7, HD605-7

(6)
CN1
Pin Specification Signal name Function Remarks
No.
1 D_OUT_0 Automatic suspension solenoid 1 H side (1A) AUTO SUS SOL A
2 D_OUT_2 Automatic suspension solenoid 2 H side (1A) AUTO SUS SOL B
3 D_OUT_4 H side (1A)
4 D_OUT_6H 24V/L side
5 D_OUT_7H 24V/L side
P/B RETARD SW
6 D_OUT_8 Push button retarder switch L side (150mA)
(FOR E/G Controller)
7 Battery direct Battery direct IN
8 Power GND GND
9 Power supply +24V Power supply +24V
10 D_OUT_1 Front brake cut solenoid H side (1A) FRONT BRAKE CUT SOLENOID
11 D_OUT_3 Kick out solenoid H side (1A) KICK OUT SOLENOID
12 D_OUT_5 Hoist changeover valve H side (1A) DUMP CHANGE CONTROL VALVE
13 D_OUT_6L Brake cut relay output H side/GND BRAKE CUT RELAY
14 D_OUT_7L Sensor power supply H side/GND SENSOR POWER
15 D_OUT_9 Body float signal L side (150mA) BODY FLOAT SIG (FOR PLM)
16 Power GND GND
17 Power supply +24V Power supply +24V
CN2

No.
1 Solenoid power supply +24V Solenoid power supply
2 A_OUT_4A+ Shut off valve 0 – 1A SHUT OFF VALVE (+) (FOR ASR)
3 A_OUT_4B+ — 0 – 1A —
4 A_OUT_5A+ — 0 – 1A —
5 A_OUT_5B+ — 0 – 1A —
Interlocked with A_OUT0
6 V_OUT
(0 – 5V)
RETARD BRAKE VALVE (L) (+)
7 A_OUT_0+ Rear wheel retarder EPC output 0 – 1A
(MANU AND AUTO)
8 A_OUT_1+ EPC output for ASR (left rear wheel) 0 – 1A RL BRAKE VALVE (+) (FOR ASR)
9 A_OUT_2+ EPC output for ASR (right rear wheel) 0 – 1A RR BRAKE VALVE (+) (FOR ASR)
10 A_OUT_3+ Hoist EPC valve 0 – 1A DUMP CONTROL PCV (+)
Interlocked with A_OUT1
11 V_OUT
(0 – 5V)
12 Power supply +24V Solenoid power supply
13 A_OUT_4A, 4B– A_OUT4AB (COM)
Suspress, steering speed sensor
14 Sensor power supply Shut off valve (–) (option)
power +12V
15 A_OUT_5A, 5B– A_OUT5AB (COM) (option)
Retarder lever, steering angle Sensor power supply +5V
16
potentio power +5V (400mA)
17 A_OUT_0– A_OUT0 (COM) RETARD BRAKE VALVE (–)
18 A_OUT_1– A_OUT1 (COM) RL BRAKE VALVE (–) (OPTION)
19 A_OUT_2– A_OUT2 (COM) RR BRAKE VALVE (–) (OPTION)
20 A_OUT_3– A_OUT3 (COM) DUMP CONTROL VALVE (–)
21 Power GND
HD465-7, HD605-7 10-195

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

(6)
CN4
No.
1 RS422 TX (+) RS422 TX (+)
2 RS422 RX (+) RS422 RX (+)
3 RS232C TXD RS232C TXD
4 RS232C RXD RS232C RXD
5 RS485 (+) RS485 (+)
6 S-NET (+) S-NET (+)
7 RS422 TX (–) RS422 TX (–)
8 Flash switch (ON/OFF) Flash switch (ON/OFF)
9 RS422 RX (–) RS422 RX (–)
10 GND (serial) GND (serial)
11 RS485 (–) RS485 (–)
12 S-NET (+) S-NET (+)
HD465-7, HD605-7 10-197

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

(6)
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 cor-
responding to this is output to the electromag-
netic proportional valve to actuate the retarder.
Overrun prevention, retarder control when there

is transmission abuse
• The electromagnetic proportional valve is con-
trolled based on the command (ON/OFF com-
mand) from the transmission controller and
actuates the retarder by a fixed amount.
HD465-7, HD605-7 10-199

(6)
Relationship between retarder lever potentiometer

and output to electromagnetic proportional valve
➀ To improve the initial response of the electro-

magnetic proportional reducing valve, the output
(trigger output) is set to a high value.
➁ To make the actuation of the hydraulic pressure
smooth in the low pressure range, the output is
set to a high value.
➂ In the range where the retarder is normally used,
the output is proportional to the angle of the
lever.
➃ To make the opening of the hydraulic pressure
smooth in the low pressure range, the output is
set to a low value.
10-200 HD465-7, HD605-7

(6)
HOIST CONTROL FUNCTION

HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function 4. Control when starting switch is turned to ON,

When the engine is running, the EPC and valve OFF, or START
(electromagnetic proportional valve) and selector Starting switch at ON:
valve are controlled according to the operation of The output is set to HOLD, regardless of the
the dump control lever and operate the dump position of the lever.
body. If the engine is not started, even if the hoist lever
is operated, the condition remains at HOLD.
2. Lever positioner function Starting switch at OFF:
The dump control lever has four positions: The dump body is held in position regardless of
RAISE, HOLD, FLOAT, and LOWER. the position of the lever.
If the dump control lever is operated to the Engine started:
RAISE position, the dump body is raised, and Immediately after the engine is started, the out-
when the top of the dump body reaches the set put is set to HOLD, regardless of the position of
position of the body position sensor, the lever is the lever.
returned to the HOLD position. After the lever is moved to the HOLD position, it
If the lever is kept at the RAISE position, the becomes possible to carry out normal opera-
RAISE output continues to be given. tions.
3. Body seating speed control

When the dump body is lowered and reaches the
position just before it is seated, the area of open-
ing 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, HD605-7 10-201

(6)
5. Float caution function

If the output is not FLOAT or the dump body is
not fully lowered, the float caution lamp on the
monitor panel lights up.
"FLOAT OUTPUT" and "SEATED" → Float cau-
tion OFF
"NO FLOAT OUTPUT" or "NOT SEATED" →
Float caution ON
6. Reverse inhibit function

The retarder controller judges if it is permissible
to travel in reverse or not, and transmits the
result of the judgment through the network to the
transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse
travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" →
Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to recog-
nize the dump body seating and the body cylin-
der stopper condition.
After adjusting the installation of the body poten-

tiometer or after replacing the retarder controller,
carry out calibration in the following order.
Order of dump control calibration (hydraulic oil
temperature: 80 – 90°C)
1) Lower the dump body completely, run the
engine, and keep the lever at FLOAT for at
least 5 seconds. (Check that the float caution
has gone out.)
2) Operate the lever to the RAISE position until
and raise the dump body until it contacts the
stopper. Keep the lever at the RAISE posi-
tion with the cylinder at the stopper position
for at least 5 seconds.
3) Run the engine at low idling and operate
RAISE → FLOAT with the dump body raised
to the maximum height, then lower the dump
body completely. Repeat this operation 10
times.
4) Run the engine at high idling and operate
RAISE → FLOAT with the dump body raised
to the maximum height, then lower the dump
body completely. Repeat this operation 10
times.
10-202 HD465-7, HD605-7

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

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

(6)
RETARDER OIL TEMPERATURE SENSOR
1. Thermistor Function
2. Plug • The sensors are installed to the retarder piping.
3. Wiring harness They take the change in resistance of the ther-
4. Connector mistor as the change in the temperature and
transmit a signal to the retarder controller. The
signal is sent from the retarder controller through
the network to the machine monitor panel to dis-
play the temperature level. When the display on
the monitor panel reaches the specified position,
the lamp lights up and the buzzer sounds to warn
of an abnormality.
RADIATOR WATER LEVEL SENSOR
1. Float Function
2. Sensor • This sensor is installed to the top of the radiator,
3. Connector and when the cooling water level goes below the
specified level, the float goes down and the
switch goes OFF. The maintenance caution lamp
lights up and the character display shows mes-
sage to warn of abnormality.
10-206 HD465-7, HD605-7

(6)
TRANSMISSION OIL FILTER SENSOR
1. Body Function
2. Tube • This sensor are installed to each filter, and when
3. Connector the filter becomes clogged, and the difference in
pressure between the low-pressure side and
A : Low pressure pickup port high-pressure side reaches the specified pres-
B : High pressure pickup port sure, the switch goes OFF. The maintenance
caution lamp lights up and the character display
shown message to warn of abnormality.
Actuating pressure:
Transmission oil filter sensor:
275 kPa {2.8 kg/cm2}
Principle of switch: Pressure difference sliding piston

type
HD465-7, HD605-7 10-207

(6)
FUEL LEVEL SENSOR
2. Float • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing to the fuel level. This movement of the float is
5. Spring transmitted by the arm and actuates a variable
6. Contact resistance. This sends a signal to the monitor
7. Spacer panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
10-208 HD465-7, HD605-7

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

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

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

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-212 HD465-7, HD605-7

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

(6)
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
• When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (11) during the stroke. (Before start of actua-
tion of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
• When this happens, rod (18) on the opposite
side is pushed up by spring (4). 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).
• Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and pro-
trusion b of rod (19), so the lever is held at the
FLOAT position.
10-214 HD465-7, HD605-7

(6)
2. Dump control lever FLOAT canceled 4. Dump control lever operated to RAISE
• When lever (1) is returned from the FLOAT posi- • When RAISE rod (18) is pushed by lever (1) and
tion, it is pushed down by a force greater than moves down, ball (14) contacts protrusion a of
the holding force of rod (19), detent spring (20), rod (19) during the stroke. (Before start of actua-
retainer (13), and ball (14). tion of mechanical detent)
• When rods (18) and (19) are pushed in further,
3. Dump control lever operated to LOWER ball (14) is being held by detent spring (20).
• When lever (1) is operated further from the While pushing retainer (13) up, it escapes to the
FLOAT position, it moves to the LOWER posi- outside, and rod (19) passes over protrusion a.
tion. • When this happens, rod (2) on the opposite side
• Rod (18) is pushed up by the spring (4) in accor- is pushed up by spring (4).
dance with the amount lever (1) is operated. • When an electric current is flowing to solenoid
• Lever (17) and rod (19), which are installed to (19), if rod (2) is pushed up, nut (10) is held in
the rotating shaft of potentiometer (16), are inter- contact with bushing (8).
connected, so a voltage matching the up or down • As a result, rod (2) is held at the pushed up posi-
movement of the rod is output from potentiome- tion, so even if the lever is released, it is held at
ter (16). the RAISE position.
5. Dump control lever RAISE canceled

• When lever (1) is returned from the RAISE posi-
tion, it is pushed down by a force greater than
the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the N position.
HD465-7, HD605-7 10-215

(6)
VHMS CONTROLLER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLOW-BY PRESSURE SENSOR
VHMS CONTROLLER
For details of the basic precautions, outlines,
method of sending and receiving data, and the
procedure for the initial setup, see TESTING
AND ADJUSTING (Drawing No. WJ021JD0500).
Specifications
1. Voltage of power supply : DC20V - DC30V
2. Size : W272 x D169 x H72
(mm)
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine con-
troller. It also gives commands for transmitting the
accumulated data through the communications sat-
ellite.
BLOW-BY PRESSURE
SENSOR
Specifications
1. Voltage of power supply : DC5V
2. Output voltage : 0.5V (engine stopped)
and up
3. Size: Mount (portion a) : R 1/4
: Outside diameter of
seat receiving pres-
sure : ø 37
: Length of cable:
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.
10-216 HD465-7, HD605-7

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE OIL PRESSURE SENSOR
ENGINE OIL PRESSURE

SENSOR
Specifications
1. Type of sensor : Thermistor
2. Range of measurement : 40 – 130 °C
: 80 – 130 °C
(guaranteed precision
± 2 °C)
3. Max. power consumption: 0.5 mW
4. Pressure resistance : 4.9 MPa {50 kg/cm2}
5. Temperature range : --30 to 140 °C
6. Performance table
Tempera- Resis- Tempera- Resis- Tempera- Resis-

ture tance ture tance ture tance
(°C) (kΩ) (°C) (kΩ) (°C) (kΩ)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
a : Heat sensing portion of sensor, outside diameter

of mount R 1/4
Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change in temperature
to the VHMS controller as a change in the resistance
of the thermistor.
HD465-7, HD605-7 10-217

(6)
EXHAUST TEMPERATURE SENSOR/AMP
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AMBIENT TEMPERATURE SENSOR
EXHAUST TEMPERATURE
SENSOR/AMP
Specifications
1. Rated voltage : DC24V
2. Detection temperature range : 100 – 1,000 °C
: 300 – 800 °C
(guaranteed accuracy ± 10 °C)
3. Output voltage characteristics: See table below
4. Actuation temperature range : --40 to 110 °C
5. Consumption current : Max. 30 mA
a : Heat sensing portion of sensor, 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 50 100 400 700 800
(°C)
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
AMBIENT TEMPERATURE
SENSOR
Specifications
1. Electricity consumption : Max. 0.5 mW
2. Pressure resistance : 0.98 MPa
{10 kg/cm2}
3. Detected temperature range (surrounding)
: --30 to 120°C
4. Retention temperature range: --30 to 140°C
5. Performance table below
Detection
temperature --20 --10 0 10 20 50
(°C)
Resistance 30.32 18.58 11.74 7.623 5.077 1.712

(kΩ)
a : Heat sensing portion of sensor, diameter of

mount 16 x 1.5
Function
The ambient temperature sensor inputs the ambient
temperature to the VHMS controller as a change in
the resistance of the thermistor.
10-218 HD465-7, HD605-7

(6)
COMMUNIVSTIONS (ORB• • • ORBCOMM)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROLLER/ANTENNA
COMMUNICATIONS
(ORB• • • ORBCOMM)
CONTROLLER/ANTENNA
CONTROLLER
Specifications
1. Power supply voltage : DC12V – DC30V
2. Size : W306 x D152 x H52 (mm)
Installation location
Install under assistant's seat.
Connector portion
CN1A (ORB-A) : AMP070-14
CN1B (ORB-B) : AMP070-10
CN2 : Communications antenna cable connector
ANTENNA
Specifications
1. Type : Helical whip antenna (1)
2. Impedance : 50 Ω
3. 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
The antenna transmits the data collected and accu-
mulated by the VHMS controller through the commu-
nications satellite to the computer center.
HD465-7, HD605-7 10-219

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PAYLOAD METER
PAYLOAD METER (HAVING VHMS)

SYSTEM CONFIGURATION
10-220 HD465-7, HD605-7

(6)
Outline • The payload meter (having VHMS) cannot be

• A dump truck is supported by 4 suspension cylin- installed to a dump truck which is not equipped
ders. By measuring the total of the loads on with the VHMS controller or which is equipped
each cylinder, it is possible to know the mass on with the VHMS controller and payload meter
the springs of the dump truck. (card type).
The measurement of the load mass is obtained
by calculating the difference between the mass
when empty and the mass when full.
Payload meter displays the load mass calcu-
lated as above on the monitor screen and dis-
plays the load level on the external display
lamps.
It also has an estimation display function: when
loading the next load, the new total load mass is
estimated and the appropriate lamp flashes.
This prevents overloading.
• The operation data, including the load mass of

each transportation cycle, can be saved in the
internal memory and downloaded with special
software (if equipped).
As the special software, the download software
for Payload meter (card type) set for HD465/
605-5 can be used as it is.
The hauled load mass can be input by the follow-
ing alternative 2 methods.
(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).
(2) Input and save the hauled load mass by sta-
tistically processing the data sampled during
the travel from the loading area to the dump
area (New method).
• The VHMS controller executes the functions of

the payload meter and saves the data of each
transportation cycle. It displays, sets, and oper-
ates various items through the machine monitor
and network.
When the payload meter is installed for the first
time or the VHMS controller is replaced, the nec-
essary items of the VHMS controller must be set
again.
Payload meter (card type) set for HD465/605-
5 can be installed for a user who needs a mem-
ory card. If it is installed, however, have the
machine monitor and VHMS controller recognize
that it will execute the functions of the payload
meter, by using rotary switch 2 of the transmis-
sion controller and VHMS initial setting tool.
For setting procedure, see TESTING AND
ADJUSTING, "Initial Setting of Payload Meter",
and [Items related to VHMS controller] "Replace-
ment of Parts".
HD465-7, HD605-7 10-221

(6)
ELECTRIC CIRCUIT DIAGRAM

See TROUBLESHOOTING, Troubleshooting of
VHMS controller.
Principle of measurement
1. Outline
2. Measurement of mass when empty

(Calibration)
• For measurement of mass when empty, see
Payload meter II (card type).
3. Measurement of mass when full

Load the dump truck and measure the mass at
that time. When loading for this purpose, set the
gearshift lever in the "N" position, set the dump
control lever in the "FLOAT" position, turn the
parking brake ON, and release the retarder
brake and foot brake on a ground where the lon-
gitudinal inclination of the dump truck is ± 5° and
the lateral inclination is ± 2°.
4. Correction on slope
If the dump truck is loaded on a slope, the mea-
sured mass is different from the mass measured
on a level ground. To solve this problem, the lon-
gitudinal inclination of the dump truck is mea-
sured and the measured mass is corrected
according to the inclination angle. (Correction
range of inclination angle: ± 5°)
5. 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 infor-
mation.
★ Travel signal sensor:
Transmission output shaft speed sensor
10-222 HD465-7, HD605-7

(6)
INITIAL SETTING OF PAYLOAD METER

In the following cases, perform "setting of rotary
switch 2 (SW2) of the transmission controller" and
"setting with VHMS initial setting manual (tool)"
according to the following table.
1. When the payload meter (having VHMS) or pay-
load meter II (card type) is installed for the first
time
2. When the payload meter (having VHMS) or pay-

load meter II (card type) is removed
3. When the VHMS controller or transmission con-

troller is replaced
4. When setting of VHMS controller is changed

Setting with VHMS initial setting tool (*2)
Set position
of rotary Date
PLM-II Time
VHMS switch 2
Setting of payload meter (card (SW2) of Variation Time
controller Model Serial No.
type) transmission code difference
controller (*1) Summer
time
Not
F – – – –
Payload meter function is not installed Not
installed installed
Installed B ST
HD465
Payload meter func- Not Set
Installed 9 or –7 PV
Payload tion is installed VHMS installed properly
HD605
meter Installed Installed B P2
PLM
function is
installed PLM Not
Installed F – – – –
(Without VHMS) installed
(*1) See "TESTING AND ADJUSTING, Adjusting transmission controller".
(*2) See "TESTING AND ADJUSTING, [Items related to VHMS controller], VHMS Initial Setting Manual (Tool)".
When there is not a problem in installation and wiring

of the payload meter but there are the following prob- 4. The storage place of the data file made by the
lems, check the above setting again. download software is not found.
1. Items related to the payload meter are not dis- Wrong setting of the model and serial No.
played on the machine monitor. with the VHMS initial setting tool.
"The payload is not displayed when the machine
is loaded and stopped", "There are not the 5. Data cannot be downloaded.
manus related to the payload meter on the match Wrong setting of the model, serial No., and
marks", etc. variation code with the VHMS initial setting
Wrong setting of rotary switch 2 (SW2) of tool.
transmission controller
6. Date and time of the downloaded data are
2. While the payload meter (having VHMS) is not wrong.
set, there are the menus related to the payload Wrong setting of the date and time with the
meter on the machine monitor. VHMS initial setting tool.
Wrong setting of rotary switch 2 (SW2) of
transmission controller
3. While the payload meter (having VHMS) is set,

the payload does not match to the lighting condi-
tion of the red lamp of the outside indicator
lamps.
Wrong setting of the model and serial No.
with the VHMS initial setting tool.
HD465-7, HD605-7 10-223

(6)
BASIC FUNCTIONS OF PAYLOAD 7. Setting of OFFSET range

METER This function is used to adjust the calculated
load mass by a set amount.
For details, see Operation Manual.
8. Selection of method of entering saved load
VARIOUS SETTING FUNCTIONS mass
(SERVICE FUNCTIONS) This function is used to select either of the fol-
lowing methods of entering the hauled load
1. Setting of travel distance to recognize com- mass.
pletion of loading 1) Save the load mass when the dump lever is
When the dump truck travels 160 m from the moved from the FLOAT position to another
loading area, the payload meter judges that the position in a dump area (This method is set
loading operation is finished. If the dump truck is when shipped).
unloaded before it travels 160 m, the payload 2) Input and save the hauled load mass by sta-
meter does not judge that the dump truck is tistically processing the data sampled during
unloaded and the cycle data is not completed at the travel from the loading area to the dump
this time. This function is used to change the area.
travel distance to recognize completion of load-
ing when the distance between the loading area
and dump area is very short.
2. Correction of calculation 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, 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, then correct the relation table
of the suspension pressure and load mass forc-
ibly with the measured masses and this function.
3. Correction of level of inclination sensor

This function is used to correct the level of the
inclination sensor.
4. Setting of criterion of maximum travel speed

This function is used to set a criterion of the max-
imum travel speed for the machine control sys-
tem.
5. Setting of load mass to recognize start of

loading
The payload meter recognizes that loading is
completed when the load mass changes by cer-
tain amount. This function is used to change that
amount. Since an easy change can cause
wrong recognition of loading, verify the machine
condition thoroughly when changing.
6. Setting of indication range of outside indicator

lamp
This function is used to change the indication
range of the outside indicator lamp. The condi-
tion for turning on the red lamp cannot be
changed. If it is changed, the red lamp cannot
warn of overloading.
10-224 HD465-7, HD605-7

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OPERATING METHOD
Select "PLM" in Service Mode 1 on the machine monitor.
For method of selection, see TESTING AND ADJUSTING, "Special functions of machine monitor (E MMS)".
HD465-7, HD605-7 10-225

(6)
1. Setting of travel distance to recognize com- 2. Correction of calculation of payload

pletion of loading Since this function affects the accuracy directly,
execute the following procedure securely.
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 proce-
dure.
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 mea-
sured. Accordingly, secure a road for this pur-
pose.
The relationship between the suspension pres-
sure and payload corrected with this function
cannot be returned to the condition at the time of
Input a travel distance to recognize completion of shipment. Accordingly, perform the following
loading by pressing the following buttons. procedure very carefully.
The setting range is 0 – 255 m (0.0 – 0.158 This function is used to match the calculation
miles). result to the indication of the load meter to be
• [>] button: Number at cursor moves forward. used. It does not always heighten the absolute
• [<] button: Number at cursor moves back- accuracy.
ward. 1) Measure the weight of the empty dump truck
• [ ] button: Enter number at cursor. with the load meter and record it (Write it on
• [ ] button: Stop inputting number. a sheet of paper, etc.)
If the set value is too small, the system may rec- 2) Input the measured weight of the empty
ognize that loading is completed while the dump dump truck and drive the dump truck for
truck is still being loaded. about 3 minutes.
i) Select "EMPTY WEIGHT".
• [>], [<] buttons:

Select "EMPTY WEIGHT" or "LOADED
WEIGHT".
• [ ] button: Enter the selection.
• [ ] button: Return to the previous screen.
If the weight of the empty dump truck has
been input and the dump truck has been
driven for about 3 minutes, "LOADED
WEIGHT" is displayed when the menu is
selected.
Check the unit of the input value. The unit is
indicated in the ( ) on the right side of
WEIGHT.
(METRIC): metric ton
(SHORT): short ton
10-226 HD465-7, HD605-7

(6)
ii) Check that measurement of the weight of iv) Check the input value.
the empty dump truck has been com-
pleted.
• [>] button: Select "YES".

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

(6)
vi) Display the progress of measurement. i) Select "LOADED WEIGHT".

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

(6)
iii) Input the measured weight of the fully v) Move the dump truck to a place where
loaded dump truck. you can drive it for about 3 minutes.
• [>] button: • [ ] button: After getting ready for

Number at cursor moves forward. drive, press this button and start
• [<] button: driving the dump truck.
Number at cursor moves back- • [ ] button: Return to the screen for
ward. inputting values.
• [ ] button: Enter number at cursor. Drive the dump truck for about 3 minutes
• [ ] button: (at a speed higher than 8 km/h) to enter
Return to the largest position of the relationship between the weight of
the number to input the value the dump truck and the suspension pres-
again. If this button is pressed sure under that weight.
again, inputting of the value is vi) Display the progress of measurement
stopped and the previous screen (Fig. 9).
appears.
Inputtable range
HD465-7: A1 ± (A1 x 0.25) (metric ton)
However,
A1 = {43.6 [t] (Operating weight) + 46 [t]
(Load capacity)}
HD605-7:
A2 ± (A2 x 0.25) (metric ton)
However,
A2 = {46.8 [t] (Operating weight) + 63 [t]
(Load capacity)}
iv) Check the input value.
• [ ] button:
Stop measurement and return to
the previous screen.
As measurement is executed, the num-
ber of [ ] increases. When measure-
ment is finished, the next screen appears
automatically.
• [<] button: Select "YES".

• [>] button: Select "NO".
• [ ] button: Enter.
HD465-7, HD605-7 10-229

(6)
6) Dump the load in the dump area (Fig. 12). 3. Correction of level of inclination sensor
1) Move the dump truck to a level place.
2) Input the clinometer reading (F) at the cur-
rent 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.
i) Enter value of (F).
• [ ] button:
If the load is dumped with the dump
lever, the menu screen appears automat-
ically.
If the load is dumped normally, correction
is finished.
• [ ] button: Enter the flashing value.
• [ ] button:
The current standard level value is dis-
played on the upper line. The clinometer
value (F) at the current position flashes.
Enter it when it is stabilized.
ii) Turn the dump truck 180 degrees (Stop it
in the opposite direction).
iii) Enter value of (R).
• [ ] button: Enter the flashing value.

• [ ] button:
The current standard level value is dis-
played on the upper line. The clinometer
value at the current position flashes.
Enter it when it is stabilized.
10-230 HD465-7, HD605-7

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

(6)
5. Setting of payload to recognize start of load- 6. Setting of indication range of outside indica-
ing tor lamps
Input a payload to recognize start of loading by Input an indication range of the outside indicator
pressing the following buttons. lamps by pressing the following buttons.
• [>] button: Number at cursor moves forward. • [>] button: Number at cursor moves forward.
• [<] button: • [<] button:
Number at cursor moves backward. Number at cursor moves backward.
• [ ] button: Enter number at cursor. • [ ] button: Enter number at cursor.
• [ ] button: Stop inputting number. • [ ] button: Stop inputting number.
The setting range is 0 – 25.5%. The setting range is 0 – 130% of the load
(Default: 15%) capacity.
This function does not assure the operation Set A (Yellow lamp) higher than G (Green
because of the contrary phenomena shown lamp) and set R (Red lamp) higher than A
below. (Yellow lamp), however.
• If the value is reduced, start of loading may
be recognized wrongly.
• If the value is increased and a loader having
a small-capacity bucket is used, the forecast
function of the outside indicator lamps and
the MMS communication may not operate
normally.
10-232 HD465-7, HD605-7

(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PAYLOAD METEROR
7. Setting of OFFSET range 8. Selection of method of entering saved pay-

load
i) Select the method of entering the saved pay-
load.
Input an offset range by pressing the following

buttons.
• [>] button: Number at cursor moves forward.
• [<] button: • [>], [<] buttons:
Number at cursor moves backward. Select "WHEN DUMPING" or "WHEN
• [ ] button: Enter number at cursor. TRAVELING".
• [ ] button: Stop inputting number. WHEN DUMPING (Setting at time of ship-
The setting range is - 5.0 – +5.0 [t]. ment)
Check the unit of the input value on the pre- The payload measured when the dump
vious menu screen. lever is shifted from the "FLOAT" position
The unit is indicated in the ( ) on the right to "another position" in the dump area is
side of the input value [t]. saved.
(METRIC): metric ton WHEN TRAVELING
(SHORT): short ton The data sampled while traveling from the
loading area to the dump area is pro-
cessed statistically and the hauled pay-
load is entered and saved when it is
dumped.
• [ ] button:
Enter the selected method.
• [ ] button:
ii) Enter the selected method.
• [<] button: Select "YES".

• [>] button: Select "NO".
• [ ] button: Enter.
HD465-7, HD605-7 10-233

(6)
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.
When replacing pressure sensor (1), leave the valve

installed to the suspension and remove only pres-
sure sensor (1).
When removing or installing pressure sensor (1), be
careful not to let valve (2) rotate.
When removing pressure sensor (1), the action of
valve core (3) prevents the suspension pressure
from going down.
The output characteristics of the sensor are as

1. Sensor
2. Tube
3. Connector
10-234 HD465-7, HD605-7

(6)
Clinometer
To carry out compensation on slopes, the clinometer
measures the tilt angle of the chassis in the front-to-
rear direction.
The output characteristics of the clinometer are as

HD465-7, HD605-7 10-235

(6)
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 commu-
nication port which is installed to download the data of the payload meter.
1. Automatic transmission
When dumping is finished, the data of the concerned cycle are transmitted automatically.
The data saved in the payload meter can be made by accumulating the above cycle data with the system on
the user side.
2. MMS communication
If the mass of a bucketful is recognized, the load mass at that time is transmitted automatically.
If the final load mass (hauled load mass of the concerned cycle) is entered, its value is transmitted automat-
ically.
Upon receiving a request command, the load mass is transmitted in real time.
RS232C is used for only the selected one of data downloading, automatic transmission, and MMS communica-
tion.
• 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 HD465-7, HD605-7

(6)
• 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.
1) If there is a code which is the same as STX or ETX in the data area of the communication frame, 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, DLE (10h) is
inserted just before that code.
3) Calculation of BCC
XOR (Exclusive-or) is checked in order from STX at the head of the frame to ETX just before BCC,
including inserted DLE.
When one of 02h (STX), 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)
• 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).
(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 Unit Range Number of byte Remarks
Header "L" ASCI1 1 L (Fixed)
Unused Integer 1 – 65535 2 0 (Fixed)
Month Month (BCD) 1
Day Day (BCD) 1
Time, hour Hour (BCD) 0 – 23 expression 1
Time, minute Minute (BCD) 1
Truck ID Integer 0 – 200 1
Open ID Integer 0 – 200 1
Load mass Metric ton (10-time value) 0 – 6553.5 2
Empty travel time MIN (10-time value) 0 – 6553.5 2
Empty travel distance km (10-time value) 0 – 25.5 1
Empty max. travel speed km/h 0 – 255 1
Empty ave. travel speed km/h 0 – 255 1
Empty stoppage time MIN (10-time value) 0 – 6553.5 2
Stoppage time for loading MIN (10-time value) 0 – 6553.5 2
Loaded travel time MIN (10-time value) 0 – 6553.5 2
Loaded travel distance km (10-time value) 0 – 25.5 1
Loaded max. travel speed km/h 0 – 255 1
Loaded ave. travel speed km/h 0 – 255 1
Loaded stoppage time MIN (10-time value) 0 – 6553.5 2
Dumping time MIN (10-time value) 0 – 25.5 1
Limited speed km/h 0 – 99 1
Cycle warning code 0 – FFFF (HEX) 2
Unused MIN (10-time value) 0 – 4.0 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
Unused Time 0 – 255 1 0 (Fixed)
[BCC]: EX-OR of each bit from STX to ETX
Answer (External device VHMS controller)

STX (02h) NAK (15h) 31H (ASCII 1) ETX (03h) BCC
Action that VHMS controller takes when answer is abnormal

If "NAK" is returned, the VHMS controller transmits up to 2 more times. If "NAK" is still returned, the VHMS
controller stops transmission.
10-238 HD465-7, HD605-7

(6)
• MMS communication
Transmission of unit distinction setting
After the VHMS controller is started by turning the key to the ON position, it transmits the unit distinction
setting information automatically.
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. It is fixed to 02 (h) in the VHMS controller.
Answer ( VHMS controller)
STX (02h) ACK (06h) 31H (ASCII 1) ETX (03h) BCC
or

If "NAK" is returned or either of "ACK" and "NAK" is not returned in 3 seconds, the VHMS controller
transmits up to 2 more times. If an answer is still not returned, the VHMS controller stops transmission.
Transmission of load mass, estimated load mass, and suspension pressure

When mass of 1 bucketful is recognized.
HD465-7, HD605-7 10-239

(6)

Format (VHMS controller)
STX (02h) [1] [2] [3] [4] [5] [6] ETX (03h) BCC
[1]: M (ASCII) fixed

[2]: 4 (ASCII) fixed
[4]: Load mass (B) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
[5]: Estimated load mass (C) [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
[6]: (B) Calculated suspension pressure [HEX] [8 BYTES]
From head
Signal name Position Name HEX
(Lower position)
P FL (Upper position) Front left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P FR (Upper position) Front right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RL (Upper position) Rear left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RR (Upper position) Rear right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5

or

Transmission of final load mass

When the concerned cycle data are entered (When dumping is finished), the final load mass (= the load
mass to be saved as the hauled load mass of the concerned cycle in the memory) is transmitted auto-
matically.
Format (VHMS controller)
STX (02h) [1] [2] ETX (03h) BCC
[1]: P (ASCII) fixed

[2]: Load mass [HEX] (2 BYTES) (Unit: Metric ton, 10-time value, 1 decimal place)
Order: Lower position upper position from the head byte of [2]

or
10-240 HD465-7, HD605-7

(6)

Transmission of real-time data

(a) Outline of communication procedure
1) The VHMS controller receives a request for the real-time data from MMS.
2) After receiving the request for the real-time data, the VHMS controller transmits the real-time data at
intervals of 0.2 seconds.
3) When the VHMS controller receives a request for finishing transmission of the real-time data, it fin-
ishes transmission of the real-time data. When the key is turned to the OFF position, transmission
of the real-time data is finished, too.
1) Request for real-time data ( VHMS controller)
Format
STX (02h) [1] [2] ETX (03h) BCC

[2]: A (ASCII) fixed
Answer (VHMS controller )

Transmission of the real-time data from the VHMS controller is used as a substitute for the answer.
HD465-7, HD605-7 10-241

(6)
2) Transmission of real-time data (VHMS controller )

Format (VHMS controller )
STX (02h) [1] [2] [3] [4] ETX (03h) BCC

[4]: Real-time data (17 BYTES)
From head
Signal name Position Name HEX
(Lower position)
P FL (Upper position) Front left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position) Front right suspension pressure (kg/

P FR (Upper position) [10-time value] 0 – 6553.5
cm2)
(Lower position)
P RL (Upper position) Rear left suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
P RR (Upper position) Rear right suspension pressure (kg/cm2) [10-time value] 0 – 6553.5
(Lower position)
INC (Upper position) Inclination angle (degree) [Complement of 2 of 100-time value]
(Lower position)
PAYLD (Upper position) Real-time load mass (Metric ton) [10-time value, to 1 decimal place)
SP (Current) Travel speed (km/h) 0 – 99
DIG STST Status of digital signals See (*1)
ANA 1 Unused 0
ANA 2 Unused 0
VEH STAT Status of dump truck 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
10-242 HD465-7, HD605-7

(6)

STX (02h) ACK (06h) ETX (03h) BCC
or
STX (02h) NAK (15h) ETX (03h) BCC

Even if "NAK" is returned or any of "ACK", "NAK", and a request for finishing RTM is not returned in
RTM transmission timing, the VHMS controller transmits the real-time data normally after 0.2 sec-
onds. If this condition is repeated 10 times, the VHMS controller stops transmission.
3) Request for finishing transmission of real-time data ( VHMS controller)

Format
STX (02h) [1] [2] ETX (03h) BCC
[1]: Q (ASCII) fixed

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)
Tools for testing, adjusting, and troubleshooting ...................................................................................... 20-101-1

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

(7)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Sym-
Measurement item Part No. Part Name Q’ty Remarks
bol
Air supply pressure -101 – 200 kPa
(boost pressure) A 799-201-2202 Boost gauge KIT 1 {-760 – 1,500 mmHg}
Wear level of front brake
pad b 566-98-41410 Gauge 1 Attached tool
799-101-1502 Digital temperature gauge 1 -99.9 – 1,299 °C
Water, exhaust, and oil

temperatures B 6215-11-8170 Sensor 1 Wire length: 490 mm
799-201-1110 Wiring harness 1
Oil pressure gauge KIT Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge KIT
Engine oil pressure 790-261-1203 (Digital) 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5002 (Analog) 1
Steering, hoist oil pressure {25, 60, 400, 600 kg/cm2}
1
circuit Oil pressure gauge KIT
790-261-1203 (Digital) 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
Power train oil pressure 1
C
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
1
Dump EPC oil pressure

circuit 3 799-101-5230 Nipple 1 14 × 1.5
Face seal type (# 02)

799-401-3100 Adapter 1 (Female: PT 1/8)
4
02896-11008 O-ring 1
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
1
Brake oil pressure 799-261-1203 (Digital) 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
J 566-35-43561 Nipple 1 18 × 1.5 (Female: PT 1/8)
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
795-611-1210 Adapter 6
6560-11-8410 O-ring (TOP) 6
6560-11-8310 O-ring (2nd) 6

2
Compression pressure D 6560-11-8210 O-ring (3rd) 6
6560-11-8510 O-ring (4th) 6
6560-11-7310 Gasket 6
795-799-5410 Adapter 1
3 Injector pull out
795-799-5420 Remover 1
20-101-1 HD465-7, HD605-7

(7)
Sym-
bol
799-101-5002 (Analog) 1
{25, 60, 400, 600 kg/cm2}
C 1
Fuel pump outlet pressure 1 795-799-5460 Cable 1
K 2 Commercially Tester 1
available
3 795-799-5550 Adapter 1
799-101-5002 Oil pressure gauge KIT 1

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
(Analog) {25, 60, 400, 600 kg/cm2}
C 1
790-261-1203 Oil pressure gauge KIT 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(Digital)
Fuel pump inlet pressure
1 795-799-5550 Adapter 1
M
2 795-799-5560 Negative pressure gauge 1 0 – -0.1 MPa {0 – -1 kg-cm2}
Blow-by pressure E 799-201-1504 Blow-by checker 1 0 – 4.9 kPa {0 – 500 mmH2O}
1 6162-23-4500 Barring device 1

Valve clearance F
2 Commercially Thickness gauge 1
available
Injector sot load F1 6162-23-4500 Barring device 1
1 799-201-9000 Handy smoke checker 1 Discoloration 0 – 70 %

Exhaust color G (with standard color)
2 795-502-1350 Smoke meter 1 (Discoloration ×1/10 Bosch index)
1 792-610-1000 Suspension tool 1
2 • 792-610-1130 • Pump assembly 1
3 • 792-610-1110 • Hose 1
Pump assembly KIT part No.
4 • 792-610-1120 • Joint 1
5 • 07020-21732 • Fitting 1
6 • 792-610-1140 • Joint 1
Suspension cylinder of H 7 • 792-610-1250 • Valve 1

adjustment
8 • 792-610-1260 • Nipple 1
H7 – H13
9 • 792-610-1480 • Stem 1 Charging tool assembly KIT part
No. 792-610-1200
10 • 792-610-1640 • Joint 1
11 • 792-610-1400 • Regulator 1
12 • 792-610-1430 • Gauge 1 24.5 MPa {250 kg/cm2}
13 • 792-610-1440 • Gauge 1 9.81 MPa {100 kg/cm2}
HD465-7, HD605-7 20-101-2

(7)
Sym-
bol
Troubleshooting of injector J 795-799-5510 Heat gun 1
At raise of emergency
dump body K 792T-491-1110 Plug 1
799-608-3101 Service KIT 1
1 799-608-3211 • Discket 1
Initial set up of VHMS con-
troller and, at repair set up L
799-608-3220 • Harness 1
2 Commercially Lap top 1 OS: Windows 98/2000

available
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

Operating effort P
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Stroke, hydraulic drift Q Commercially Scale 1

available
Work equipment speed R Commercially Stopwatch 1

available
Voltage, resistance S Commercially Tester 1

available
799-601-7400 T-adapter 1
799-601-3450 Adapter 1 For MS-5
799-601-7330 Adapter 1 For S-16 (White)
799-601-7340 Adapter 1 For M-8
799-601-7360 Adapter 1 For relay (5 pins)
1 799-601-7370 Adapter 1 For relay (6 pins)
799-601-7510 Adapter 1 For AMP070-10
799-601-7520 Adapter 1 For AMP070-12

Sensor, wiring harnesses T
799-601-7530 Adapter 1 For AMP070-14
799-601-7540 Adapter 1 For AMP070-18
799-601-7550 Adapter 1 For AMP070-20
2 799-601-9000 T-adapter 1 For DT connector
3 799-601-9300 T-adapter 1 For DT connector (For 24, 40 pin)
4 795-799-5520 Socket (S) 1 For speed sensor
5 795-799-5530 Socket (S) 1 For intake temperature sensor

For coolant temperature sensor
6 795-799-5540 Socket (S) 1 For fuel temperature sensor
20-101-3 HD465-7, HD605-7

(7)
Sym-
bol
795-799-5460
7 Cumins Part No. Table 1 Atmosphere pressure sensor
Fuel rail pressure sensor
 3824774  Timing rail pressure sensor
795-799-5470 Fuel pump actuator
Sensor, wiring harnesses T 8 Cumins Part No. Table 1 Fuel rail pump actuator
 3824775  Timing rail actuator
Engine oil pressure sensor
795-799-5480 Boost pressure sensor
9 Cumins Part No. Table 1 Fuel pump pressure sensor
 3824776 
HD465-7, HD605-7 20-101-4

(7)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED 4. Measuring torque converter stall speed

1) Switch the machine monitor display to the
Stop the machine on flat ground, turn the park- monitoring function of service mode 1 and
ing brake switch PARKING, and block the tires. display the following 2 items at the same
time with the monitoring function.
★ Measure the engine speed under the following ★ Monitoring items
condition. (1) Code No. 01001:
• Engine water temperature: Within operating Engine speed
range (2) Code No. 30100:
• Torque converter oil temperature: Within oper- Torque converter oil temperature
ating range ★ For details of the method of operation,
• Hydraulic oil temperature: 45 – 55°C see SPECIAL FUNCTIONS OF MACHINE
MONITOR.
1. 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.
★ For the operating method, see "Special func-
tions of machine monitor (EMMS)".
• Monitoring code: 01001 (Engine speed)
★ The unit of displayed engine speed is 1 rpm.
2) Start the engine and raise the temperature of

the hydraulic oil and transmission oil.
★ Transmission oil temperature: 60 – 80°C
★ Hydraulic oil temperature: 45 – 55°C
3) Depress the parking brake pedal, turn the
parking brake switch TRAVEL, then set the
gearshift lever to the D position.
★ If the gearshift lever is operated to any
position other than the D position, the
2. Measuring low idling speed machine may move off even if the brake
1) Set the shift lever N and dump lever in is being depressed, so always measure
HOLD. at the D position.
2) Start the engine and set the accelerator 4) Depress the accelerator pedal gradually, run
pedal in the low idling position and measure the engine at high idling and stall the torque
the engine speed. converter to raise the torque converter oil
temperature.
3. Measuring high idling speed
1) Set the shift lever N and dump lever in There is danger of damage to the inter-
HOLD. nal parts of the transmission, so never
2) Start the engine and set the accelerator operate the gearshift lever to any posi-
pedal in the high idling position and measure tion other than the D position during
the engine speed. the stall operation.
5) When the torque converter oil temperature
goes above 90°C, run the engine immedi-
ately at low idling and return the gearshift
lever to the N position.
Never operate the gearshift lever with
the accelerator pedal depressed. It will
cause a big shock and will also lead to
a reduction in the service life of the
machine.
20-102 HD465-7, HD605-7

➀
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED 5. After completing the adjustment, switch the

machine monitor to the display of "Monitoring
SENSOR function of service mode 1", and check that the
engine speed is displayed normally.
a If the engine speed sensor has been removed a For details of the method of operation, see
and installed or the flywheel has been removed SPECIAL FUNCTIONS OF MONITOR PANEL
or installed, adjust as follows. (EMMS).
1. Remove engine speed sensor (1).
a Before adjusting, remove the engine speed
sensor, check that the tip of the sensor is not
scratched and that there are no iron particles
sticking to it, then install it again.
2. Screw in sensor (1) until the tip of the sensor

contacts the tip of the tooth of flywheel ring gear
(2).
Thread: Loctite hydraulic sealant
(No. 21028)
3. Return sensor (1) by the specified angle from

that position.
a Angle to return: 1/2 – 3/4 turns
a Clearance a of 0.75 – 1.25 mm is made
between the tip of the sensor and the tip of
the gear tooth.
4. Fix engine speed sensor (1) and tighten locknut

(3).4
Nut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}
20-104 HD465-7, HD605-7

(7)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
Special tool list
Symbol Part No. Part Name Remarks
Digital tempera-
799-101-1502 –99.9 – 1,299°C
ture gauge
B 6215-11-8170 Sensor Wire length: 490 mm
799-201-1110 Wiring harness
Wait for the temperature of the exhaust pipe to

go down before removing or installing the mea-
suring equipment.
Open the engine hood and remove the adia-
batic cover of the turbocharger. 3. Method of periodic measurement for preventive
maintenance service.
a Measure the exhaust temperature under the fol-
a To prevent the torque converter from over-
lowing conditions.
heating, use the full stall (torque converter
• Coolant temperature: Within operating range
stall + hydraulic relief) to stabilize the
• Torque converter oil temperature: Within oper-
exhaust temperature, then stall only the
ating range
torque converter and measure the tempera-
• Hydraulic oil temperature: 45 – 55°C
ture.
1) Turn the power mode switch to the HIGH
Method using measuring equipment
POWER position.
1. Remove exhaust temperature measurement
2) Start the engine and raise the temperature of
plug (1).
the cooling water to the operating range.
3) Depress the parking brake pedal, turn the
parking brake switch TRAVEL, then set the
gearshift lever to the D position.
If the gearshift lever is operated to any
machine may move off even if the
brake is being depressed, so always
measure at the D position.
4) Depress the accelerator pedal gradually, run
the engine at high idling and stall the torque
converter. At the same time, operate the
dump lever to the LOWER position and
relieve the oil pressure (full stall).
2. Install sensor !, then connect to digital tempera- a Continue until the exhaust temperature
ture gauge B. reaches the standard value of 670°C.
a Clamp the wiring harness of the temperature
gauge at a suitable place to prevent it from There is danger of damage to the inter-
touching any hot part. nal parts of the transmission, so never
operate the gearshift lever to any posi-
tion other than the D position during
the stall operation.
20-108 HD465-7, HD605-7

(7)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5) When the temperature stabilizes at near the Method using monitoring

target temperature, return the dump lever to a This method applies only to the VHMS specifica-
FLOAT and measure the temperature with tion machine.
only the torque converter stalled. 1. Switch the machine monitor display to [Service
a The exhaust temperature will start to go mode 1] and use the monitoring function to dis-
down from the full stall condition, so play the following two items at the same time.
measure the temperature when it stabi- a Monitoring items
lizes. (1) Code No. 01001 : Engine speed
a If the exhaust temperature does not go (2) Code No. 42600 : Exhaust temperature
down but rises, make the set tempera- (front)
ture at full stall higher.
a After completing the measurement, lower
the engine speed to low idling, then
return the gearshift lever to the N posi-
tion.
4. When measuring the maximum value for the

exhaust temperature during troubleshooting, do
as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
a Use the PEAK mode of the digital tempera-
ture gauge. (Set the temperature gauge to
the PEAK mode. The maximum temperature (1) Code No. 01001 : Engine speed
automatically recorded.) (2) Code No. 42601 : Exhaust temperature
a The exhaust temperature largely depends on (rear)
the outside air temperature (intake air tem-
perature of the engine). Accordingly, if any
abnormal value is obtained, correct it by the
following calculation.
• Corrected value [°C] = Measured value +
2 x (20 – ambient temperature)
5. After completing the measurement, remove the

measuring equipment and set to the original con-
dition.
a For details of the method of measuring, see

HD465-7, HD605-7 20-109

(7)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Special tool list
0 – 4.9 MPa
799-201-1504 Blow-by checker
{0 – 500 mmH2O}

1. Install nozzle and hose ➀ to blow-by hose (1),
then connect to blow-by checker E.
5. After completing the measurement, remove the

measuring equipment and set to the original con-
dition.
Method using monitoring

★ This method applies only to the VHMS specifica-
tion machine.
1. Switch the machine monitor display to [Service
mode 1] and use the monitoring function to dis-
play the following two items at the same time.
2. Start the engine and raise the temperature of the ★ Monitoring items
cooling water to the operating range. (1) Code No. 01001: Engine speed
(2) Code No. 42800: Blow-by pressure
3. Depress the parking brake pedal, turn the park-
ing brake switch TRAVEL, then set the gearshift
lever to the D position.
If the gearshift lever is operated to any
machine may move off even if the brake is
being depressed, so always measure at
the D position.
4. Depress the accelerator pedal gradually, run the

engine at high idling and stall the torque con-
verter, and measure the blow-by pressure.
There is danger of damage to the internal
parts of the transmission, so never operate ★ For details of the method of measuring, see
the gearshift lever to any position other Method using measuring equipment
than the D position during the stall opera-
tion.
★ After completing the measurement, run the
engine at low idling, then return the gearshift
lever to the N position.
20-110 HD465-7, HD605-7

➁
TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF
INJECTOR
Special tool list
S ym bol Part No. Part Name
J 795-799-5510 Heat gun
★ If the engine output drops or there is any other

problem, if there is the possibility of defective
combustion due to defective injection by the
injector, carry out troubleshooting of injector.
1. Stop the engine and leave it to cool down.

★ When cooling the engine down, as a guide- 6. Adjust the temperature of each cylinder mea-
line, wait for the temperature of the exhaust sured 12 minutes after by the compensation
manifold to cool down to a temperature of value and find out the abnormal cylinder.
"ambient temperature +20°C". ★ Compensation value
Unit:°C
2. Make marks a for measurement to the exhaust Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Compensa- +20
manifolds of the all cylinders. tion value
+5 0 0 +5 +20
★ Make marks to the same points on the upper
★ Method of judgment
side or lower side of the exhaust manifolds of
Add up the temperatures after compensat-
the all cylinders.
ing, then calculate the average temperature.
If the temperature of any cylinder is more
than 20°C lower than the average, judge that
the cylinder is abnormal.
1) Measurement and judgment example 1:
No.2 cylinder is more than 20°C lower than
the average value, so judge that No.2 cylin-
der is abnormal.
Unit:°C
Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Measured
85 62 79 112 89 82
value
Compensa- 105 67 79 112 94 102
tion value
Average 93
value
3. Using the heat gun J, measure the exhaust man- 2) Measurement and judgment example 2:
No.3 cylinder is more than 20°C lower than
ifold outlet temperature of each cylinder before
the average value, so judge that No.3 cylin-
starting the engine.
der is abnormal.
★ Apply the measuring beam (center) of heat
Unit:°C
gun J to part "a" of each cylinder to "prevent Cylinder No.1 No.2 No.3 No.4 No.5 No.6
dispersion of the measurement results" Measured
value 86 96 73 91 94 103
caused by difference in the measuring point.
Compensa-
tion value 106
101 73 91 99 123
4. Run the engine at low idling. Average
value 99
5. Using the heat gun J, measure the exhaust man- 3) Measurement and judgment example 3:
ifold outlet temperature of each cylinder 3, 6, 9, No cylinder is more than 20°C lower than the
and 12 minutes after starting the engine. average value, so judge that all cylinders are
★ Apply the measuring beam (center) of heat normal.
gun J to part "a" of each cylinder to "prevent Unit:°C
dispersion of the measurement results" Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Measured
caused by difference in the measuring point. value
70 88 88 93 86 72
Compensa- 90
93 88 93 91 92
tion value
Average
91
value
HD465-7, HD605-7 20-111

➃
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION 4. Remove injector push rods (2) and injectors (3).
a Using tool D3, pull out each injector (See
PRESSURE DISASSEMBLY AND ASSEMBLY).
a Special tools list

Symbol Part No. Part Name
1 795-502-1590 Compression gauge
795-611-1210 Adapter
6560-11-8410 O-ring (Top)
6560-11-8310 O-ring (2nd)
2
F 6560-11-8210 O-ring (3rd)
6560-11-8510 O-ring (4th)
6560-11-7310 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
When measuring the compression pressure, 5. Install adapter assemblies D2 to the all cylinders
take care not to burn yourself on the exhaust and secure them with the holders.
manifold, muffler, etc. or get caught in a rotat- a Install the adapter assemblies with the drain
ing part. holes in the diagonal direction of the holders.
a Secure the adapter assemblies with the
a Measure the compression pressure after the injector holders.
3 Holder mounting bolt:
engine is warmed up (Engine oil temperature: 40
– 60°C).
a Since adapter assemblies D2 of the all cylinders 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
should be removed and installed simultaneously
for efficiency, prepare 6 sets of them.
1. Open the right side cover and left side cover of

the engine.
2. Remove all cylinder head covers.
3. Remove rocker arm assemblies (1) of all the cyl-

inders.
20-111-1 HD465-7, HD605-7

(7)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
6. Install rocker arm assemblies (1) and adjust the 10. After finishing measurement, remove the mea-
valve clearance. suring instruments and return the removed parts.
4 Threads and seat of mounting bolt:

a Measure the stem length of the injector
holder mounting bolt. If it is longer than 80
3 Mounting bolt:
Engine oil (EO30CD) mm, replace the bolt.
2 Threads and seat of holder mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
Engine oil (EO30CD)
3 Holder mounting bolt:
a For details, see ADJUSTING VALVE CLEAR-
ANCE.
1st time: 24.5 – 34.3Nm {2.5 – 3.5kgm}
7. Disconnect 2 connectors (4) (POW) and (SIG) of 2nd time: Tighten by 90 – 120°
2 Threads and seat of rocker arm assembly
the engine.
a After this step, the fuel pump does not supply
mounting bolt: Engine oil (EO30CD)
3 Rocker arm assembly mounting bolt:
fuel to the injectors.
235.2 – 254.8 Nm {24 – 26 kgm}

a Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
a Adjust the set load of the injector. For details,
see ADJUSTING SET LOAD OF INJECTOR.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
8. Connect compression gauge D1 to adapter

assembly D2 of the cylinder to be measured.
9. Crank the engine with the starting motor and

measure the compression pressure.
a Read the gauge when its pointer is stabi-
lized.
HD465-7, HD605-7 20-111-2

(7)
HANDLING EQUIPMENT IN FUEL SYSTEM
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
HANDLING EQUIPMENT IN MEASURING FUEL PUMP

FUEL SYSTEM OUTLET PORT PRESSURE
a Precautions for inspection and maintenance of Special tool list
fuel system Symbol Part No. Part Name
The HPI type fuel injection system is constructed
799-101-5002 Hydraulic tester
of more precise components than the conven- C 1
790-261-1203 Digital hydraulic tester
tional fuel injection pump and nozzle, so prob-
lems may occur if dirt or dust get in. 1 795-799-5460 Cable
When carrying out inspection and maintenance K 2
Commercially
Tester
available
of the fuel system, pay more attention than usual
to prevent dirt or dust from getting in. If there is 3 795-799-5550 Adapter
any dirt stuck to any part, use clean fuel to wash
it off completely. 1. Measuring pressure sensor signal voltage
a Precautions when replacing fuel filter cartridge 1) Disconnect connector CN-PMPR (1) of the
Always use a genuine Komatsu part for the fuel fuel pump pressure sensor, then connect
filter cartridge. cable K1 to the male and female ends.
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so a spe-
cial filter with high efficiency filtering ability is
used to prevent dirt or dust from getting in.
For this reason, if any filter is used as a substi-
tute for the genuine filter, there is danger that
problems will occur with the fuel system. To pre-
vent this, never use such filters.
2) Start the engine, switch the machine monitor

to the display of "Monitoring function of ser-
vice mode 1", and prepare to measure the
engine speed.
a For details of the method of operation, see
SPECIAL FUNCTIONS OF MACHINE
MONITOR (EMMS).
a The engine speed is displayed in units of
1 rpm.
20-112 HD465-7, HD605-7

(7)
MEASURING FUEL PUMP INLET PORT PRESSURE (NEAGIVE PRESSURE)
TESTING AND ADJUSTING VISUAL INSPECTION OF RETURN FUEL
MEASURING FUEL PUMP 3. Run the engine at a medium speed to bleed the
oil from the hose.
INLET PORT PRESSURE ★ Insert the connection of the negative pres-
(NEGATIVE PRESSURE) sure gauge and hose about halfway, repeat
the action to open the self-seal portion at the
Special tool list hose end to bleed the oil.
S ym bo l Part No. Part Name ★ If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
799-101-5002 Hydraulic tester
C 1 used.
790-261-1203 Digital hydraulic tester
★ If there is oil inside the hose, the gauge will
1 795-799-5550 Adapter not work, so always bleed the oil.
M Negative pressure gauge
2 795-799-5560
(0 – -0.1 MPa{0 – -1.02 kg/cm2})
4. Run the engine at full throttle and measure the
pump inlet port pressure (See Table 1).
1. Fit adapter M1 to pump inlet port pressure mea-
suring nipple (1). Table 1
2. Fit nipple ➀ of hydraulic tester C1 and hose ➁ to Fuel filter Fuel pump inlet port pressure
adapter M1 and connect them to negative pres- New Max. – 13.60 kPa {Max. – 102 mmHg}
sure gauge M2.
Used Max. – 27.10 kPa {Max. – 203 mmHg}
VISUAL INSPECTION OF
RETURN FUEL
★ 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.
★ If the engine does not revolve normally or fuel
consumption is abnormally high, inspect the
return fuel according to the following procedure.
1. Disconnect the fuel return hose before the fuel

tank.
★ Plug the hole of the fuel tank.
★ Keep the return hose open and receive the
fuel with an oil pan, etc.
2. Start the engine and check that the fuel flows out
of the fuel return hose smoothly.
★ Fuel spillage (Reference)
At low idling: 4 – 6 /min
At high idling: 10 – 12 /min
★ If the fuel spillage is extremely low, check the
return piping and fuel cooler for clogging.
20-114 HD465-7, HD605-7

➃
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
ADJUSTING INJECTOR SET a The cylinder where the injector is adjusted is

different from the cylinder at compression top
LOAD dead center, so check the chart below when
carrying out the operation.
Special tool list • Cylinder at compression top dead center and
Symbol Part No. Part Name cylinder where injector is inspected.
F1 6162-23-4500 Barring device
Compression top 1 5 3 6 2 4
dead center
1. Open the engine hood cover. Injector to 2 4 1 5 3 6
adjustment
2. Remove all cylinder head covers (1).
3. Rotate the crankshaft in the normal direction,

align [1.6TOP] line a on the damper with pointer 4. Loosen locknut (2) of the injecter to be adjusted
(2), and set the No.1 cylinder at compression top and adjustment screw (1) completely, and then
dead center. tighten the adjustment screw with your fingers.
a Remove the flywheel housing cover and a Check that the socket at the tip of the rocker
install barring device F1 to rotate the crank- arm and the ball of the push rod are both fit-
shaft. ted securely into the injector and push rod,
respectively.
5. Tighten adjustment screw (1), repeat the loosen-

ing operation, then tighten finally.
Adjustment screw:
1st time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2nd time : Loosen fully
3rd time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4th time : Loosen fully
5th time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a At compression top dead center, the rocker

arm of the No.1 cylinder can be moved by
hand and amount equal to the valve clear-
ance. If the rocker arm does not move, it is
not at compression top dead center, so
rotate the crankshaft one more turn.
HD465-7, HD605-7 20-115

(7)
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
6. Hold adjustment screw (1) in position, then

tighten locknut (2).
Locknut: 205.8 – 245 Nm {21 – 25 kgm}
7. After completing the adjustment, set to the origi-

nal position.
Cylinder head mounting bolt :
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
20-116 HD465-7, HD605-7

➃
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE 4. Insert feeler gauge F2 into clearance b between

rocker arm (3) and crosshead (4), and adjust the
CLEARANCE valve clearance with adjustment screw (5).
★ Insert the feeler gauge and turn the adjust-
Special tool list ment screw until the clearance is a sliding fit.
S ym bo l Part No. Part Name
1 6162-23-4500 Barring device 5. Hold adjustment screw (5) in position, then
F Commercially tighten locknut (6).
Feeler gauge
available
Locknut:
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
1. Open the engine hood. ★ After tightening the locknut, check the valve
clearance again.
2. Remove all cylinder head covers (1).
6. Rotate the crankshaft 120° each time in the nor-

3. Rotate the crankshaft in the normal direction, to
mal direction and repeat the procedure in Steps
set the No.1 cylinder at compression top dead
3 – 5 to adjust the valve clearance of each cylin-
center, and align [1.6TOP] line a on the damper
der according to the firing order.
with pointer (2).
• Firiing order: 1–5–3–6–2–4
★ Use a barring device F1 on the flywheel
housing to carry out cranking.
★ At compression top dead center, the rocker
arm of the No.1 cylinder can be moved by
hand an amount equal to the valve clear-
ance. If the rocker arm does not move, it is
not at compression top dead center, so
rotate the crankshaft one more turn.
★ Valve clearance (at cold).

Intake valve : 0.32 ± 0.2 mm
Exhaust valve: 0.62 ± 0.2 mm
7. After completing the adjustment, set to the origi-

nal condition.
Cylinder head cover mounting bolt:
9.8 ± 1.0Nm {1.0 ± 0.1 kgm}
20-120 HD465-7, HD605-7

➃
TESTING AND ADJUSTING HYDRAULIC
TESTING AND ADJUSTING PRESSURE IN STEERING, HOIST CIRCUIT

HYDRAULIC PRESSURE IN
STEERING, HOIST CIRCUIT
★ Special tool list
Pressure gauge:
Analog hydrau- 2.5, 5.9, 39.2,
799-101-5002
lic meter 58.8 MPa {25, 60,
C1 400, 600 kg/cm2}
Pressure gauge:
Digital hydrau-
790-261-1203 58.8 MPa
lic meter
{600 kg/cm2}
2. Adjusting hydraulic pressure in steering cir-

Stop the machine on level ground, apply the
cuit
parking brake, and put blocks under the tires. If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
Lower the body to the frame, stop the engine,
• Steering pressure (adjust with demand valve)
then remove the cap from the hydraulic tank 1) Remove cap (2), then loosen locknut (3) and
and release the pressure inside the cylinder turn adjustment screw (4) to adjust.
circuit. ★ To INCREASE pressure, turn CLOCK-
WISE
Starting circuit To DECREASE pressure, turn COUN-
1. Measuring hydraulic pressure in steering cir- TERCLOCKWISE
cuit ★ One turn of the adjustment screw adjusts
1) Raise the hydraulic oil temperature. by 2.45 MPa {25 kg/cm2}.
★ Oil temperature when measuring :
45 – 55°C
2) Remove plug (1) and install tool C1 (39.22
MPa {400 kg/cm2}).
3) Operate the steering wheel fully to the left or
right, and measure the hydraulic pressure
when the circuit is relieved. 10860
HD465-7, HD605-7 20-145

➄
2) After adjusting, hold the adjustment screw Hoist circuit

with a screwdriver to prevent it from turning,
then tighten the locknut and install the cap. 1. Measuring hydraulic pressure in hoist circuit
1) Raise the hydraulic oil temperature.
cap: 0.29 – 0.39 Nm {3 – 4 kg/m2} ★ Oil temperature when measuring :
45 – 55°C
3) Check again so that the hydraulic pressure is
2) Remove oil pressure measurement plug (1)
within the specified value.
and install tool C1 (39.22 MPa {400 kg/cm2}).
For details, see MEASURING HYDRAULIC
3) Operate the hoist control lever, ans move the
PRESSURE IN STEERING CIRCUIT.
dump body to the maximum dump position to
★ The pressure of crossover relief valve (5)
relieve the circuit, then measure the hydrau-
cannot be adjusted when it is installed on the
lic pressure with the engine at full throttle.
machine, so do not adjust the pressure.
3. Measuring steering valve charge pressure

MPa {400 kg/cm2}).
2) Measure in the same way as when measur-
ing the hydraulic pressure in the steering cir-
cuit.
4. Measuring hydraulic pressure in steering cyl-

inder
1) Remove pressure measurement plug (7)
(when turning the steering to the left) or pres-
sure measurement plug (8) (when turning the
steering to the right), and install tool C1
(39.22 MPa {400 kg/cm2}).
ing the hydraulic pressure in the steering cir-
cuit.
20-146 HD465-7, HD605-7

➄
2. Adjusting hydraulic pressure in hoist circuit

If the hydraulic pressure is not within the stan-
dard value, adjust as follows.
Hoist cylinder pressure (adjust with hoist valve)
1) Loosen locknut (2) and turn adjustment
screw (3) to adjust.
★ To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
★ One turn of the adjustment screw adjusts
by 4.2 MPa {42.8 kg/cm2}.
2) After adjusting, hold the adjustment screw
with a screwdriver to prevent it from turning,
then tighten the locknut.
3) Check again so that the hydraulic pressure is
within the specified value.
For details, see MEASURING HYDRAULIC
PRESSURE IN STEERING CIRCUIT.
3. Measuring hoist cylinder pressure

MPa {400 kg/cm2}).
ing the hydraulic pressure in the hoist circuit.
HD465-7, HD605-7 20-147

➄
TESTING AND ADJUSTING OIL PRESSURE IN DUMP EPC CIRCUIT
TESTING AND ADJUSTING 2) Install nipple C3 and hose ➁ and connect oil
pressure gauge C1 [5.9 MPa {60 kg/cm2}].
OIL PRESSURE IN DUMP EPC 3) Start the engine and measure the oil pres-
CIRCUIT sure when the dump lever is in neutral.
★ Special tool list

Pressure gauge:
Analog hydrau- 2.5, 5.9, 39.2,
799-101-5002
lic meter 58.8 MPa {25, 60,
1 400, 600 kg/cm2}
Pressure gauge:
Digital hydrau-
790-261-1203 58.8 MPa
lic meter
C {600 kg/cm2}
3 799-101-5230 Nipple 14 × 1.5
Face seal type
799-401-3100 Adapter (#02)
4 (Female: PT 1/8)
02896-11008 O-ring —
2. Measuring dump EPC valve output pressure
Loosen the oil filler cap of the hydraulic tank 1) Disconnect EPC hose (3) or (4) to be mea-
sured.
slowly to release the residual pressure from
(3): Dump raise side (Port PB)
the tank.
(4): Dump lower side (Port PA)
Measuring
1. Measuring dump EPC valve main pressure
1) Remove oil pressure pickup plug (2) (M14 x
1.5) from dump EPC valve (1) inside the
hydraulic tank (inside the machine).
2) Install adapter C4 to hoist valve and connect

the hose.
3) Install nipple ➀ and hose ➁ and connect oil

pressure gauge C1 [5.9 MPa {60 kg/cm2}].
4) Start the engine and raise or lower the dump

lever and measure the circuit oil pressure.
20-148 HD465-7, HD605-7

➄
TESTING AND ADJUSTING PROCEDURE FOR RAISING DUMP BODY IN EMERGENCY
PROCEDURE FOR RAISING 1) If the engine can be started, start the engine
under this condition, and the dump body
DUMP BODY IN EMERGENCY rises.
2) If the engine cannot be started, turn the
★ Special tool list emergency steering switch M and raise the
dump body with the hydraulic pressure of the
emergency steering pump.
K 792T-491-1110 Plug —
★ Do not operate the emergency steering
pump for more than 90 seconds continu-
★ If the dump body cannot be raised because of a ously. If the load cannot be dumped in
failure in the controller or electric system, raise it 90 seconds, cool down the steering
to dump the load according to the following pro- pump, and then operate it again.
cedure.
3. Stop the engine and remove tool [K] and install
1. Stop the engine and remove the hydraulic tank plug (1).
cap to release the residual pressure from the
Tightening torque of plug:
hoist circuit.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
2. Remove plug (1) and tighten tool [K] fully.
★ If tool [K] is tightened in fully, the spool is 4. When lowering the dump body, remove plug (2)
moved to the rising stroke end. and tighten tool [K] slowly.
★ Distance between valve end and spool end:
103 mm. When performing this procedure, be sure
not to go under the dump body but stand
on the ground.
★ The dump body lowers by itself. Keep it at

safe lowering speed by adjusting the tighten-
ing depth tool [K].
5. After the dump body lowers completely, remove

tool [K] and install plug (2).
Tightening torque of plug:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
K: Plug
20-150 HD465-7, HD605-7

➄
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
ADJUSTING BODY • DECREASE link length to IN-

CREASE voltage
POSITIONER SENSOR 4) Install mounting bolt (2).
5) Tighten locknut (1).
a If the body positioner rod has been disconnected 6) Repeat the checking procedure above to
and connected again or the body positioner sen- check that the input voltage is within the nor-
sor has been removed and installed again, mal range.
inspect and adjust the body positioner sensor as
follows.
1. 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 volt-
age.
a Monitoring item
Code No. 34400: BODY POSITION
a For details of the method of operation,
see SPECIAL FUNCTIONS OF MA-
CHINE MONITOR.
3. Calibrating system
Stop the machine on a level place and set

chocks under the tires securely.
a Hydraulic oil temperature: 80 – 90°C
1) With the body seated perfectly, start the
engine.
2) Keep the dump control lever in the FLOAT
position for at least 5 seconds.
a Check that the FLOAT caution lamp is
turned off.
3) With the body raised to the cylinder stopper,
2) Start the engine. run the engine at low idling and keep the
3) Operate the dump lever and check the moni- dump control lever in the RAISE position for
toring voltage when the dump lever is operat least 5 seconds.
ated fully to the LOWER position and RAISE 4) Run the engine at high idling and raise the
position. body to the stroke end. Then, lower the
a When operated fully to LOWER: engine speed to low idling and set the dump
0.38 – 0.44 V control lever in the FLOAT position to lower
a When operated fully to RAISE: the body to the seating position.
3.80 – 4.70 V a Repeat the operations of 3) and 4) above
5 – 10 times.
2. Adjusting link length 5) Run the engine at high idling and raise the
a If the monitoring voltage is not within the nor- body to the stroke end. Then, keep the
mal range, adjust the length of the link as fol- engine speed at high idling and set the dump
lows. control lever in the LOWER position to lower
1) Loosen locknut (1). the body to the seating position.
2) Remove mounting bolt (2). a Repeat this operation 5 – 10 times.
3) Turn rod end (3) to adjust the length of
the link (4).
a Standard installing length a: 433 mm.
a Do not set installing length a less
than 430 mm.
a Adjust the input voltage as follows.
• INCREASE link length to DE-
CREASE voltage
HD465-7, HD605-7 20-151

(7)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
• In the following cases, check the settings of the rotary switches, dipswitches, and option setting connectors
at the rear face of the machine monitor (EMMS), and change the settings as necessary.
• When the machine monitor has been removed and installed again.
• When machine monitor (EMMS) have been replaced with new parts (service meter, odometer, reverse
travel odometer setting)
★ When carrying out of these settinigs, it is necessary to use the special operation of the character
display and mode switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).
• When service code [DAFOKM] is displayed
★ There is probably mistaken connection of the option setting connector, so see TROUBLESHOOT-
ING OF MACHINE MONITOR SYSTEM (MON MODE) for details.
• When the specification is changed as shown in Table 1, change the setting.
Table 1: Condition of switch setting functions and option setting connectors.
Switch Position Purpose of switch Connector Remarks
Correction of travel speed

SW1 0–F Unnecessary Standard tire is set to position 7.
(Correction of tire size)
SW2 • Setting of max. speed
0–F • Setting of max. speed when body is Unnecessary
raised
SW3 0–F Setting of specification Unnecessary
OFF Unit of speed meter: km/h Unnecessary
1 Unit of speed meter: MPH Only in area where MPH is used
ON Unnecessary
as unit
Exhaust brake: Not installed Open
OFF
2 (Not connected)
SW5 ON Exhaust brake: Installed Connected

OFF Connected
3
ON Spare
Open
OFF Front brake cut: Not installed
4 (Not connected)
ON Front brake cut: Installed Connected
Open
OFF Maintenance function: Not installed
1 (Not connected)
ON Maintenance function: Installed Connected
Setting of caution when body is raised: Open
OFF
Not installed (Not connected)
2
SW6 Setting of caution when body is raised:
ON Connected
Installed
OFF Spare
3
ON Spare
OFF Spare
4
ON Spare
• The condition of each switch and connector can be checked with the special function of the machine moni-
tor (EMMS) (monitoring function).
• Connector OP7 is used for the special function of the machine monitor.
★ For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).
HD465-7, HD605-7 20-157

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

(7)
TESTING AND ADJUSTING INITIAL SETTING OF PAYLOAD METER
INITIAL SETTING OF PAYLOAD METER

In the following cases, perform "setting of rotary switch 2 (SW2) of the transmission controller" and "setting with
VHMS initial setting manual (tool)" according to Table 1.
1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time
2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed
3. When the VHMS controller or transmission controller is replaced
4. When setting of VHMS controller (PLM ) is changed
Table 1
Setting with VHMS initial setting manual

(tool) ( 2)
Card-type Set position of
PLM rotary switch 2
VHMS function in payload Payload Date
meter meter (PLM) (SW2) of Time
controller VHMS transmission
controller function Variation Time differ-
(PLM- ) controller ( 1) Model Type code ence (GMT)
Summer
time
Not installed — Not installed Not installed F — — — —
Not installed — Installed Installed F — — — —
Installed Not installed Not installed Not installed B ST

HD465
Installed Not installed Installed Installed F or –7 P2 Set
HD605 properly
Installed Installed Installed Installed 9 PV
( 1) For the set position of rotary switch 2 (SW2) of the transmission controller, see the section of adjust-
ment of the transmission controller.
( 2) For setting of the model, type, variation code, etc., 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,
check the above setting again.
1. Items related to the payload meter are not displayed on the machine monitor.
"The payload is not displayed when the machine is loaded and stopped", "There are not the manus
related to the payload meter on the match marks", etc.
★ Wrong setting of rotary switch 2 (SW2) of transmission controller
2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on
the machine monitor.
★ Wrong setting of rotary switch 2 (SW2) of transmission controller
3. While the payload meter in the VHMS is set, 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. with the VHMS initial setting tool.
4. The storage place of the data file made by the download software is not found.
★ Wrong setting of the model and serial No. with the VHMS initial setting tool.
5. Data cannot be downloaded.
★ Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool.
6. Date and time of the downloaded data are wrong.
★ Wrong setting of the date and time with the VHMS initial setting tool.
HD465-7, HD605-7 20-160-1

➄
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 dis-
played on the character display in the middle of the machine monitor. The display items are divided by the inter-
nal setting of the machine monitor (EMMS), into automatic display items and items displayed when the machine
monitor switches are operated.
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.
2) Special functions 1: Service mode 1
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
3) Special functions 2: Service mode 2
When the machine monitor has been replaced, functions from Service mode 1 can be further displayed and
operated with the special switches
Operator mode ↔ Service mode 1 ↔ Service mode 2

Service meter, odometer display Electric system fault history dis- 17 Service meter setting function
1 9
function (default) (*1) play function 18 Odometer value setting function
Reverse travel distance display Mechanical system fault history Reverse travel distance value set-
2 10 19
function display function ting function
Filter replacement, oil change 11 Machine data monitoring function
3
interval display function
12 Adjustment function
Telephone number input func-
4 Filter replacement, oil change
tion 13
interval setting function
5 Language selection function
14 Snapshot function
6 PLM setup function
15 PLM setup function
7 Action code display function
Initialize function (factory use
16
8 Failure code display function only)
*1: PLM (payload meter) display function when receiving VHMS data
HD465-7, HD605-7 20-161

➁
FLOW MODES AND FUNCTION
20-162 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-163

➁
20-163-1 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-163-2

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

(7)
4. Telephone number input function

The telephone number set inside the machine
monitor can be input, corrected, or canceled by
operating the switches (Fig. 5).
★ When action code [E03] is displayed, the
telephone number is displayed at the same
time as [CALL].
★ For details, see STRUCTURE AND FUNC-
TION, Machine monitor system.
5. Language selection function

The language used for the machine monitor dis-
play can be selected by operating the switches
(Fig. 6)
★ The functions of Service mode 1 and Service
mode 2 are not included in the functions for
display selection, so they are always dis-
played in English.
★ For details, see STRUCTURE AND FUNC-
TION, Machine monitor system.
6. PLM setting function

★ 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. 10).
★ For details, see the operation manual for the
"PLM in VHMS".
7. Action code display function

If any abnormality occurs on the machine, the de-
gree of the abnormality is automatically displayed
as a user code on the machine monitor to recom-
mend appropriate action to the operator (Fig. 7).
★ The diagram on the right shows an example
of action code [E03] and [CALL+ Telephone
number] being displayed in turn.
★ When action codes [E01] and [E02] are dis-
played, [CALL+ Telephone number] is not
displayed.
★ Correspondence between action code and
recommendation to operator
20-166 HD465-7, HD605-7

➄
Action code CALL+ Telephone number Action recommended to operator
• Carry out inspection and maintenance after comple-

E01 Not displayed tion of operations or when changing shifts between
operators
• When overrun related display is shown:

Reduce engine speed and machine speed while con-
tinuing operations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range
speed under no load.
• Stop engine and machine immediately and contact

E03 Displayed
serviceman.
8. Failure code display function

While the action code is being displayed on the
machine monitor, press the [>] button once to dis-
play the failure codes for the existing failures (Fig.
8: example).
• [>] Button: Displays failure code
★ The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are recorded
as trouble data. (For details, see Service
mode 1.)
★ If more than one failure is occurring, press
the [>] button once more to display the other
failure codes.
★ After pressing the [>] button to display all the
existing failures, press the [>] button once
more to return to the service meter/odometer
display screen.
If the [>] button is pressed once more, the
failure codes will be displayed again from the
beginning.
If the switch is not operated for 10 seconds,
the display will switch automatically to the ac-
tion code screen.
★ With the service code display function, the
following data are displayed (Fig. 9).
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
★ For details of the displayed failure codes, see
FAILURE CODE TABLE.
★ With the failure code display function and
trouble data display function (Service mode
1), the data that are displayed are partially
different.
★ If no switch is operated on the failure code
display screen for more than 30 seconds, the
display automatically returns to the action
code display screen.
HD465-7, HD605-7 20-167

➄
FAILURE CODES LIST

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

➄

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

➄

C265KX Abnormality in fuel temperature sensor Disconnection or short circuit (KZ) ENG E01
C316KZ Abnormal current in fuel injection pump actuator Disconnection or short circuit (KZ) ENG E01
C318LK Pump actuator defective See separate list (LK) ENG E01
C346KT ECM power-down error Internal defect of controller (KT) ENG E03
C423L6 Timing rail pressure in-range error See separate list (L6) ENG E03
C431L4 Abnormality in idling validation switch See separate list (L4) ENG E01
C432L5 Idling validation process error See separate list (L5) ENG E03
C441KK Abnormality in battery voltage Lowering of source/input voltage (KK) ENG E01
C442KG Abnormality in battery voltage High source voltage (KG) ENG E03
C451KX Abnormality in fuel rail pressure sensor Out of input signal range (KX) ENG E03
C452KX Abnormality in fuel rail pressure sensor Out of input signal range (KX) ENG E03
C455KZ Abnormality in fuel rail actuator circuit Disconnection or short circuit (KZ) ENG E03
C467LK Timing actuator control error See separate list (LK) ENG E03
C468LK Rail actuator control error See separate list (LK) ENG E03
C514LK Rail actuator defective See separate list (LK) ENG E03
C554L6 Fuel rail pressure sensor in-range error See separate list (L6) ENG E03
D1B0KZ Cut-out relay Disconnection or short circuit (KZ) TM E03
D1C0KZ Brake cut-out relay Disconnection or short circuit (KZ) BK E03
D5ZMKZ Disconnection/Grounding fault/Short circuit in engine Disconnection or short circuit (KZ) TM E01
output mode command line
D5ZNKZ Failure in front brake cut-out output system Disconnection or short circuit (KZ) BK E01
(Disconnection, grounding fault, short circuit) (OPT)
DAF0KM Monitor panel Mistake in operation or setting (KM) MON E03
DAF9KM Monitor panel Mistake in operation or setting (KM) MON E03
DAFSKQ Monitor panel Disagreement of model selection MON E03

signals (KQ)
DAQ0KK Transmission controller Lowering of source/input voltage (KK) TM E03
DAQ1KK Transmission controller main power source line Lowering of source/input voltage (KK) TM E03
DAQ2KK Transmission controller load power source line Lowering of source/input voltage (KK) TM E03
DAQ3KK Transmission controller battery direct power source Lowering of source/input voltage (KK) TM E03
line
DAQ9KM Transmission controller wiring harness Mistake in operation or setting (KM) TM E03
DAQ9KQ Transmission controller wiring harness Disagreement of model selection TM E03

signals (KQ)
DAQAKQ Transmission controller rotary switch Disagreement of model selection TM E03
signals (KQ)
DAQSKR Transmission controller S-NET line Communication defective/Abnormality in MON E03
objective component (KR)
DAQSMA Transmission controller Malfunction (MA) TM E03
DASRKR COMMUNICATION ERROR ENG Communication defective/Abnormality in MON E03

DB10KK Retarder controller Lowering of source/input voltage (KK) BK E03
20-170 HD465-7, HD605-7

➄

DB11KK Retarder controller main power source line Lowering of source/input voltage (KK) BK E03
DB12KK Retarder controller load power source line Lowering of source/input voltage (KK) BK E03
DB13KK Retarder controller battery direct power source line Lowering of source/input voltage (KK) BK E03
DB19KM Retarder controller wiring harness Mistake in operation or setting (KM) BK E03
DB1SKR Retarder controller S-NET line Communication defective/Abnormality in MON E03

DB1SKQ Wrong information on model selection Disagreement of model selection BK E03
signals (KQ)
DBBSKR Communications error VHMS Defective communications, abnormality MON E01
in target component system (KR)
DDD7KX Failure in travel speed setting switch system (OP) Out of input signal range (KX) BK E03
DDD8KA Disconnection ARSC system switch (OP) Disconnection (KA) BK E03
DDD8KB Short circuit ARSC system switch (OP) Short circuit (KB) BK E03
DDDAKA Disconnection ASR system switch (OP) Disconnection (KA) BK E01
DDDAKB Short circuit ASR system switch (OP) Short circuit (KB) BK E01
DDTGKA Fill switch for lockup clutch Disconnection (KA) TM E03
DDTHKA Fill switch for Hi clutch Disconnection (KA) TM E03
DDTJKA Fill switch for Lo clutch Disconnection (KA) TM E03
DDTKKA Fill switch for 1st clutch Disconnection (KA) TM E03
DDTLKA Fill switch for 2nd clutch Disconnection (KA) TM E03
DDTMKA Fill switch for 3rd clutch Disconnection (KA) TM E03
DDTNKA Fill switch for R clutch Disconnection (KA) TM E03
DDTPKA Failure in flow sensor valve for 4th clutch Disconnection (KA) TM E03
DF10KA Gear shift lever Disconnection (KA) TM E03
DF10KB Gear shift lever Short circuit (KB) TM E03
DGF1KX Transmission valve oil temperature sensor Out of input signal range (KX) TM E03
dGR2L8 Failure in retarder oil temperature sensor system See separate list (L8) BK E03
DGR2L8 Brake oil temperature sensor (Rear) See separate list (L8) BK E01
DGT1KX Torque converter oil temperature sensor Out of input signal range (KX) TM E01
dHP4KX Failure in suspension pressure sensor (FR) system Out of input signal range (KX) BK E03
(OPT)
DhP4KX Suspension pressure sensor (FR) Out of input signal range (KX) PLM E01
DHP4KX Failure in suspension pressure sensor (FR) system Out of input signal range (KX) BK E01
(OPT)
dHP5KX Failure in suspension pressure sensor (FL) system Out of input signal range (KX) BK E03
(OPT)
DhP5KX Suspension pressure sensor (FL) Out of input signal range (KX) PLM E01
DHP5KX Failure in suspension pressure sensor (FL) system Out of input signal range (KX) BK E03
(OPT)
DHP6KX Suspension pressure sensor (RR) Out of input signal range (KX) PLM E01
DHP7KX Suspension pressure sensor (RL) Out of input signal range (KX) PLM E01
HD465-7, HD605-7 20-171

➄

DHT5KX Torque converter oil pressure sensor Out of input signal range (KX) TM E01
DHT5L6 Torque converter oil pressure sensor See separate list (L6) TM E01
DHU2KX Accumulator oil pressure sensor (Front) Out of input signal range (KX) BK E01
DHU3KX Accumulator oil pressure sensor (Rear) Out of input signal range (KX) BK E01
DJF1KA Fuel level sensor Disconnection (KA) TM E01
DK11KX Throttle angle sensor Out of input signal range (KX) TM E03
dK11KX Failure in acceleration sensor system (OPT) Out of input signal range (KX) BK E03
Dk11KX Failure in acceleration sensor system (OPT) Out of input signal range (KX) BK E01
DK30KX Failure of steering angle potentiometer (OP) Out of input signal range (KX) BK E01
DK51L5 Retarder lever potentiometer See separate list (L5) BK E03
DK52KX Dump lever potentiometer 1 Out of input signal range (KX) BK E03
DK53L8 Dump lever potentiometer 2 See separate list (L8) BK E03
DK54KX Body positioner sensor Out of input signal range (KX) BK E03
DKD0L6 Failure in steering speed sensor (OPT) See separate list (L6) BK E01
DKH1KX Abnormality in angle sensor Out of input signal range (KX) PLM E01
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor See separate list (LC) TM E03
DLF1KA Transmission input shaft speed sensor Disconnection (KA) TM E03
DLF1LC Transmission input shaft speed sensor See separate list (LC) TM E03
DLF2KA Transmission intermediate shaft speed sensor Disconnection (KA) TM E03
DLF2LC Transmission intermediate shaft speed sensor See separate list (LC) TM E03
DLF8KA Disconnection in wheel speed sensor (RR) (OP) Disconnection (KA) BK E01
DLF8LC Failure in wheel speed sensor (RR) system (OP) See separate list (LC) BK E01
DLF9KA Disconnection in wheel speed sensor (RL) (OP) Disconnection (KA) BK E01
DLF9LC Failure in wheel speed sensor (RL) system (OP) See separate list (LC) BK E01
DLT3KA Transmission output shaft speed sensor Disconnection (KA) TM E03
dLT3KA Disconnection in transmission output shaft speed Disconnection (KA) BK E01

sensor
dLt3KA Disconnection in transmission output shaft speed Disconnection (KA) BK E01
sensor
DLT3LC Transmission output shaft speed sensor See separate list (LC) TM E03
DLT3LC Transmission output shaft speed sensor See separate list (LC) BK E01
dLT3LC Failure in transmission output shaft speed sensor Disconnection (LC) BK E01
DV00KB Short circuit in buzzer output Short circuit (KB) MON E01
DW35KZ Failure in auto suspension solenoid 1 output system Disconnection or short circuit (KZ) BK E01
DW36KZ Failure in auto suspension solenoid 2 output system Disconnection or short circuit (KZ) BK E01
20-172 HD465-7, HD605-7

➄

Failure in kick-out solenoid output system
DW72KZ (D_OUT3) (Disconnection, grounding fault, short circuit) Disconnection or short circuit (KZ) BK E01
Failure in hoist select valve output system
DW73KZ (D_OUT5) (Disconnection, grounding fault, short circuit) Disconnection or short circuit (KZ) BK E03
DWNBK4 Shutt-off valve Not control (K4) BK E01
DWNBKA Disconnection in shutt-off valve system Not control (KA) BK E01
DWNBKB Grounding fauit in shutt-off valve system Short circuit (KB) BK E01
DWNBKY Short circuit in shutt-off valve system Short circuit with power line (KY) BK E01
DWNBMA Shutt-off valve Malfunction (MA) BK E01
DX11K4 Electromagnetic proportional pressure reducing Disconnection (K4) BK E03

valve
Disconnection in output circuit of rear wheel
DX11KA electromagnetic proportional pressure reducing valve Disconnection (KA) BK E03
(A_OUT2)
Short circuit in output circuit of rear wheel
DX11KB electromagnetic proportional pressure reducing valve Short circuit (KB) BK E03
(A_OUT2)
Grounding fault in output circuit of rear wheel
DX11KY electromagnetic proportional pressure reducing valve Short circuit with power line (KY) BK E03
(A_OUT2)
DX11MA Electromagnetic proportional pressure reducing Malfunction (MA) BK E03
valve
DX13KA Disconnection in output circuit of hoist EPC valve Disconnection (KA) BK E03
(A_OUT3)
DX13KB Grounding fault in output circuit of hoist EPC valve Short circuit (KB) BK E03
(A_OUT3)
DX13KY Short circuit in output circuit of hoist EPC valve Short circuit with power line (KY) BK E03
(A_OUT3)
DX17K4 ASR proportional solenoid pressure reducing valve Not control (K4) BK E03
(Right)
DX17KA Disconnection in output circuit of ASR proportional Disconnection (KA) BK E01
solenoid pressure reducing valve (Right) (OP)
DX17KB Short circuit in output circuit of ASR proportional Short circuit (KB) BK E01
DX17KY Grounding fault in output circuit of ASR proportional Short circuit with power line (KY) BK E01
DX17MA ASR proportional solenoid pressure reducing valve Malfunction (MA) BK E01
(Right)
DX18K4 ASR proportional solenoid pressure reducing valve Not control (K4) BK E01
(Left)
DX18KA Disconnection in output circuit of ASR proportional Disconnection (KA) BK E01
solenoid pressure reducing valve (Left) (OP)
DX18KB Short circuit in output circuit of ASR proportional Short circuit (KB) BK E01
DX18KY Grounding fault in output circuit of ASR proportional Short circuit with power line (KY) BK E01
DX18MA Grounding fault in output circuit of ASR proportional Malfunction (MA) BK E01
DXH1KA Disconnection in output circuit of lockup clutch solenoid Disconnection (KA) TM E03
DXH1KB Short circuit in output circuit of lockup solenoid Short circuit (KB) TM E03
DXH2KA Disconnection in output circuit of H clutch solenoid Disconnection (KA) TM E03
DXH2KB Short circuit in output circuit of H clutch solenoid Short circuit (KB) TM E03
DXH3KA Disconnection in output circuit of L clutch solenoid Disconnection (KA) TM E03
DXH3KB Short circuit in output circuit of L clutch solenoid Short circuit (KB) TM E03
DXH4KA Disconnection in output circuit of 1st clutch solenoid Disconnection (KA) TM E03
DXH4KB Short circuit in output circuit of 1st clutch solenoid Short circuit (KB) TM E03
HD465-7, HD605-7 20-173

➄

DXH5KA Disconnection in output circuit of 2nd clutch solenoid Disconnection (KA) TM E03
DXH5KB Short circuit in output circuit of 2nd clutch solenoid Short circuit (KB) TM E03
DXH6KA Disconnection in output circuit of 3rd clutch solenoid Disconnection (KA) TM E03
DXH6KB Short circuit in output circuit of 3rd clutch solenoid Short circuit (KB) TM E03
DXH7KA Disconnection in output circuit of R clutch solenoid Disconnection (KA) TM E03
DXH7KB Short circuit in output circuit of R clutch solenoid Short circuit (KB) TM E03
DXHHKA Disconnection in output circuit of 4th clutch solenoid Disconnection (KA) TM E03
DXHHKB Short circuit in output circuit of 4th clutch solenoid Short circuit (KB) TM E03
★ For details of the VHMS controller related failure codes not displayed on the machine monitor, see Trouble-
shooting VHMS control system.
★ Separate table: Detailed phenomena of L Series problem codes (L )
Problem code Nature
L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF

L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match

L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, water temperature
L6
switch, etc. do not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match

LC Speed signals for 2 systems do not match
LH Fill signal is OFF when command current to ECMV is ON
★ Failure codes with ( )

These failure codes are not recorded as trouble data for either the electrical system or the mechanical sys-
tem.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the trou-
bleshooting section are linked, so check the controller code for the failure code displayed, then go to the ap-
plicable troubleshooting mode.
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 HD465-7, HD605-7

➄
9. Electrical system trouble data display func-

tion (ELECTRIC FAULT)
The machine monitor retains the data for prob-
lems that occurred in the electrical system in the
past as failure codes. They can be displayed as
follows.
1) Menu selection
Select the display function for trouble data on
the menu screen of Service mode 1 (Fig. 1).
★ The total number of trouble data items re-
corded in memory is displayed in the [ ]
portion.
2) Trouble data display

With the menu selected, press the [ ] button
and display the trouble data recorded in
memory (Fig. 2: example).
• [ ] button: Runs menu
3) Displayed trouble data

With the display function for trouble data of
the electrical system, the following data can
be displayed (Fig. 3).
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 occur-
rences of same code in past)
3: Elapsed time 1 (time elapsed on service
meter since first occurrence)
meter since last occurrence)
★ Failure codes for problems that are still exist-
ing are shown on a flashing display.
★ For details of the failure codes displayed, see
FAILURE CODE TABLE in the explanation
for the failure code display function.
★ Note that with the trouble data display func-
tion and failure code display function for the
electrical system, the displayed data are par-
tially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and [–] is
displayed on the display portion for A, 2, 3,
and 4.
HD465-7, HD605-7 20-177

➄
10. Mechanical system trouble data display func-

tion (MACHINE FAULT)
The machine monitor retains the data for prob-
lems that occurred in the electrical system in the
past as failure codes. They can be displayed as
follows.
1) Menu selection
Select the display function for trouble data on
the menu screen of Service mode 1 (Fig. 1).
★ The total number of trouble data items
recorded in memory is displayed in the
[ ] portion.
2) Trouble data display

and display the trouble data recorded in
memory (Fig. 2: example).
3) Displayed trouble data

With the display function for trouble data of
the mechanical system, the following data
can be displayed (Fig. 3).
1: Record number
A: Failure code (4-digit location code + 2-
digit problem code)
2: Number of occurrences (number of oc-
currences of same code in past)
meter since first occurrence)
meter since last occurrence)
★ Failure codes for problems that are still
existing are shown on a flashing display.
★ For details of the failure codes displayed,
see FAILURE CODE TABLE in the ex-
planation for the failure code display
function.
★ Note that with the trouble data display
function and failure code display function
for the mechanical system, the displayed
data are partially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and
[–] is displayed on the display portion for
A, 2, 3, and 4.
HD465-7, HD605-7 20-179

➄
11. Machine data monitoring function (REAL-

TIME 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.
In the machine data monitoring function, the fol-
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
on the menu screen of Service mode 1 (Fig.
1).
2) Display sub menu

and display the initial screen of the sub menu
(Fig. 2).
3) Select sub menu

If the [>] button or [<] button is pressed on the
sub menu screen, the sub menu displays
endlessly in the following order (Fig. 3).
★ The sub menu is displayed in the [ ] por-
tion.
• [>] button: Goes on to next menu
• [<] button: Goes back to last menu
(1) MONITOR PANEL: Machine monitor
system
(2) TRANSMISSION: Transmission control-
ler system
(3) ENGINE: Engine controller system
(4) BRAKE: Retarder controller system
(5) 2 ITEMS: 2-item display
HD465-7, HD605-7 20-181

➄
BRAKE (Retarder controller system)
No. Monitoring item Item display Monitoring Display range Unit

code
1 Brake service meter SERVICE METER 31101 0 - 65535 h
Command value of rear retarder EPC solenoid output
2 current F BK OUTP DIR 33800 0 – 1020 mA
3 Sensed value of rear retarder EPC solenoid output current F BRAKE OUTPUT 33801 0 – 1020 mA
0.00 – 5.10
4 Retarder lever input (Voltage & conversion quantity) RETARD LEVER 33900 (0 – 100)
V (%)
5 Input status of retarder lever validation switch (1 & 2) RLV SW 1,2 34000 ON/OFF, ON/OFF Status display
WORKING/
6 Operation status of retarder lever switch RETARDER 34100 RELEASE
Status display
7 Input voltage of dump lever potentiometer 1 DUMP LEVER 1 34300 0.00 – 5.10 V
8 Input voltage of dump lever potentiometer 2 DUMP LEVER 2 34301 0.00 – 5.10 V
9 Input voltage of body positioner sensor BODY POSITION 34400 0.00 – 5.10 V
10 Input status of body seating switch BODY SEATING 34600 ON/OFF Status display
11 Output status of dump lever kick-out solenoid KICKOUT SOL 34700 ON/OFF Status display
12 Output status of dump select solenoid SWV FOR HOIST 34800 ON/OFF Status display
13 Command value of dump EPC solenoid output current EPC HOIST DIR 34900 0 – 1020 mA
14 Output current detection value for dump EPC solenoid EPC HOIST 34901 0 – 1020 mA
15 Input status of overran command OVERRUN SIG 35000 ON/OFF Status display
16 Input status of service brake oil pressure switch SERVICE BRAKE 35100 ON/OFF Status display
17 Input status of starting switch terminal C KEY SW C 32300 ON/OFF Status display
18 Connector check input status (1 & 2) CONN CHK 1,2 30702 ON/OFF, ON/OFF Status display
19 Front accumulator oil pressure ACC OIL PRE F 35500 0.00 – 50.26 MPa
20 Rear accumulator oil pressure ACC OIL PRE R 35501 0.00 – 50.26 MPa
CLOGGED/NOR-
21 Clogging status of brake cooling filter RETARD FILTER 35700 MAL Status display
22 Wear sensor DISK WEAR RR 35806 WEAR/NORMAL Status display
23 Wear sensor DISK WEAR RL 35807 WEAR/NORMAL Status display
24 Inclination angle switch INCLINATION SW 39000 ON/OFF Status display
25 Command of front brake cut FBK CUT DIR 39100 ON/OFF Status display
26 Hoist lower pressure HOIST PRESS 34501 0.00 – 50.26 MPa
27 Auto suspension mode AUTO SUS MODE 39200 MEDIUM/SDFT/ Status display
HARD
28 Auto suspension solenoid 1 output AUTO SUS DIR 1 39300 ON/OFF Status display
29 Auto suspension solenoid 2 output AUTO SUS DIR 2 39301 ON/OFF Status display
30 Front suspension pressure (right) SUS PRESS (FR) 32802 0.00 – 20.10 MPa
31 Front suspension pressure (left) SUS PRESS (FL) 32803 0.00 – 20.10 MPa
32 Judgment of load EMPTY OR LOAD 39400 EMPTY/LOAD Status display
HD465-7, HD605-7 20-189

➁
BRAKE [Retarder controller system]

code
33 Accelerator sensor THROTTLE POS 31704 0.00 – 3.10 V
34 Travel speed set with ARSC switch ARSC SET SP SW 37701 0.00 – 3.10 V
35 ARSC command ARSC STATUS 39500 ON/OFF Status display
36 Travel speed set with ARSC ARSC SET SPEED 39501 0 – 255 km/h
37 ASR command ASR STATE 39600 ON/OFF Status display
38 (ASR output (L) (Command value)) ASR OUTP DIR L 39601 0 – 1020 mA
39 (ASR output (L) (Sensed value)) ASR OUTPUT (L) 39602 0 – 1020 mA
40 (ASR output (R) (Command value)) ASR OUTP DIR R 39603 0 – 1020 mA
41 (ASR output (R) (Sensed value)) ASR OUTPUT (R) 39604 0 – 1020 mA
42 (ASR switch (R)) ASR SW (R) 39605 ON/OFF Status display
43 (ASR switch (L)) ASR SW (L) 39606 ON/OFF Status display
44 Steering angle STRG ANGLE 35400 0.00 – 5.10 V
45 Steering angle speed STRG ANG 35401 0.0 – 99.99 rad/s

SPEED
46 Wheel speed (RL) WHEEL SPEED 39700 0.0 – 65535 pm
RL
47 Wheel speed (RR) WHEEL SPEED 39701 0.0 – 65535 rpm
RR [0000 – FFFF]
XXXXRYYY
[3rd – 10th digits of
part No. from left
are displayed]
48 Part No. of software (For main CPU) BRAKE ROM 1 20206 Example: If part Status display
No. is 7831-46-
R110, 3146R110 is
displayed.
XXXXRYYY
[3rd – 10th digits of
part No. from left
are displayed]
49 Part No. of software (For sub-CPU) BRAKE ROM 2 20207 Example: If part Status display
No. is 7831-46-
R110, 3146R110 is
displayed.
★ Note: The following monitoring items display data for 2 systems at the same time.
• No. 5: Retarder lever input (displays 2 types at same time; does not display unit for conversion %)
• No. 6: Retarder lever validation switch input status (displays 2 systems at same time)
• No. 18: Connector check input status (displays 2 systems at same time)
20-190 HD465-7, HD605-7

➄
VHMS (VHMS controller system)

code
1 Exhaust temperature (F) EXHAUST TEMP F 42600 200 – 950 °C
2 Exhaust temperature (R) EXHAUST TEMP R 42601 200 – 950 °C
3 Engine oil temperature ENG OIL TEMP 42700 0 – +180 °C
4 Ambient temperature AIR TEMP 37501 -30 – +100 °C
5 Blow-by pressure BLOW PRESS 42800 0.0 – 20.0 kPa
6 Payload PAYLOAD 42200 0.0 – 6553.5 t (metric ton

––––( ) or short ton)
7 Suspension pressure (FR) SUS PRESS (FR) 32804 0.0 – 20.10 MPa
––––( )
8 Suspension pressure (FL) SUS PRESS (FL) 32805 0.0 – 20.10 MPa
––––( )
9 Suspension pressure (RR) SUS PRESS (RR) 32806 0.0 – 20.10 MPa
––––( )
10 Suspension pressure (RL) SUS PRESS (RL) 32807 0.0 – 20.10 MPa
––––( )
11 Angle sensor INCLINOMETER 32901 -0.42 – +0.44 rad
––––( )
12 FLOAT signal FLOAT SIG 42300 ON/OFF Status display
––––( )
13 Gearshift lever N signal SHIFT LEVER N 42500 ON/OFF Status display
––––( )
14 Machine status TRUCK STATUS 42400 0–8 Status display
––––( )
★ The ( ) mark in the data display range column shows the case when the PLM is not set up.
HD465-7, HD605-7 20-190-1

➁
12. Adjustment function (TUNING)

Through the transmission controller, 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 differ-
ences in the ECMV. It can also carry out the self-
adjusting learning function so that a constant
gearshifting feeling is maintained in accordance
with the wear of the transmission clutch.
When the following operations related to the
power train have been carried out, perform the
adjustments.
• When the transmission has been overhauled
or replaced
• When the transmission valve has been re-
placed
• When the transmission controller has been Failure code Component name
replaced
DLF1KA Transmission input shaft
• When an abnormality has occurred in the
DLF1LC speed sensor
power train speed sensor and it has been re-
paired (for details, see the failure code in the DLF2KA Transmission intermediate
chart on the right) DLF2LC shaft speed sensor
• When an abnormality has occurred in the DLT3KA Transmission output shaft R
transmission oil temperature sensor and it DLT3LC speed sensor
has been repaired (for details, see the failure
Transmission valve oil
code in the chart on the right) DGF1KA
temperature sensor
• When the transmission oil filter has become
15B0NA Transmission oil filter
clogged and it has been repaired (for details,
see the failure code in the chart on the right)
For the adjustment operation, operate the ma-

chine monitor and machine itself, and carry out
the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjust-
ment operation.
(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)
★ The MANUAL menu of [02: ECMV TUNING]
is a special function for the factory and is not
used for service.
HD465-7, HD605-7 20-191

➄
Preparatory work:
Adjusting ECMV oil temperature
a It is necessary to carry out the adjustment opera-
tion at the specified oil temperature, so check that
there is no abnormality on the machine and ad-
just the ECMV oil temperature as follows.
1) Start the engine.
2) Display [ECMV oil temperature] with the

machine data monitoring function. (Fig. 1).
• TRANSMISSION No. 48
3) Raise ECMV oil temperature to 70 – 80°C by

raising engine speed.
4) Keep engine speed in low idling for 3 minutes.

Before carrying out adjustment, be sure to check
that ECMV oil temperature is kept within 70 –
80°C.
20-192 HD465-7, HD605-7

(7)
Adjustment operation (1): Adjusting individual

difference of valve
a See Preparatory work and check that the ECMV
oil temperature is at the specified temperature.
a The adjustment operation is carried out automat-
ically four times for the Lo, Hi, R, 1st, 2nd, 3rd
and 4th valves.
1) Set the machine to the following conditions.
• Parking brake switch: PARKING
• AISS LOW switch: LOW
• Gearshift lever: N position
• Engine: Low idling
• Accelerator pedal: OFF (released)
2) Operate the machine monitor and display the
adjustment menu screen (Fig. 4).
• Adjustment menu: 02: ECMV TUNING
AUTO
3) Check the condition of the machine again, press
the [ ] button, and start the adjustment opera-
tion (Fig. 5).
• [ ] 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.
a For each adjustment operation, the result is dis-
played as normal or abnormal, so take action ac-
cording to the display (Fig. 6).
• If [4-4 OK] is displayed:
The adjustment operation has been completed
correctly.
(When the starting switch is turned OFF, the ad-
justed value is recorded in the controller.) No. Valve 1st time 2nd time 3rd time 4th time
• If [NG 1] (Outside compensation condition) is dis- 1 Lo IP L-1 IP L-2 IP L-3 IP L-4
played:
2 Hi IP H-1 IP H-2 IP H-3 IP H-4
Adjust the ECMV oil temperature correctly, check
the set conditions of the machine again, then re- 3 R IP R-1 IP R-2 IP R-3 IP R-4
peat from Step 1). 4 1st IP 1-1 IP 1-2 IP 1-3 IP 1-4
• If [NG 2] (No fill) is displayed: 5 2nd IP 2-1 IP 2-2 IP 2-3 IP 2-4
Carry out troubleshooting for failure codes 6 3rd IP 3-1 IP 3-2 IP 3-3 IP 3-4
[15S[ ]MA] [DDT[ ]KA], and if it is found to be 7 4th IP 4-1 IP 4-2 IP 4-3 IP 4-4
normal, repeat from Step 1).
• If [NG 3] (Compensation value over] is displayed:
Carry out troubleshooting for failure code
[15S[ ]L1], and if it is found to be normal, repeat
from Step 1).
HD465-7, HD605-7 20-193

(7)
Adjustment work (3): Initial learning of stabiliza-

tion of gear shifting feel
a Referring to PREPARATION WORK, check that
the ECMV oil is at the specified temperature.
Perform the adjustment work in a place wide suf-

ficiently for travel, taking care of the safety
around the machine.
$ When performing the adjustment work by
driving the vehicle actually, perform it on fin-
ished flat ground, as long as possible.
1) Display R CLUTCH FILL STATE with the machine
monitoring function (Fig. 10).
• No. 38 of TRANSMISSION
FILL R: Fill state of R clutch
2) Run the engine at low idling and hold the gear-
shift lever in the N position for 10 seconds, and
then operate the gearshift lever in the following
order.
a Operation of gearshift lever: N o R o N
3) Check the fill state with the monitoring display.
a If "0" is displayed, go the next step.
a If "1" is displayed, repeat step 2) until "0" is
displayed.
a After step 2) is repeated 3 times, if "0" is still
not displayed, display R CLUTCH FILL TIME
with the machine monitoring function.
(1) If the fill time is 250 msec or shorter, go
to 4).
(2) If the fill time is 900 msec or longer,
return to 1) and repeat step 2) until the fill
state of the R clutch becomes "0".
• FILL TIME R: Fill time of R clutch
(Fig. 11)
a If the above condition is still not satisfied after
the steps are repeated 5 times, the ECMV
may be defective. In this case, replace the
ECMV.
HD465-7, HD605-7 20-195

(7)
4) Set the gearshift lever in the 6 position. Run the

engine at full throttle and shift up the gear to F6.
5) Drive the machine in F6 for 10 seconds, and
then release the accelerator pedal and shift
down the gear to F1 by coasting run.
a Shifting down:
F6 o F5 o F4 o F3 o F2 o F1
a Do not operate the brake during coasting
run.
6) Display 4TH CLUTCH FILL STATE, 2nd CLUTCH
FILL STATE, and 1st CLUTCH FILL STATE with
the machine monitoring function and check the fill
states (Fig. 12, Fig. 13, and Fig. 14).
FILL 4: Fill state of 4th clutch
FILL 2: Fill state of 2nd clutch
FILL 1: Fill state of 1st clutch
a If "0" is displayed, correction is completed.
a If "1" is displayed, repeat steps 4) and 5) until
"0" is displayed for the all clutches.
a After steps 4) and 5) are repeated 3 times, if
"0" is still not displayed as the fill state of the
1st clutch, display 1ST CLUTCH FILL TIME
to 7).
return to 4) and repeat steps 4) and 5)
until the fill state of the 1st clutch
becomes "0".
FILL TIME 1: Fill time of 1st clutch
(Fig. 15)
a If the above condition is still not satisfied
after the steps are repeated 6 times, the
ECMV may be defective. In this case,
replace the ECMV.
20-195-1 HD465-7, HD605-7

(7)

8) Stop the machine and display HI CLUTCH FILL
STATE with the machine monitoring function and
check the fill state (Fig. 16).
FILL H: Fill state of Hi clutch
a If "1" is displayed, repeat steps 7) and 8) until
"0" is displayed.
a After steps 7) and 8) are repeated 3 times, if
"0" is still not displayed as the fill state of the
Hi clutch, display HI CLUTCH FILL TIME
to 9).
return to 7) and repeat steps 7) and 8)
until the fill state of the Hi clutch
becomes "0".
FILL TIME H: Fill time of Hi clutch
(Fig. 17)
a If the above condition is still not satisfied
after the steps are repeated 5 times, the
ECMV may be defective. In this case,
replace the ECMV.
HD465-7, HD605-7 20-195-2

(7)
9) Display LO CLUTCH FILL STATE with the

machine monitoring function and check the fill
state (Fig. 18).
FILL L: Fill state of Lo clutch
a Take care not to shift up the gear to F4. If the
gear has been shifted to F4, repeat the step
from starting.
11) Drive the machine in F3 for 5 seconds, and then
shift up the gear to F4 with the engine at full
throttle.
12) While the machine is traveling in F4, press con-
trol switch [U] to keep displaying the machine
monitoring function.
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. 19).
a Judge the fill state of the Lo clutch by the
value displayed and held during travel at F4.
Once holding is reset, the value is updated.
FILL 3: Fill state of 3rd clutch
a If "1" is displayed, repeat steps 9) – 13) until
"0" is displayed for both clutches.
a After steps 9) – 13) are repeated 6 times, if
"0" is still not displayed, the ECMV may be
defective. In this case, replace the ECMV.
a The display keeping function of the machine
monitoring function is reset automatically
when any switch is operated.
a If the starting switch is turned OFF or control
switch [t] is pressed 3 times, the machine
monitoring function screen disappears and
the ordinary screen appears.
20-195-3 HD465-7, HD605-7

(7)
13. Filter, oil replacement time setting function

(MAINTENANCE MONITOR)
The machine monitor can set the maintenance
interval for filters and oil, which form the base for
the filter and oil replacement time and display.
1) Menu selection
Select Filter, oil replacement time setting
function on the menu screen of Service mode
1 (Fig. 1).
2) Selecting filter, oil replacement time setting

item
i) With the menu selected, press the [ ]
button and display the initial screen of
the set item (Fig. 2).
ii) Press the [>] or [<] buttons to select the
item to be set.
• [>] 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, see Ta-
ble of filter and oil replacement time set
items).
3) If the maintenance items in the display for

the filter and oil replacement time set items
are selected, the following content is dis-
played (Fig. 3).
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, press the
[ ] button and display the interval input
screen (Fig. 4: example).
• [ ] button: Executes change func-
tion
$ The presently set interval is dis-
played on the screen.
20-196 HD465-7, HD605-7

!
a For this function, see "Execution of PM clinic

14. Snap shot function
using manual snap shot (Another name:

Quick PM)" (Drawing No. WJ021D060) (Fig.
1).
a This function is applied to "PLM having

15. PLM setting function
VHMS" (only when the option is set).

• Various items of the "PLM having VHMS" are
displayed and set with this function.
1) Setting of travel distance to recognize com-

pletion of loading
Input a travel distance to recognize comple-
tion of loading by pressing the following but-
tons (Fig. 3).
• [>] button: Number at cursor moves for-
ward.
• [<] button: Number at cursor moves back-
ward.
• [U] button: Enter number at cursor.
a The setting range is 0 – 255 m (0.0 –

• [t] button: Stop inputting number.
0.158 miles).
If the set value is too small, the system
may recognize that loading is completed
while the dump truck is still being load-
ed.
2) Correction of calculation of payload
Since this function affects the accuracy
directly, execute the following procedure
securely.
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.
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. Ac-
cordingly, secure a road for this pur-
pose.
20-197-1 HD465-7, HD605-7

➄
The relationship between the suspen-

sion pressure and payload corrected
with this function cannot be returned to
the condition at the time of shipment.
Accordingly, perform the following pro-
cedure very carefully.
This function is used to match the calcu-
lation result to the indication of the load
meter to be used. It does not always
heighten the absolute accuracy.
i) Measure the weight of the empty dump
truck with the load meter and record it
(Write it on a sheet of paper, etc.)
ii) Input the measured weight of the empty
dump truck and drive the dump truck for
about 3 minutes.
(1) Select "EMPTY WEIGHT" (Fig. 4).
• [>], [<] buttons:
Select "EMPTY WEIGHT" or
"LOADED WEIGHT".
• [U] button: Enter the selection.
(After selecting, go to Fig. 5.)
• [t] button: Return to the previ-
a If the weight of the empty dump

ous screen.
truck has been input and the

dump truck has been driven for
about 3 minutes, "LOADED
WEIGHT" is displayed when the
menu is selected (See Fig. 11).
• Check the unit of the input
a The unit is indicated in the ( )

value.
on the right side of WEIGHT.

(METRIC) --- metric ton
(SHORT) ---- short ton
(2) Check that measurement of the
weight of the empty dump truck has
a Display on the screen (Fig. 5)

been completed.
• [U] button: Check that measure-

ment has been completed and
go to the next step.
ous screen.
HD465-7, HD605-7 20-197-2

➄
(3) Input the measured weight of the

empty dump truck (Fig. 6).
• [>] button: Number at cursor
moves forward.
• [<] button: Number at cursor
moves backward.
• [U] button: Enter number at cur-
sor.
• [t] button: Return to the largest
position of the number to input
the value again. If this button is
pressed again, inputting of the
value is stopped and the previ-
a Inputtable range
ous screen appears.
HD465-7:
43.6 [t] (Operating weight) ± 15%
(metric ton)
HD605-7:
46.8 [t] (Operating weight) ± 15%
(metric ton)
(4) Check the input value (Fig. 7).
• [t] button: Enter.
(5) Move the dump truck to a place

where you can drive it.
• [U] button: After getting ready

for drive, press this button and
a Drive the dump truck for about 3

start driving the dump truck.
minutes (at a speed higher than

8 km/h) to enter the relationship
between the weight of the dump
truck and the suspension pres-
sure under that weight.
• [t] button: Return to the screen
for inputting values.
20-197-3 HD465-7, HD605-7

➄
(6) Display the progress of measure-

ment (Fig. 9).
• [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
a As measurement is executed,
screen.
the number of " * " increases.

When measurement is finished,
the next screen appears auto-
matically.
iii) Load the dump truck to measure the
weight of the fully loaded dump truck
(Fig. 10).
• [t] button: Return to the menu
a When loading is started, the menu

screen.
s cr een app ears automati cal ly.

When indicating the current load for
reference while the dump truck is be-
ing loaded, go out of "Service mode
1" temporarily and return to "Display
of load/integrated odometer". On
this screen, you can check the cur-
rent load.
iv) Measure the weight of the fully loaded
dump truck with the load meter and
record it (Write it on a sheet of paper,
etc.)
v) Input the measured weight of the fully
loaded dump truck and drive the dump
truck for about 3 minutes.
(1) Select "LOADED WEIGHT" (Fig.
a For the method of displaying the

11).
following screen, see the steps

up to ii) - (1).
• [>], [<] buttons:
Select "EMPTY WEIGHT" or
"LOADED WEIGHT".
• [U] button: Enter the selection.
• [t] button: Return to the previous
a If the weight of the empty dump

screen.
truck has been input and the

dump truck has been driven for
about 3 minutes, "LOADED
WEIGHT" is displayed when the
menu is selected (See Fig. 11).
• Check the unit of the input
a The unit is indicated in the ( )

value.
on the right side of WEIGHT.

HD465-7, HD605-7 20-197-4

➄
(2) Check that measurement of the

weight of the fully loaded dump truck

has been completed.
• [U] button: Check that measure-

ment has been completed and
go to the next step.
ous screen.
(3) Input the measured weight of the ful-

ly loaded dump truck (Fig. 6).
• [>] button: Number at cursor
moves forward.
• [<] button: Number at cursor
moves backward.
• [U] button: Enter number at cur-
sor.
• [t] button: Return to the largest
position of the number to input
the value again. If this button is
pressed again, inputting of the
value is stopped and the previ-
a Inputtable range
ous screen appears.
HD465-7:
However,
A1 = {43.6 [t] (Operating weight)
+ 46 [t] (Load capacity)}
HD605-7:
However,
A2 = {46.8 [t] (Operating weight)
+ 63 [t] (Load capacity)}
(4) Check the input value (Fig. 7).
20-197-5 HD465-7, HD605-7

➄
(5) Move the dump truck to a place

where you can drive it.
• [U] button: After getting ready

for drive, press this button and
a Drive the dump truck for about 3

start driving the dump truck.
minutes (at a speed higher than

8 km/h) to enter the relationship
between the weight of the dump
truck and the suspension pres-
sure under that weight.
• [t] button: Return to the screen
for inputting values.
(6) Display the progress of measure-
ment (Fig. 9).
• [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
a As measurement is executed,
screen.
the number of " * " increases.

When measurement is finished,
the next screen appears auto-
matically.
vi) Dump the load in the dump area (Fig.
12).
a If the load is dumped with the dump

screen.
lever, the menu screen appears au-

tomatically.
If the load is dumped normally, cor-
rection is finished.
3) Correction of level of inclination sensor
i) Move the dump truck to a level place.
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.
(1) Enter value of (F) (Fig. 13).
• [U] button: Enter the flashing
value.
a The current standard level value

screen.
is displayed on the upper line.

The clinometer value (F) at the
current position flashes. Enter it
when it is stabilized.
HD465-7, HD605-7 20-197-6

➄
(2) Turn the dump truck 180 degrees

(Stop it in the opposite direction).
(3) Enter value of (R).
• [U] button: Enter the flashing
value.
a The current standard level value

screen.
is displayed on the upper line.

The clinometer value at the cur-
rent position flashes. Enter it
when it is stabilized.
(4) Enter the standard level value (Fig.

15).
4) Setting of criterion of maximum travel speed

Input a criterion of the maximum travel speed
by pressing the following buttons (Fig. 16).
ward.
ward.
a The setting range is 0 – 99 km/h (0 – 62

MPH). (Default: 99 km/h)
5) Setting of payload to recognize start of load-

ing
Input a payload to recognize start of loading
by pressing the following buttons (Fig. 17).
ward.
ward.
a The setting range is 0 – 25.5%.

(Default: 15%)
This function does not assure the opera-
tion because of the contrary phenomena
shown below (on the next page).
20-197-7 HD465-7, HD605-7

➄
• If the value is reduced, start of loading

may be recognized wrongly.
• If the value is increased and a loader
having a small-capacity bucket is used,
the forecast function of the outside indi-
cator lamps and the MMS communica-
tion may not operate normally.
6) Setting of indication range of outside indica-
tor lamps
Input an indication range of the outside indi-
cator lamps by pressing the following buttons
(Fig. 19).
ward.
ward.
a The setting range is 0 – 130% of the load

capacity.
Set A (Yellow lamp) higher than G (Green
lamp) and set R (Red lamp) higher than A
(Yellow lamp), however.
7) Setting of OFFSET function
Input an offset range by pressing the follow-
ing buttons (Fig. 20).
ward.
ward.
a The setting range is -5.0 – +5.0 [t].

• Check the unit of the input value on
a The unit is indicated in the ( ) on

the previous menu screen (Fig. 21).
the right side of the input value

[t].
HD465-7, HD605-7 20-197-8

➄
8) Selection of method of entering saved pay-

load
i) Select the method of entering the saved
payload (Fig. 22).
• [>], [<] buttons: Select "WHEN
DUMPING" or "WHEN TRAVEL-
ING".
• 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 travel-
ing from the loading area to the
dump area is processed statisti-
cally and the hauled payload is
entered and saved when it is
dumped.
• [U] button: Enter the selected meth-
od.
screen.
ii) Enter the selected method (Fig. 23).
16. Initialize function (INITIALIZE)

(exclusive function for factory)
★ This is a special function for the factory and
is not used for service.
20-198 HD465-7, HD605-7

➄
17. Service meter setting function (hourglass

mark)
1) Menu selection
Select the setting function for the service
meter on the menu screen of Service mode 2
(Fig. 1).
2) Setting service meter

button and display the service meter
input screen (Fig. 2).
ii) Operate each button and input the ser-
vice meter times.
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes
down
• [ ] button: Number at cursor is con-
firmed
• [■] button: Returns to initial screen
(see Note)
★ The time must always be input with
five digits. For numbers of less than
five digits, input 0 at the beginning.
iii) When all the times are confirmed, the
change confirmation screen is dis-
played, so operate the buttons accord-
ing to the screen display (Fig. 3).
• [<] button: Select YES
• [>] button: Select NO
• [■] button: Run
HD465-7, HD605-7 20-201

➄
18. Odometer setting function (ODO)

1) Menu selection
Select the setting function for the distance
traveled on the menu screen of Service
mode 2 (Fig. 1).
2) Setting odometer value

button and display the odometer input
screen (Fig. 2).
ii) Operate each button and input the
odometer values.
down
firmed
(see Note)
★ The distance must always be input
with five digits before the decimal
point and 1 digit after. For places
where no numeral is needed, input
an 0.
20-202 HD465-7, HD605-7

➄
19. Distance traveled in reverse setting function

(BACKWARD ODO)
1) Menu selection
Select the setting function for the distance
traveled in reverse on the menu screen of
Service mode 2 (Fig. 1).
2) Setting backward odometer value

button and display the backward odom-
eter input screen (Fig. 2).
ii) Operate each button and input the val-
ues for the distance traveled in reverse.
down
firmed
(see Note)
★ The distance must always be input
with five digits before the decimal
point and 1 digit after. For places
where no numeral is needed, input
an 0.
HD465-7, HD605-7 20-203

➄
TESTING AND ADJUSTING BASIC PRECAUTIONS
BASIC PRECAUTIONS that is connected directly to the battery

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

➁
b. When installing battery isolator or other

battery shut-down device
i) 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.
ii) 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 start-
ing switch is turned OFF before
the permanent power source is
shut down.
• If there is no timer, wait for at
least 3 minutes before turning off
the permanent power source.
• If the above shut-down time is
shorter than 3 minutes, the accu-
mulated data may be damaged.
4. Precautions when VHMS power source is ON

• For the first few seconds after the power is
switched ON, the VHMS controller carries
out the initial check (LEDs flash). Do not
carry out any of the following operations until
the initial check is completed.
• Operation of manual snapshot switch
• Downloading from PC
(Check that the LEDs are displaying the
aggregate numerals in turn before oper-
ating.)
5. Precautions when replacing VHMS and trans-

mission controller
1) Before starting replacement
a. Download VHMS data b. Specified method of shutting down
When the VHMS controller is replaced, VHMS power source
the data collected up to that point is lost, i) Use the starting switch to turn the
so be sure to download the accumuldata normal power source OFF
before starting the replacement opera- ii) Maintain the permanent power
tion. source in the specified condition
Next, send the accumulated data to web for at least 3 minutes.
care. iii) Turn the permanent power source
For details of the method of download- (battery direct) OFF.
ing, see the separate instruction manual
for the technical analysis tool box.
HD465-7, HD605-7 20-203-2

➁
2) Method of replacement, action after

replacement
When replacing the VHMS controller, be
careful not to subject the VHMS controller or
wiring harnesses to any excessive force or
impact, and carry out the initial setup. For
details, see the separate instruction manual
for the technical analysis tool box.
6. Handling communications controller (ORB

• • • Orbcomm)
1) The ORB controller must be used. If the
ORB controller is not used, it is impossible to
carry out the request to open communica-
tions before starting to use.
If the control power is turned on before com-
pleting the request, the transmission will be
unauthorized and there will be problems with
the communications system.
If there are any problems or any part is
unclear, please contact Komatsu or the per-
son responsible for operation.
2) Finally, turn on the ORB power ON (connect
the connector). After the VHMS controller
confirmation is completed, connect the ORB
controller connector (ORB-A, ORB-B).
20-203-3 HD465-7, HD605-7

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

➁
2. Basic structure (2)
20-203-5 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-203-6

➁
3. Position of equipment
Install monitoring controller (VHMS controller) (1)
on the machine, and collect the operation data
for the engine, transmission, and PLM.
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.
20-203-7 HD465-7, HD605-7

➁
3) External communication function

• Connect the PC (personal computer) to
the VHMS controller, download the data,
and transmit the data through the Inter-
net.
• Send the data automatically from remote
areas through the communications satel-
lite (ORB).
(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

➁
TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER
SETTING UP VHMS 2. Setting items

• VHMS: For details of the setup method, see
CONTROLLER the instruction manual for the technical anal-
ysis tool box (for service).
1. Setting up VHMS controller 1) Calendar (data, time, time difference
• In the following cases, always carry out the from GMT, summer time (daylight saving
setup. time))
1) When making the initial installation of the 2) Machine model, Serial No., variation
VHMS system code
2) When replacing or overhauling the fol- 3) Engine model, Serial No.
lowing components 4) Transmission Serial No.
• VHMS controller • For details of the method of setting PLM II
• Engine and VHMS with PLM function, see the sepa-
• Transmission rate PLM instruction manual.
• PLM II (option) 1) Time of the start of data collection
• When carrying out the setup, the following 2) Data collection unit (day)
are needed • Opening communications with Orbcomm:
1) PC (personal computer) For details of the setup method, see the
2) VHMS analysis tool (software) instruction manual for the technical analysis
(799-608-3211) tool box (for service).
3) Download cable (799-608-3220) 1) Communications method (stop/start, inter-
• For details of the setup method, see val, transmission time)
the instruction manual for the techni- 2) Time of PLM data collection
cal analysis tool box (for service). 3) Country code for communications con-
• The setup operation is carried out by troller (GCC)
trained personnel under the guidance
of the person responsible at your
company.
• Or contact Komatsu.
3. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON (starting switch ON) Check that no error is generated by the VHMS controller or other
1 • Check for generation of errors controller
• Start setup tool If there is any error, repair or correct to return condition to normal
• Calendar (data, time, time difference from GMT, summer time
(daylight saving time))
2 Setting up VHMS • Machine model, Serial No., variation code
• Engine model, Serial No.
• Transmission Serial No.
Setting up PLM function or PLM II (when the • Time of start of data collection
3 PLM function is available or machine is PLM II
specification) • Data collection unit (day)
4 Starting switch OFF (starting switch OFF) • Saving settings
5 Starting switch ON (starting switch ON) • Checking VHMS functions

Start engine • Performing test (quick PM)
6 Test (quick PM) • Downloading
Starting switch OFF • Checking data (content of data)
Starting switch ON (starting switch ON) • Checking operation of Orbcomm
7 • Check for errors • Setting up communications
• Start setup tool (need for communications file, communications frequency, GCC
code)
8 Starting switch OFF (starting switch OFF)

• Setup completion report, content of setup (data), sending checksheet
• Sending download data
20-203-9 HD465-7, HD605-7

➁
TESTING AND ADJUSTING SETTING UP VHMS CONTROLLER
4. Checking operation, actuation

★ Check the functions of the VHMS system as follows.
Start
Turn starting switch to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Abnormality in machine syastem Possible abnormality in VHMS cont-

See machine shop manual roller
5. Collection of data
★ If there is no abnormality in the system, the machine will operate and the operation data for the machine
will automatically be saved by the VHMS controller.
HD465-7, HD605-7 20-203-10

➁
TESTING AND ADJUSTING COLLECTION, TRANSMISSION OF DATA
COLLECTION, TRANSMISSION OF DATA

1. Collection of data
1) Downloading with PC (personal computer) ★ For details of downloading and sending
<Necessary tools> the data, see the instruction manual for
• PC (personal computer) the technical analysis tool box (for ser-
• VHMS analysis tool (software) vice).
(799-608-3211) 2) Automatic transmission by communications
• Download cable (799-608-3220) satellite (machines with Orbcomm specifica-
When using a PC to download the collected tion)
data, send the data to the file server in the • Error data and other specified data are
computer center by e-mail (Internet). automatically sent by communications
(There are limitations to the capacity of satel- satellite to the file server in the computer
lite communications, so use this method to center.
send all the data.)
2. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON (starting

switch ON) Check that no error is generated by VHMS controller or other controller
1 • Check for generation of errors If there is any error, repair or correct to return condition to normal
• Start setup tool
• Checking satellite communications data, setting communications fre-
2 Setting up communications quency
• Setting GCC code
3 Starting switch OFF (turn key to OFF) • Saving set values

• Reporting completion of setup
3. Carrying out quick PM

★ For details, see TESTING AND ADJUSTING,
Performing PM clinic using manual snap-
shot.
• To collect data under the normal working
conditions, and to collect data when operat-
ing under such conditions as torque con-
verter stall or high idling, carry out the quick
PM (equivalent to PM clinic) before down-
loading with the PC.
4. Method of downloading with PC (personal

computer)
To ensure safety, stop the machine on flat
ground and put blocks under the tires to
prevent the machine from moving.
When turning the starting switch ON, check
that the parking brake is ON and that the
gearshift lever is at the N position.
Sound the horn to warn people in the sur-
rounding area before starting the engine.
★ For details of the method of using the PC,
see the instruction manual for the technical
analysis tool box (for service).
<Preparatory work>
• Prepare a PC for downloading and a download
wiring harness.
★ The download connectors are provided in 2
places: rear of assistant's seat inside cab (7) and
behind front left tire of machine (6).
20-203-11 HD465-7, HD605-7

➁
<Downloading from connector inside cab> <Downloading from ground level connector>
1) Remove the connected wiring harness and install 1) Remove the clamp at the top of the download
the download cable. box.
2) Connect the other end of the download wiring 2) Use the engine key to open the cover at the front
harness to the PC. of the box.
3) Turn the machine starting switch ON, check that 3) Remove the cap of the download connector and
the monitor controller is working, then download install the download cable.
to the PC. 4) When turn (wake-up) switch (10) is turned, the
★ To check that the VHMS controller is working, VHMS is actuated and pilot lamp (11) lights up.
check that the VHMS controller starts up, 5) Check that pilot lamp (11) is lighted up, then
LEDs flash (see diagram below), and aggre- carry out the PC download.
gate numerals are displayed in order. 6) When [complete] is displayed on the download
4) When [complete] is displayed on the download PC, the download operation is completed.
PC, the download operation is completed. 7) Return the turn switch to its original position,
5) Turn the machine starting switch OFF, then turn remove the download cable, then install the cap.
the PC power OFF, remove the download cable, 8) Check that pilot lamp (11) is out, then close the
and return the wiring harness to its original condi- box cover.
tion. If the turn switch is not off, the cover will not
close.
9) Turn the engine key and lock the front cover.
Close the clamps at the top of the box also.
4. Types of data collection files

1) Index file : This records the common data for the machine model, serial No., and service meter
(SMR).
2) VHMS history : This records changes in the VHMS.
3) Machine history : This records the actual engine operation data.
4) Fault history : This records errors that occurred in order of occurrence.
5) Trend analysis : This records the maximum or minimum values for each measurement device at the
specified intervals. (See Table 1)
6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures.
(see Table 2)
7) Snapshot : This records the data for a specified time before and after the occurrence of an error
(see Table 3.1, 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 (option) : This records the payload meter data
15) Payload data cycle (option) : This records the operating cycle data for the machine
HD465-7, HD605-7 20-203-12

➁
TREND DATA ITEMS
Table 1: Trend analysis data

No. Item Content Unit Data collection point Remarks
1 SMR Service meter h
2 Calendar Calendar y/m/d h:m:s
3 Engine speed max. Engine speed (max) rpm Engine controller Maximum value within set trend data
Crankcase internal
4 Blow-by press. max. Blow-by pressure (max) mmAg (Every 20 hours) See as below
pressure sensor
Exhaust temperature
5 F. Exh. temp. max. Front engine exhaust temperture (max) deg C
sensor
Exhaust temperature
6 R. Exh. temp. max. Rear engine exhaust temperture (max) deg C sensor
7 E. oil press. max. Engine oil pressure (max) kg/cm2 Engine controller
8 E. oil P. L min. Engine oil pressure at low idling (min) kg/cm2 Engine controller
9 E. oil P. H min. Engine oil pressure at high idling (min) kg/cm2 Engine controller
Engine oil temperature
10 Eng. oil temp. max. Engine oil temperature (max) deg C sensor
11 Fuel rate Fuel consumption rate (average) Liter/h Engine controller
12 Cool temp. max. Engine coolant temperature (max) deg C Engine controller
13 Cool temp. min. Engine coolant temperature (min) deg C Engine controller
Engine controller (ambi-
14 Ambient temp. max. Ambient temperature (max) deg C
ent temperature sensor)
15 Ambient temp. ave. Ambient temperature (average) deg C ent temperature sensor)
16 Ambient temp. min. Ambient temperature (min) deg C
ent temperature sensor)
17 Atmos. press. ave. Atmospheric pressure (average) hPa Engine controller
18 F. brake P. max. Front brake oil pressure (max) 2 Retarder controller

kg/cm
19 R. brake P. max. Rear brake oil pressure (max) kg/cm2 Retarder controller
Table 2: Machine trend data


T/C oil temp. 120– Time of use for each torque converter
3 T/C oil temp. 130– Transmission controller
oil temperature
T/C oil temp. 140–
sec.
Rtrdr. oil temp. T120– Time of use for each retarder oil tem-
4 Rtrdr. oil temp. T130– Retarder controller
perature
Rtrdr. oil temp. T140–
Table 3.1 Observation items (trigger items) for auto snapshot

No. Content Failure code No. Content Failure code
No. 1,2,3 cylinder exhaust temperature is high 11 Problem with No. 2 clutch 15L0MW(b025)
1 (stage 1) F@BYNS(M361)
No. 4,5,6 cylinder exhaust temperature is high 12 Problem with No. 3 clutch 15M0MW(b026)
2 (stage 1) F@BZNS(M371)
3 Blow-by pressure is high F@BBZL(M338) 13 Problem with No. 4 clutch 15N0MW(b027)

No. 1,2,3 cylinder exhaust temperature is high 14 Problem with R clutch C115KZ
4 (stage 2) F@BYNR(M362)
No. 4,5,6 cylinder exhaust temperature is high 15 Problem with M clutch C151NS
5 (stage 2) F@BZNR(M362)
6 Double meshing of transmission clutch 1500L0(b005) 16 Abnormality in torque converter output signal C261NS
7 Problem with lock-up clutch 1380MW(b021) 17 Overheating of torque converter B@CENS(A0d2)
8 Problem with High clutch 15H0MW(b022) 18 Overheating of rear brake oil B@C7NS(A0d4)
9 Problem with Low clutch 15J0MW(b023) 19 Overrun A00N1(M201)
10 Problem with No. 1 clutch 15K0MW(b024) 20 Abnormal drop in engine oil pressure C143ZG
20-203-13 HD465-7, HD605-7

➄
Table 3.2 Data items for manual snapshot

1 Time Elapsed time sec. VHMS
2 Eng. speed Engine speed rpm Engine controller
3 Fuel inject Fuel injection amount mm3/st Engine controller

Crankcase internal
4 Blow-by press. Blow-by pressure mmAg pressure sensor
Exhaust temperature (No. 1,2,3 cylin- Exhaust temperature
5 F. exh. temp. deg C
ders) sensor
Exhaust temperature (No. 4,5,6 cylin- Exhaust temperature
6 R. exh. temp. deg C
sensor
ders)
7 Eng. oil. press. Engine oil pressure kg/cm2 Engine controller
8 Eng. oil. temp. Engine oil temperature deg C Oil temperature sensor
9 Eng. cool. temp. Engine coolant temperature deg C Engine controller

10 Ambient temp. Ambient temperature deg C ent temperature sensor)
11 Boost press. Engine boost pressure mmHg Engine controller
12 Accelerator pos. Accelerator angle % Engine controller

FLOAT = 0, HOLD = 1, LOWER = 2,
13 Hoist lev. pos. Hoist lever position — Retarder controller RAISE = 3, Max height = 4, Other = 5
14 T/C oil temp. Torque converter oil temperature deg C Transmission controller
15 T/M out. speed Transmission output speed rpm Transmission output

shaft speed sensor
16 Shift indicator Gearshift range (position) — Transmission controller R = 10, N = 0, F1 = 1, ••• F7= 7
17 Lockup signal Lock-up clutch ON-OFF Transmission controller
18 Retarder temp. Retarder oil temperature deg C Retarder controller
19 F. brake press. Front brake oil pressure kg/cm2 Retarder controller
20 R. brake press. Rear brake oil pressure kg/cm2 Retarder controller
21 Retarder position Retarder brake use ON-OFF Retarder controller
22 Foot brake position Foot brake use ON-OFF Retarder controller
Table 4: Transmission trend data


Trig. time Low
(fill time)
Trig. time High
(fill time)
Trig. time Rev.
(fill time)
Trig. time 4th
3 Transmission fill-up time msec. Transmission controller (Every 200 h)
(fill time)
Trig. time 3rd
(fill time)
Trig. time 1st
(fill time)
Trig. time 2nd
(fill time)
HD465-7, HD605-7 20-203-14

➁
5. Confirming data <Checking quick PM data>

For details of the method of confirming the data, • Engine speed (high idling, torque converter stall)
see the instruction manual for the technical anal- • Blow-by pressure (high idling, torque converter
ysis tool box. stall)
★ Check that each file has been saved. Check • Exhaust temperature (torque converter stall)
also that there is no abnormal data. • Engine oil pressure (low idling, high idling, torque
★ Compare the quick PM data and the PM converter stall)
clinic data to check that there are no abnor- • Engine oil temperature (no PM data ••• reference
mal values. value)
★ After downloading, if there is no problem with
the data, clear only the snapshot data.
For details of the method of clearing, see the
instruction manual for the technical analysis
tool box (for service).
20-203-15 HD465-7, HD605-7

➁
TESTING AND ADJUSTING INSPECTION AND MAINTENANCE, REPLACING PARTS
INSPECTION AND REPLACING PARTS

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

➁
TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS
Timing Operation step Operation step
-3 Setting up payload meter Click the PLT tag to

(Machine with PLM II or 1) Setting start time and interval (days) for
VHMS with PLM function) data collection
• In the example on the right, the start time
(For details of setting up PLM, see is set at 11 PM and the interval at 2 days.
the separate PLM instruction manual)
Click Apply to register the setting
Starting switch OFF Check the 7-segment display in the VHMS controller inspection window.
Saving of contents of setting • The display continues for several seconds after the starting switch is turned OFF. Check that
Turn the starting switch OFF to save the the saving-to-memory display goes out completely.
data in the VHMS controller.
Check the normal operation (*) of the LED in the 7-segment display window of the VHMS controller.
Starting switch ON * The normal operation of the LED means that the 7 segments flash in the rotation state after the
Check of normal operation of VHMS starting switch is turned to the ON position and then they count up in hexadecimal notation.
controller For details, see the Shop Manual.
Start engine [Outline of procedure]

Execution of quick Pm clinic 1) Execute the quick PM while the engine is warm.
Execute the quick Pm clinic according to 2) Select the service mode with the monitor panel, change the function, display "SNAPSHOT", and
the procedure shown in the Shop Manual. press the < > switch. Then, run the engine at Lo/Hi idle Be extremely careful about safety
and stall the torque converter in 7 minutes 30 seconds. when carrying out the torque
converter stall.
Starting switch OFF
Saving in VHMS Check lighting of the 7 segments in the inspection window of the VHMS controller.
Turn the starting switch OFF to save the • The segments keep lighting for several seconds after the starting switch is turned off. (Saving operation)
data in the VHMS controller. Check that the segments go off perfectly.
Starting switch ON Check that the VHMS controller is connected to the portable personal computer by the cable.
Download Start the "VHMS analysis tool" (VHMS technical analysis tool box) on the personal computer display.
Download all files.
For details, see the instruction manual for the
technical analysis tool box.
After downloading is finished, check the VHMS data with the
Check of downloaded data "VIEW" function.
• Check that the set contents are displayed correctly.
(Date, time, service meter, machine serial No., etc.)
• Check that the data of the quick Pm executed
in are saved in "Snap Shot".
Saving in VHMS
Turn the starting switch OFF to save the
data in the VHMS controller. 1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
power for the VHMS is turned OFF), if the all system is normal.
Starting switch OFF 2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
After returning to office This completes the initial setup of the VHMS.
Finish setting of the VHMS and The setup of the database (Web server) is carried out by Komatsu, so after you have
notify to KOMATSU completed the operation, inform Komatsu as follows.
　 Send the check sheet by fax.
Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS, WebCARE Support Center

(Service Business Development Group Customer Support Division Komatsu Head Office)
Welcome to WebCARE Tel: 03-5561-2765
Use WebCARE to check the data Fax: 03-5561-4766
https://wcare.komatsu.co.jp E-mail: webcare@komatsu.co.jp
Set positions of rotary switch 2 (SW2) of transmission controller and variation codes of VHMS and PLM
controller
Setting with VHMS initial setting manual (tool)
PLM Set position of ( 1)
Card-type rotary switch 2
VHMS function in payload meter Payload meter Date
controller VHMS (SW2) of Set
(PLM) function Time
controller (PLM- ) transmission Model Type variation Time difference
controller code (GMT)
Summer time
Not installed — Not installed Not installed F — — — —
Not installed — Installed Installed F — — — —
Installed Not installed Not installed Not installed B ST
HD465
Installed Not installed Installed Installed F Set
or –7 P2
properly
HD605
Installed Installed Installed Installed 9 PV
★ A variation code is an item among the model, date, etc. that are set with the personal computer software when the
VHMS is set initially. It is used to notify the VHMS "whether the PLM in the VHMS is effective (Code: PV), whether PLM
is connected (Code: P2), and whether the machine has the payload meter (PLM) function (Code: ST)".
★ Since A and B of the short connector to be connected to connector No. HM-50 are not used, connect them normally.
( 1) The transmission controller switch (SW2) is used to notify the monitor panel "whether the VHMS is installed",
"whether the PLM function in the VHMS is turned on", and "whether PLM- is installed". (See the section of
adjustment of the transmission controller.)
HD465-7, HD605-7 20-203-18

➄
TESTING AND ADJUSTING PROCEDURE FOR INITIAL SETUP OF VHMS
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS INITIAL SET-UP CHECK SHEET sheet
(For HD465/605-7 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, hexadecimal count-up display)
Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up" ?
Initial setup of VHMS controller Is model name same as name of machine? yes no
–1 Set machine data Has machine serial No. been input correctly? yes no
Was selection of variation code set correctly? yes no
This sets the basic data for the machine Has engine serial No. been input correctly? yes no
in the VHMS controller. Has date been set to today's date? yes no
Has time been set to correct time? yes no
Save settings After saving operation, did LED (7 segments) go off? yes no
Setting of payload meter

–1 Check of functions of VHMS Did LED operate normally? yes no
–2 Starting of VHMS initial setting tool Is selection of mode of setting tool

yes no
"Set up"?
–3 Setting of payload meter Enter set value of PLM collection

(When PLM II or PLM function is installed) Time to start collection
Collection interval (day) day
Check VHMS functions Did LED operate normally? yes no
Perform quick PM clinic Were service mode and "SNAPSHOT" selected and
yes no
was switch pressed?
Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
Download Did LED operate normally? yes no
Check downloaded data Have all files been downloaded? yes no

Time of download (use wrist watch)
[Check data]
Is there any MFAO error in Fault History? yes no
In Fault History, do set values for SMR and
yes no
time match?
Are there any data missing in Snapshot? yes no
Are there any data in Transmission Shift Change Map? yes no
Save to VHMS memory After saving operation, did LED (7 segments) go off? yes no
Point of Contact VHMS, WebCARE Support Center

Tel: 03-5561-2765
Fax: 03-5561-4766
E-mail: webcare@komatsu.co.jp
20-203-19 HD465-7, HD605-7

(7)
TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE
Timing Operation step Operation step
Starting switch OFF Save to VHMS memory Check the 7-segment display in the VHMS controller inspection window.
Turn the starting switch OFF to save the • The display continues for several seconds after the starting switch is turned OFF.
data in the VHMS controller. Check that the saving-to-memory display goes out completely.
1) After the starting switch is turned to the OFF position, the LED of the VHMS displays
SF and SH (Processing time of memory), and then the all operation is finished (the
power for the VHMS is turned OFF), if the all system is normal.
2) If the power is turned OFF immediately after the starting switch is turned to the OFF
position, the power is not applied constantly.
After returning to office
Completing operation to set up VHMS This completes the setup for Orbcomm.
and contacting Komatsu The setup of the reception inside of the satellite communications is carried out by Komatsu,
　 so after you have completed the operation, inform Komatsu as follows.
Send the check sheet by fax.
Send the downloaded VHMS data by Notes or E-mail to the following address.
VHMS, WebCARE Support Center

Welcome to WebCARE Tel: 03-5561-2765
Use WebCARE to check the data Fax: 03-5561-4766
https://wcare.komatsu.co.jp E-mail: webcare@komatsu.co.jp
20-203-21 HD465-7, HD605-7

➄
TESTING AND ADJUSTING PROCEDURE FOR OPENING ORBCOMM SERVICE
Address: VHMS, WebCARE Support Center Date of setup Month Day Year
(Service Business Development Group Customer Support Division Komatsu Head Office) Date of fax Month Day Year
Name of
Fax: 03-5561-4766 distributor/branch
Name of person
filling in check
VHMS INITIAL SET-UP CHECK SHEET sheet
(For HD465/605-7 Dump Truck)
Steps for setup Check items Results
Name of machine
Check machine and component Serial No.
nameplates Service meter
Engine serial No.
Transmission serial No.
VHMS controller serial No.
Orbcomm controller serial No.
Connect PC and VHMS controller Are they are properly connected? yes no
Check that operation of VHMS Does it work properly?

yes no
controller is normal (After rotation, count-up display)
(Check operation of Orbcomm) Does VHMS monitor (7-segment) display decimal point?
yes no
(OFF, ON, Slow/Quick flash)
Start VHMS initial setup tool Is selection of mode for setup tool
yes no
"Data Clear and Set up"?
Initial setup of VHMS controller
–1 Set up communications Input set value of short Fault History

Condition of communications On Off
* (The setting of the machine data and PLM Number of items (default value: 8) items
is already completed) Input set value of short Trend Analysis
Interval (default value: 20 hrs) Hrs
Input set value of short Payload data
Time of start of data collection
Data collection interval (day) day
–2 Set start of communications Is GCC code set to 130 (if Japan) yes no
Point of Contact VHMS, WebCARE Support Center

Tel: 03-5561-2765
Fax: 03-5561-4766
E-mail: webcare@komatsu.co.jp
HD465-7, HD605-7 20-203-22

(7)
PERFORMING PM-CLINIC USING MANUAL
TESTING AND ADJUSTING SNAPSHOT (= QUICK PM)
PERFORMING PM-CLINIC USING MANUAL SNAPSHOT (= QUICK PM)

What is quick Pm?
If a serious error occurs, 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).
This snapshot function can be studied by pressing the manual switch. After the button is pressed, all data is
automatically saved for seven minutes 30 seconds. All data can be automatically collected in cases such as
torque converter stall, so it is possible to reduce the time taken for measurements in the Pm Clinic.
However, 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. To raise the precision of the data, it is necessary to create the con-
ditions (torque converter stall, etc.) for this 2 minutes 30 seconds and record the data.
Necessary tools
• Personal computer
• VHMS technical analysis toolbox (software)
799-608-3211
• Download cable 799-608-3220
To ensure safety, stop the machine on flat

ground and put blocks under the tires to pre-
vent the machine from moving.
1. Start the engine.
2. Select SNAPSHOT with the monitor panel

(EMMS).
★ For details of the method of selecting, see
Special functions of vehicle monitor (EMMS).
20-204 HD465-7, HD605-7

➁
3. Press the [ ] button.

"READY" is displayed.
(Waiting status)
4. When the [ ] button is pressed, Snapshot is

started and the time advances.
(Running)
If you want to stop, press the [ ] button to return
to the Waiting status screen.
5. Run the engine at low idling and stabilize it for 2

minutes.
★ Check that the coolant temperature gauge
and torque converter oil temperature gauge
are in the white range.
6. After starting, operate the machine as shown in

Table 1.
Table 1
Measurement conditions
Start Finish Time Operation of machine Remarks
AISS switch Power mode Shift lever Parking Retarder Dump lever
setting brake
1 0 : 00 2 : 00 120 sec Low idling (Low) Auto Economy N ON ON Hold
2 2 : 00 3 : 00 60 sec Low idling (Hi) Auto Economy N OFF OFF Hold ( 1)
3 3 : 00 4 : 00 60 sec High idling (Stationary mode) Auto Economy N ON ON Float
4 4 : 00 5 : 00 60 sec Low idling (Hi) Auto Economy N ON ON Hold
5 5 : 00 5 : 30 30 sec High idling (Economy mode) Auto Economy N ON ON Hold
6 5 : 30 6 : 00 30 sec Torque converter stall (Economy mode) Auto Economy D OFF ON Hold ( 2, 3)
7 6 : 00 6 : 30 30 sec High idling (Power mode) Auto Power N ON ON Hold
8 6 : 30 7 : 00 30 sec Torque converter stall (Power mode) Auto Power D OFF ON Hold ( 2, 3)
High idling (Power mode)
9 7 : 00 7 : 30 30 sec + Auto Power N ON ON Hold
20 pumping operations of foot brake
( 1) Press the foot brake.

( 2) When stalling the torque converter [Portion marked with ( )], do not overheat it.
[Stall of torque converter for 30 seconds is only a reference. When the oil temperature gauge reaches the top of the
white range while the torque converter is stalled, return the transmission (gearshift) lever to the N position.]
( 3) When setting the gearshift lever in the D position, return the engine speed to low idling temporarily (to prevent the
machine from running out).
HD465-7, HD605-7 20-204-1

➄
7. After 7 minutes 30 seconds, the screen on the

right is displayed for 5 seconds, and then it
returns to the opening screen.
(Completion of Snapshot)
8. Download the snapshot data to the personal

computer. For details, see Procedure for down-
loading VHMS data to personal computer.
NOTICE
The quick PM data is only recorded once. If the
operation is carried out again, the data is over-
written, so after performing the quick PM, always
download the data to the personal computer.
9. Use the technical analysis tool box to read the

quick PM data.
★ For details of the method of using the techni-
cal analysis tool box, see the instruction
manual.
• Open the quick PM data and make a graph
• For the X-axis, select Time and for the Y-
axis, select
1) Engine Speed
2) Blowby Press
3) Exhaust Temp 1, 2 & 3
4) Exhaust Temp 4, 5 & 6
5) Engine Oil Press
and put a check mark against Graph value dis-
play at click position (marked by ).
20-204-2 HD465-7, HD605-7

➁
• If the graph is clicked, the values for each measured item on the X-axis are displayed on the graph.
(Example of graph display)
• Enter these values on the Pm Clinic check sheet.

The relationship between the measurement conditions and the necessary data in the Pm Clinic is as
shown below.
Conditions Measurement items
Brake oil
Engine speed Mode Engine Blow-By Lublicating oil Exhaust pressure
speed pressure pressure temperature
( 1)
1 Low idling Low
2 Low idling High
3 High idling Stationary mode
4 Low idling Economy mode
5 High idling Economy mode
6 Torque converter Economy mode
stall
7 High idling Power mode
8 Torque converter Power mode
stall
High idling
9 + Power mode
20 pumping opera-
tions of foot brake
( 1) Cut OUT oil pressure and brake cut IN.
HD465-7, HD605-7 20-204-3

➄
TESTING AND ADJUSTING PM-CLINIC SERVICE
HD465-7, HD605-7 20-205

➄
20-206 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-207

➄
TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................... 20- 302

Sequence of events in troubleshooting ..................................................................................................... 20- 303
Points to remember when carrying out maintenance................................................................................ 20- 304
Checks before troubleshooting ................................................................................................................. 20- 312
Categories, procedure, and method of using troubleshooting charts........................................................ 20- 313
Connection table for connector pin numbers ............................................................................................ 20- 318
T-adapter table .......................................................................................................................................... 20- 341
Types and locations of connectors ........................................................................................................... 20- 344
Connector arrangement location............................................................................................................... 20- 356
Troubleshooting of engine controller system (ENG mode) ....................................................................... 20- 401

Troubleshooting for transmission controller system (TM mode) ............................................................... 20- 501
Troubleshooting for retarder controller system (BK mode) ....................................................................... 20- 701
Troubleshooting for payload meter system (card type) (LC mode) ........................................................... 20- 801
Troubleshooting for monitor system (MON mode) .................................................................................... 20- 901
Troubleshooting of VHMS controller system (VHMS mode) ..................................................................... 20-1001
Troubleshooting of hydraulic and mechanical systems (H mode) .............................................................20-1101
Troubleshooting of engine system (S mode) ............................................................................................20-1151
HD465-7, HD605-7 20-301

(7)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

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

shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

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

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
HD465-7, HD605-7 20-303

➁
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Since the DT 8-pole and 12-pole heavy duty wire con-

nectors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female conector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c
• Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it
off with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do
not use high-pressure water or steam directly on the
wiring harness.
If water gets directly on the connector, do as follows.

1) Disconnect the connector and wipe off the water
with a dry cloth.
★ If the connector is blown dry with compressed
air, there is the risk that oil in the air may
cause defective contact, so remove all oil and
water from the compressed air before blowing
with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
★ Hot air from the dryer can be used, but regu-
late the time that the hot air is used in order
not to make the connector or related parts too
hot, as this will cause deformation or damage
to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to check for
any short circuits between pins caused by water.
★ After completely drying the connector, blow it
with contact restorer and reassemble.
20-308 HD465-7, HD605-7

(6)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

(1. Check before starting and 2. Other check items)
Item Judgement value Action
1. Check fuel level Fuel level Add fuel
2. Water, sediment in fuel tank Drain

lubricating oil,coolant
Hydraulic oil,
3. Check oil level in transmission case Sight gauge Drain
4. Check oil level in hydraulic tank Sight gauge Drain
5. Check oil level in engine oil pan Oil level gauge Add oil
6. Check coolant level — Add water
7. Check dust indicator Dust indicator Clean, replace
8. Check that steering wheel play is correct Max. 135 mm Adjust
9. Check emergency steering Actuation 20 sec Repair
10. Check length of suspension cylinder Label Repair

Air, hydraulic, mechanical components
11. Check tire inflation pressure, check for damage — Inflate or replace
Torque (see DISASSEM- Tighten
12. Check hub nuts
Check before starting items
BLY AND ASSEMBLY)
13. Check foot brake effect — Adjust
14. Check parking brake effect — Adjust or repair

1 15. Check that emergency brake works properly — Adjust or repair
16. Check that there is no abnormality in operation of steering — Adjust or repair
17. Check that direction of rear view mirror and under mirror is correct — Adjust
18. Check that there is no abnormality in exhaust color or sound — Adjust or repair
19. Check that retarder brake works properly — Adjust or repair
20. Check that body mount rubber is normal — Replace
21. Check that horn sounds — Repair
22. Check that lamps flash properly — Repair or replace

Electrical components
23. Check that gauges work properly during operation — Adjust or repair
24. Check monitor panel — Adjust or repair
25. Check mechanical monitor system — Repair or replace
26. Check central warning lamp — Adjust or repair
27. Check for looseness, corrosion of battery terminal wiring — Retighten or clean
28. Check for looseness, corrosion of alternator terminal wiring — Retighten or clean
29. Check for looseness, corrosion of starting motor terminal wiring — Retighten or clean
20-312 HD465-7, HD605-7

➁
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
Item Judgement value Action
30. Check for abnormal noise or smell — Repair

mechanical
equipment
Hydraulic,
31. Check for oil leakage — Repair
32. Air bleed operation — Bleed air
33. Check battery voltage (engine stopped) 24V Charge or replace

Other check items
Electrics, electrical components
34. Check battery electrolyte level — Add distilled water

35. Check wiring for discoloration, burn marks, peeling of — Replace
2 cover
36. Check for loose wiring clamps, hanging wiring — Repair
37. Check for wet wiring (be particularly careful to check connec- — Dry
tors and terminals)
38. Check for blown fuses, defective contact — Replace

39. Check alternator voltage after several minutes of running After operating for
Replace
(engine at 1/2 throttle or above) several minutes
40. Check for actuation sound from battery relay (when starting — Replace
switch is turned ON-OFF)
HD465-7, HD605-7 20-312-1

➁
CATEGORIES, PROCEDURE, AND METHOD OF
TROUBLESHOOTING USING TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING TROU-

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

➄
Phenomena considered to be failures and troubleshooting No.

★ With mark ● go to troubleshooting No. on failure code display
Troubleshooting
No. Phenomena considered to be failures
Error ENG TM BK LC MON VHMS H (Engine)
code mode mode mode mode mode mode mode
Error code related
1 Error code is displayed in error code display mode ●
Engine related
2 Starting performance is poor (starting always takes time) ENG-1 S-1
3 Engine does not turn S-2 a)

Engine does not Engine turns but no exhaust
4 S-2 b)
start smoke comes out
5 Exhaust smoke comes out but S-2 c)
engine does not start
6 Engine does not pick up smoothly (follow-up is poor) S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly (hunting) S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive S-8

(or exhaust smoke is blue)
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil is in cooling water, or water spurts back, or water S-11

level goes down
15 Oil pressure caution lamp lights up S-12
(drop in oil pressure)
16 Oil level rises S-13
17 Water temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
Engine is not preheated ENG-2a)

Failure in
20 preheating Engine is still preheated after ENG-2b)
preheating time
When AISS switch is set in AUTO, ENG-3a)
AISS function LOW SPEED control is selected
21 does not work
normally When AISS switch is set in LOW ENG-3b)
SPEED, AUTO control is selected
22 Not error code is displayed in error code display mode TM-
1 – 27
Transmission controller related
23 Fuel level gauge does not operate normally TM-1

(It always indicates "FULL")
When the shift lever is set in the
24 "R" position, the backup lamp and TM-2a)
backup buzzer are not turned ON
Abnormality in Backup lamp is not turned ON
25 backup lamp (Backup buzzer is normal) TM-2b)
and backup
26 buzzer Backup buzzer is not turned ON TM-2c)
(Backup lamp is normal)
27 While shift lever is not operated, TM-2d)
backup lamp and backup buzzer
20-314 HD465-7, HD605-7

➁
Troubleshooting
Retarder controller related
When the parking brake switch is
set in the OFF position, the BK-1a)
Parking brake parking brake s not released
28 does not
operate normally When the parking brake switch is
set in t he PARK posit ion, the BK-1b)
parking brake does not work
29 Retarder brake oil temperature gauge does not BK-2
operate normally
30 Inclination alarm is turned ON when dump body is BK-3
raised
31 Touch up/down and cancellation cannot be performed BK-4
Payload meter related
32 When starting switch is turned ON, any item is not LC-1

displayed
33 After starting switch is turned ON, all external pilot LC-2
lamps do not light up
34 External lamps light up while condition for lighting is LC-3
not set
35 Lighting level of external pilot lamps is abnormal LC-4
36 Cycle data and engine ON/OFF data not recorded LC-5

(charge level signal system: judges that engine is
Calibration cannot be performed and displayed clock
37 does not conform to condition LC-6
(shift lever "N" position signal system)
38 When loaded dump truck starts LC-7a)
traveling, "0" is kept displayed
After loaded dump truck start
39 traveling, display of odometer LC-7b)
does not increase
Displayed logic
40 is abnormal When travel speed exceeds limit LC-7c)
speed, "SP:SP" does not go off
41 Integrated pay load is not LC-7d)
displayed
42 Displayed and saved pay load is LC-7e)
not correct
Payload meter keeps displaying "b:FL"
43 (body "FLOAT" signal system: dump lever is not in LC-8
"FLOAT" position while truck is not dumping)
44 Payload meter displays "F:09" LC-9
(lowering of internal backup battery voltage)
45 Payload meter displays " :FULL" (data saving LC-10
memory is full)
46 Payload meter displays "F-20" :failure in power source LC-11
of suspension pressure sensor and clinometer system
47 Payload meter displays "F-21" – "F-24" : disconnection LC-12
or grounding fault in suspension sensor signal system
48 Payload meter displays "F-25" – "F-28" : short circuit LC-13
with power source in suspension sensor signal system
49 Payload meter displays "F-CAL" LC-14
(negligence of calibration or internal damage of
50 Payload meter displays "F:43" – "F:45" LC-15
(short circuit with power source in external pilot lamp relay
51 Payload meter displays "L-bad" LC-16
(cycle data were saved while truck body was pitching)
External pilot lamp indicates forecast while truck is not
52 being loaded or clock is displayed while truck travels LC-17
for 160 m after it is loaded
53 Payload meter displays "F-31" : grounding fault or LC-18
disconnection in clinometer sensor signal system
54 Payload meter displays "F-32" : short circuit with LC-19
power source in clinometer sensor signal system
55 Payload meter displays "F:18" LC-20
(disconnection in charge level signal system)
HD465-7, HD605-7 20-315

➁
Troubleshooting
Monitor related
56 When starting switch is turned ON, machine monitor MON-1

does not display any item
57 When starting switch is turned OFF and machine MON-2
monitor does not operate normally
Alarm buzzer does not sound MON-3a)
58 Alarm buzzer
defective Alarm buzzer does not stop MON-3b)
sounding
Items displayed Items displayed by gauges are MON-4
by gauges, different from machine condition
caution lamps, Items displayed by caution lamps
59 and character MON-4
are different from machine
display of
machine monitor Character display does not display MON-4
are abnormal any item or it displays abnormally
60 Operation of machine monitor cannot be checked MON-5
normally
Display of Machine monitor mode select MON-6
character switch 1 system is abnormal
61 display cannot Machine monitor mode select MON-6
be selected switch 2 system is abnormal
62 Power mode select function does not work normally MON-7
Lamp lights up while seat belt is MON-8a)
Seat belt caution fastened
63 lamp does not
operate normally Lamp does not light up while seat MON-8b)
belt is unfastened
When turn signal lever and hazard
lamp switch are operated, any turn MON-9a)
signal lamp does not flash
When turn signal lever and hazard
lamp switch are operated, the turn
signal lamps do not flash but light MON-9b)
up
When turn signal lever is
operated, turn signal lamps on
either or both sides do not flash
(W hen hazard lamp swit ch is MON-9c)
Turn signals and operated, however, turn signal
hazard lamp do lamps flash normally)
64 not operate W h e n h a z a r d l a m p s w it c h i s
normally turned ON, any turn signal lamp
does not flash (When turn signal MON-9d)
lever is operated, however, 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, turn signal lamps
cont inue f las hing (W hen tur n MON-9e)
signal lever is operated, however,
turn signal lamps flash normally)
Turn signal pilot lamps do not flash
normally (Turn signal lamps flash MON-9f)
normally, however)
When lamp switch is set in 1st or
2nd position, any of small lamp, MON-10a)
night lamp, and head lamp does
not light up
When lamp switch is set in 1st
position, small lamp and night MON-10b)
Night lighting is lamp do not light up
65 abnormal When lamp switch is OFF, small
lamp and night lamp light up MON-10c)
When dimmer switch is operated,
brightness of night lighting does MON-10d)
not change
Head lamp "Hi" beam does not
light up MON-10e)
20-316 HD465-7, HD605-7

➁
Troubleshooting
Head lamp "Lo" beam does not
light up MON-10f)
Abnormal in Head lamp cannot be set to "Hi" or
65 backup lamp "Lo" MON-10g)
and bukup
buzzer When head lamp is set to "Hi"
beam, pilot lamp of machine MON-10h)
monitor does not light up
Left window does not work MON-
Power window 11a)
66 does not
operate normally Right window does not work MON-
11b)
Air conditioner does not operate MON-
12a)
Air is not blown out or airflow MON-
cannot be adjusted 12b)
Air is not cooled or temperature MON-
c a n n o t b e a d ju s t e d ( E l e c t r i c
system) 12c)
Inside air and fresh air cannot be MON-
selected 12d)
Defective air
67 MON-
conditioner Air outlet cannot be selected
12e)
Cooling capacity is low MON-
(Mechanical system) 12f)
Heating capacity is low MON-
(Defective hot water circuit) 12g)
Abnormal noise comes out MON-
12h)
Water leaks MON-
12i)
VHMS
Satellite communication data are
Abnormality in not transmitted
68 satellite data VHMS-1
communication Downloading into PC
69 Abnormality in saving in VHMS controller VHMS-2

(Data are not saved)
Engine blow-by pressure of monitoring display is low
70 (when measurement equipment shows blow-by VHMS-3
pressure is normal)
Hydraulic and mechanical related
71 Machine does not start H-1
72 Machine does not travel smoothly (machine jerks) H-2
73 Lock-up clutch cannot be disengaged (engine stalls) H-3
74 Excessive shock when starting or shifting H-4
75 Transmission does not shift up H-5
Abnormality at all speed ranges H-6a)

Machine lacks
76 power or speed Torque converter lock-up does not H-6b)
when traveling engage
Abnormality at specific speed H-6c)
ranges
77 Time lag is excessive when starting or shifting gear H-7
78 Torque converter oil temperature is high H-8
79 Torque converter oil pressure is low H-9
80 Front brake is ineffective, or effective only on one side H-10
81 Rear brake is ineffective, or effective only on one side H-11
HD465-7, HD605-7 20-317

➄
Troubleshooting
82 Steering wheel is heavy H-12
83 Steering wheel does not work H-13
84 Steering wheel vibrates H-14
85 Hoist cylinder lacks lifting force (lifting speed) H-15
86 Hoist cylinder does not work H-16
87 Excessive hydraulic drift of dump body H-17
20-317-1 HD465-7, HD605-7

➄
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. M-type connector

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

(7)
MIC type connector

No.
of pins T-adapter
Male (female housing) Female (male housing)
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7 —
Qty.: 5 Qty.: 5
1 —
Qty.: 5 Qty.: 5
5 799-601-2710

Qty.: 5 Qty.: 5
9 799-601-2950

Qty.: 5 Qty.: 5
13 799-601-2720

Qty.: 2 Qty.: 2
20-324 HD465-7, HD605-7

(7)
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
HD465-7, HD605-7 20-339

(7)
DTM series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD series connector

No. of
pins T-adapter
Part No.
Part No.: 08192 - 31200 (contact size #12) Part No.: 08192 - 31100 (contact size #12)
08192 - 41200 (contact size #8) 08192 - 41100 (contact size #8)
08192 - 51200 (contact size #4) 08192 - 51100 (contact size #4)
20-340 HD465-7, HD605-7

➄
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
—
Port No. Connector type Pin No.
799-601-9230 HD30 18-20 ! !

799-601-9240 HD30 18-21 ! !
799-601-9250 HD30 24-9 ! !
799-601-9260 HD30 24-16 ! !
799-601-9270 HD30 24-21 ! !
799-601-9280 HD30 24-23 ! !
799-601-9290 HD30 24-31 ! !
799-601-9310 Plate For HD30 ! ! !
799-601-9320 For measuring box For DT, HD ! ! !
799-601-9330 Case !
799-601-9340 Case !
799-601-9350 DEUTSCH 40P !
799-601-9360 DEUTSCH 24P !
799-601-9410 For NE, G sensor 2P !
For boost pressure,
799-601-9420 fuel 3P !
799-601-9430 PVC socket 2P !
HD465-7, HD605-7 20-343

(7)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

Address
Con- Type Num- 3-dimen-
nector of ber Location sional System diagram
No. connector of pin wiring
diagram ENG TM BK PLM MON VHMS ASR
01 Terminal 1 Battery relay (B) B9 J-1 K-8 H-9 K-9 N-9
02 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
03 Terminal 1 Battery relay (B) B9 J-1 K-8 H-8 K-8 N-8
04 Terminal 1 Battery relay (M) B9 J-1 K-8 H-8 K-8 N-8
05 Terminal 1 Emergency steering relay (B) A8 K-9
06 Terminal 1 Emergency steering relay (M) A8 K-9
07 Terminal 1 Emergency steering relay (B) A8 J-1 K-8 H-9 K-9
08 Terminal 1 Emergency steering relay (M) A9 J-1 K-8 H-8 K-8
11 Terminal 1 Battery relay (E) B-8 J-1 J-1 K-8
12 Terminal 1 Battery relay (BR) B-8 J-1 J-1 K-8 H-8 K-8
12 KES0 2 Washer tank motor — J-1 H-8 K-8
13 Terminal 1 Battery relay (E) C-8 J-1 K-8 H-8 K-8 N-8
14 Terminal 1 Battery relay (BR) C-8 H-8 K-8 N-8
15 Terminal 1 Emergency steering relay (E) A-8 K-9
16 Terminal 1 Emergency steering relay (BR) A-7 K-9
17 Terminal 1 Emergency steering relay (E) B-7 K-9
18 Terminal 1 Emergency steering relay (BR) B-7 K-8
20 — 1 Circuit breaker A-9 L-8 N-8
21 — 1 Circuit breaker A-9 L-8 N-7
22 — 1 Circuit breaker A9 J-2 K-8 I-8 L-8 N-8
23 — 1 Circuit breaker B9 I-2 K-8 I-8 L-8 N-7
1939 HD30 9 Connector for connecting J1939 device — G-9 A-3
A One-pin 1 Lamp (Optional for payload meter) — J-9

connector
A One-pin 1 Lamp (Optional for payload meter) — H-1
connector
A1 M 1 Emergency reset connector X6 B-7
A2 M 1 Emergency reset connector V8 B-7
AAPR PACKARD 3 Air pressure sensor AH5 B-1
ABS M 6 ABS system switch O2 E-9
AC1 One-pin
connector 1 Air conditioner wiring harness M3 C-7
ACBM YAZAKI 2 Air conditioner blower motor T2 A-9
ACCF DT-T 3 ACC oil pressure sensor (Front) L4 L-2 K-4
ACCR DT-T 3 ACC oil pressure sensor (Rear) K3 L-2 K-4
ACM1 AMP 5 Temperature regulation servomotor V3 A-8
ACM2 AMP 5 Air outlet mode selection servomotor M6 B-9
20-344 HD465-7, HD605-7

➄
Address
Con- Type Num-
3-dimen-
Recirculated/Fresh air selection
ACM3 AMP 5 servomotor W3 A-7
ACP1 AMP 16 Air conditioner control panel O7 B-9
ACP2 AMP 12 Air conditioner control panel O7 B-9
ACPS SUMITOMO 2 Air conditioner pressure switch U2 A-8
ACR1 Relay 4 Blower main relay W3 A-8
ACR2 Relay 4 Blower Hi relay W4 A-8
ACR3 Relay 4 Blower M2 relay W4 A-7
ACR4 Relay 4 Blower M1 relay W4 A-7
ACR5 Relay 4 Compressor clutch relay W4 A-7
ACRE AMP 4 Air conditioner blower resistor U2 A-8
ACTH YAZAKI 2 Thermistor U3 A-8
AISS M 6 AISS switch M3 L-5
ARC M 3 ARSC set switch P8 F-9
ARSC M 6 ARSC system switch N3 C-1 F-9
AS1 SWP 6 Acceleration sensor N2 L-2
AS2 X 3 Acceleration sensor O2 C-8
ASR M 6 ASR system switch O2 F-9 F-5
ASR1 DT-T-T 2 Steering angle sensor C2 C-9
ASR2 DT-T-T 2 Shut off valve L2 D-9
ASR3 DT-T-T 2 ASR valve (R) K3 D-9
ASR4 DT-T-T 2 ASR valve (L) L3 E-9
ASR5 DT-T 2 ASR oil pressure switch (R) K3 E-9
ASR6 DT-T 2 ASR oil pressure switch (L) L2 F-9
ASR7 DT-T 2 ASR oil ptessure switch (Main) K1 F-9
ASS DT-T 2 Air suspension seat T2
ATC1 MIC 17 Transmission controller Z1 L-8 A-7 E-1 E-1 H-1
ATC2 MIC 21 Transmission controller Z1 A-7
ATC3A AMP040 20 Transmission controller Z4 L-8 A-6 E-1 E-1
ATC3B AMP040 16 Transmission controller Z4 A-6 E-1
ATC4 AMP040 12 Transmission controller AA4 L-7 A-5 E-1 F-1 I-1
ATC5A AMP040 20 Transmission controller AA1 L-7 A-5
ATC5B AMP040 16 Transmission controller AA4 A-4
ATC6 X 4 Software rewriting connector

(Transmission controller) W4 A-3
B01 DT-T 6 Intermediate connector K9 M-5
B02 DT-T 6 Intermediate connector K8 M-5
HD465-7, HD605-7 20-345

➄
Address
B03 DT-T 6 Winker lamp, stop lamp, tail lamp J9 M-6
B04 Terminal 1 Backup lamp J9 F-9 M-6
B05 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B06 Terminal 1 Backup alarm buzzer J9 F-9 M-6
B07 DT-T 3 Body position sensor K9 K-5
B1 One-pin
connector 1 Lamp (Optional for payload meter) — I-9
B1 One-pin 1 Lamp (Optional for payload meter) — H-1

connector
B10 Terminal 1 Grounding K8 G-9 M-4
B11 Terminal 1 Grounding L8 M-5
B2 One-pin 1 Lamp (Optional for payload meter) — J-9

connector
B2 One-pin
connector 1 Lamp (Optional for payload meter) — H-1
B3 One-pin 1 Lamp (Optional for payload — J-9

connector meter)
B3 One-pin 1 Lamp (Optional for payload — H-1
connector meter)
BCOM One-pin 1 Beacon lamp T9 A-2
connector
BK DT-T
(Gray) 8 Intermediate connector F9 H-2 M-2
BL One-pin 1 Intermediate connector C7 I-8

connector
BLS M 6 Rotary lamp switch (Optional) N1 C-9
BR One-pin 1 Air conditioner wiring harness M4 C-7

connector
BRC1 MIC 17 Retarder controller Y2 J-9 C-1 A-8 D-1 H-1
BRC2 MIC 21 Retarder controller Y2 A-7 A-1
BRC3A AMP040 20 Retarder controller Y4 C-1 A-6 D-1 B-1
BRC3B AMP040 16 Retarder controller Y4 A-5
BRC4 AMP040 12 Retarder controller Z4 J-9 C-1 A-5 D-1 H-1
BRC5A AMP040 20 Retarder controller Y1 A-4
BRC5B AMP040 16 Retarder controller Y2 C-1 A-3 D-1
BRC6 X 4 Software rewriting connector

(Retarder controller) S9 A-2
BT DT 6 Intermediate connector C9 I-2 H-6 G-8 J-6 M-9
BT1 — — Fuse box X5 E-3 E-7 K-3
BT2 — — Fuse box X7 L-4 E-2 F-3 E-7 I-3 F-4
BT3 — — Fuse box X6 L-4 E-2 F-3 E-6 K-3
BT4 — — Fuse box X6 L-3 E-2 E-6 I-3
BZ2 M 2 Buzzer R1 D-9
CAB1 DT-T 8 Intermediate connector Q9 F-1

(Gray)
CAB2 DT-T 8 Intermediate connector Q9 B-9
(Black)
CAN DT 3 CAN connector AJ6 H-9 L-6 M-3 A-2
20-346 HD465-7, HD605-7

➄
Address
CAN1 DT-T 3 VHMS CAN connector T9 C-9
CAN2 DT-T 3 Resistor Q1 F-9 D-9
CG1 One-pin 1 Cigarette lighter M5

connector
CG2 — 1 Cigarette lighter M5
CH1 S 8 Machine monitor mode selector switch 1 M1 E-9
CH2 S 8 Machine monitor mode selector switch 2 M1 E-9
CJA DT-T 6 Joint connector D8 L-9
CJB DT-T 8 Joint connector B7 I-1 M-9

(Black)
CJB DT-T 6 Joint connector E8 L-9
CJC DT-T 6 Joint connector D8 G-8 H-9
CJD DT 6 Joint connector D8 H-9 H-9 M-9
CJE2 DT-T 6 Joint connector AI9 G-1 M-1
CJE3 DT-T 8 Joint connector A12 G-1 M-1 L-3 K-1 N-7
(Black)
DT-T
CJH1 (Black) 8 Joint connector — I-9 J-1 M-1
CJH2 DT-T 6 Joint connector — J-1 J-1
CJK DT 6 Joint connector B8 I-1 J-9 H-9 J-9 M-9
CJL DT-T 6 Joint connector L7 I-1 M-1
CJN DT (Black) 8 Joint connector J3 I-1
CJP DT-T 6 Joint connector I9 I-1 J-1
CJP1 DT-T 6 Joint connector H9 I-1
CJP2 DT-T 6 Joint connector I9 H-1
CJPR DT-T 6 Joint connector C8 I-9
CJS DT-T 6 Joint connector L7 N-5
CJSL DT-T 6 Joint connector I9 I-1
CJT DT 8 Joint connector L8 G-9 N-5

(Black)
CJT1 DT-T 8 Joint connector L7 G-1
(Black)
CJT2 DT-T 6 Joint connector H9 G-1
CJW DT-T 6 Joint connector F-7
CK1 YAZAKI 6 Bulb breakage check switch M2 F-9
CLTP PACKARD 2 Cooling water temperature sen- AE8 A-1

sor
CM DT-T 8 Lighting switch, passing switch, turn Q8 B-2
(Green) switch
CN3 DT-T 2 Input shaft speed sensor AC9 M-8
CN4 DT-T 2 Intermediate shaft speed sensor AC9 M-8
CN5 DT-T 2 Output shaft speed sensor AD7 M-8 G-2 K-4
CN6 DT-T 2 Solenoid for transmission 1st clutch AB9 M-6
HD465-7, HD605-7 20-347

➄
Address
CN7 DT-T 2 Fill switch for transmission 1st clutch AB9 N-6
CN8 DT-T 2 Solenoid for transmission 2nd clutch AB9 M-6
CN9 DT-T 2 Fill switch for transmission 2nd clutch AA9 N-6
CN10 DT-T 2 Solenoid for transmission R clutch AA9 M-6
CN11 DT-T 2 Fill switch for transmission R clutch AA9 N-6
CN12 DT-T 2 Solenoid for transmission 3rd clutch AA9 M-6
CN13 DT-T 2 Fill switch for transmission 3rd clutch AA9 N-6
CN14 DT-T 2 Solenoid for transmission 4th clutch AA9 M-5
CN15 DT-T 2 Fill switch for transmission 4th clutch Z9 N-5
CN16 DT-T 2 Solenoid for transmission L clutch Z8 M-7
CN17 DT-T 2 Fill switch for transmission L clutch Z8 N-6
CN18 DT-T 2 Solenoid for transmission H clutch Y8 M-7
CN19 DT-T 2 Fill switch for transmission H clutch Y7 N-7
CN20 DT-T 2 Solenoid for torque converter lockup Z8 M-7

clutch
CN21 DT-T 2 Fill switch for torque converter lockup
clutch Z8 N-7
CN22 DT-T 3 Torque converter intermediate pres- Z5 M-8

sure sensor
CN23 DT-T 2 Torque converter oil temperature AA5 M-7
sensor
CN24 DT-T 2 Transmission valve oil temperature AC5 M-7
sensor
CNS1 DT-T 12 Intermediate connector H-8
(Brown)
CNS2 DT-T 12 Intermediate connector B-9 B-2 H-8
(Green)
CNS3 DT-T 12 Intermediate connector A-9 E-7
(Black)
COM One-pin
connector 1 Air conditioner wiring harness M3 C-7
D01 DT-T 2 Diode V8 L-5 C-9 F-8 F-8 I-9
D02 DT-T 2 Diode W8 A-1 F-1
D03 DT-T 2 Diode W8 F-1
D04 DT-T 2 Diode M6 A-8
D05 DT-T 2 Diode W8 A-1 E-1
D07 DT-T 2 Diode P2 I-9
D08 DT-T 2 Diode W8 K-5 C-9 F-8 F-8 I-9
DL DT-T 12 Intermediate connector X6

(Black)
DPC1 AMP070 20 Machine monitor P8 I-9 E-9 C-1 A-7
DPC2A AMP070 18 Machine monitor P1 A-6
DPC2B AMP070 12 Machine monitor P1 C-1 A-6 F-1
DPC3A AMP070 18 Machine monitor P8 A-5
DPC4 AMP070 12 Machine monitor Q1 I-9 E-9 D-9 A-5
20-348 HD465-7, HD605-7

➄
Address
DPC6 AMP040 8 Machine monitor O7
DPC7 X 4 Software rewriting connector N3

(Machine monitor)
DSL — 1 Door switch (Left) F1
DSR — 1 Door switch (Right) T2
DT7 DT-T 12 Intermediate connector T2 D-2 F-1
DT8 DT-T 4 Intermediate connector J2
E Terminal 1 Emergency steering motor L-9
E01 Terminal 1 Alternator AE7 H-1 N-3 L-4 K-3 N-7
E02A DT-T 2 Starting motor AH1 H-2 M-3
E02B DT-T 2 Starting motor AH1 G-2 M-2
E03 DT-T 2 Engine speed sensor AF1 N-3
E04 DT-T 2 Oil level switch (Optional) AH5 M-3
E05 Terminal 1 Oil filter switch C2 H-9
E06 Terminal 1 Alternator AE6, H-1 N-4

AF1
E07 DT-T 2 Compressor AF8 N-7
E08 DT-T 2 Diode AG9
E09 Terminal 1 Alternator AE6 H-1 N-3
E10 Terminal 1 Grounding AG9
E11A Terminal 1 Heater relay AJ9 F-3 N-5
E11B Terminal 1 Ribbon heater AH9 F-2 N-4
E12A Terminal 1 Heater relay AJ9 F-3 N-4
E12B Terminal 1 Ribbon heater AG9 F-1 N-4
E13A DTHD 1 Intermediate connector AG1 I-2 K-5

(#4)
E13B DTHD 1 Intermediate connector AG1 H-2 K-5
(#4)
E15 Terminal 1 Grounding AI2 G-1 M-3
E16A Terminal 1 Grounding AI9 F-3 N-5
E16B Terminal 1 Grounding AH9 F-2 N-4
E17A DT-T 2 Diode AJ8 F-3 N-5
E17B DT-T 2 Diode AJ8 F-2 N-4
E2B DT 2 Diode AE5 A-3
ECM A DRC26 40 Engine controller AG5 A-8 L-1 K-8 M-4
ECM B DRC26 40 Engine controller AG9 C-8 L-1 K-8 M-4 B-3
EG4 DT-T 12 Intermediate connector V9

(Brown)
ENG DT-T 8 Intermediate connector AJ7 H-2 H-3 J-7 J-3 M-7
(Gray)
ER Terminal 1 Grounding C9, C8, I-1 J-8 H-8 J-7 M-8
E9, G9
HD465-7, HD605-7 20-349

➄
Address
ER1 Terminal 1 Grounding P1 D-8 F-7
ER2 Terminal 1 Grounding X7 H-6 A-8 C-1 B-7 F-1
ER3 Terminal 1 Grounding O2
FBC M 6 Front brake cutting switch N3 G-9
FL01 DT-T 2 Radiator water level sensor B3 H-9
FL04 YAZAKI 2 Washer motor B3 M-1
FL05 DT-T 2 Air conditioner dual switch B2 L-1
FLB — 1 Flasher R1 A-4
FLL — 1 Flasher R1 A-4
FLTP PACKARD 2 Fuel temperature sensor AF9 A-1
FOG M 6 Fog lamp switch (Optional) N1 C-9
FR01 DT-T 2 Air cleaner clogging sensor B7 G-9
FS2 One-pin 2 Spare terminal X6

connector
connector
FS4 One-pin
connector 2 Spare terminal X7

connector
FS8 One-pin 2 Spare terminal X6 J-4
connector
FSO– Terminal 1 Fuel shut-off valve – AE7 E-1
FSO+ Terminal 1 Fuel shut-off valve + AE7 E-1
FUA Terminal — Fuse box (30 A) C9 K-2 L-9 I-9 L-9 N-8
FUB Terminal — Fuse box (120 A x 2) C9 K-1 L-9
G One-pin 1 Lamp (Optional for payload meter) — I-9

connector
G One-pin 1 Lamp (Optional for payload meter) — H-1
connector
G21 Terminal 1 Grounding S1 B-7
GND Terminal 1 Engine block GND AF8 E-2 K-1 L-8 M-4
H01 DT-T 2 Steering flow switch K3
H10 One-pin 1 Heater unit M4

connector
H20 One-pin 1 Heater unit M4
connector
HAZ M 6 Hazard switch O7 G-9
HEAT DT 2 Heater control AJ7 F-6 J-2
HEPC DT-T 2 Hoist EPC valve L5 L-2
HES Terminal 1 Grounding —
HN One-pin 1 Horn switch Q8 D-9

connector
HN1A — 1 Horn valve A4 L-9
HN1B — 1 Horn valve A4 L-9
20-350 HD465-7, HD605-7

➄
Address
HN2A — 1 Horn valve A4
HN2B — 1 Horn valve A3
HSL DT-T 4 Intermediate connector V3 D-1
HSL DT-T 4 Hoist lever potentiometer V3 D-1
HSOL DT-T 3 Hoist selector valve L5 L-2
HTA DT-T
(Gray) 8 Intermediate connector L6 I-8 J-3
HTB DT-T 8 Intermediate connector L6 I-8 K-3 J-4 M-2

(Black)
IMPR PACKARD 3 Intake air pressure sensor AF8 B-1
IMTP PACKARD 2 Intake air temperature sensor AF8 B-1
J01 HD30 9 Intermediate connector I2 G-4 F-6 H-7 G-7 I-6
J02 HD30 31 Intermediate connector I2 G-3 F-6 H-7 G-6 I-6 C-7
J03 HD30 31 Intermediate connector I2 F-6 H-6 G-5 I-5 C-7
J04 HD30 31 Intermediate connector H1, H-5 G-4 I-5 C-6

AN6
J05 HD30 31 Intermediate connector H1, F-5 H-4 G-4
AN6
J07 HD30 14 Intermediate connector H1 F-5 H-3 G-4 C-5
J08 HD30 31 Intermediate connector G1 F-5 C-4
J09 HD30 31 Intermediate connector G1 G-6 F-4 H-4 I-5 C-4
J10 HD30 31 Intermediate connector G1 G-4 F-4 H-3 G-3 I-5 C-3
JC01 DT 6 Joint connector AI6 A-4
JC02 DT (Black) 8 Joint connector AI5 A-5
JC03 DT (Black) 8 Joint connector AH5 A-5
JC04 DT (Black) 8 Joint connector AG5 A-6 K-1 L-7 M-4
JC11 DT 6 Joint connector AG5 E-9 K-1
JC12 DT 6 Joint connector AH5 E-9
JC13 DT (Black) 8 Joint connector AI5 F-9 K-1 L-7
JC14 DT (Black) 8 Joint connector AI6 G-9 K-1 L-7 M-3 A-2
JC15 DT 6 Joint connector AI6 H-9 L-1 L-6 M-3
JCA DT-T 8 Joint connector X5 E-1

(Black)
JCB DT-T 8 Joint connector X5 K-6 C-1 A-1 C-1 G-1
(Black)
JCC DT-T 8 Joint connector X5 K-6 B-1 A-2 C-1 G-1
(Black)
JCD DT-T
(Black) 8 Joint connector X4 K-6 B-1 A-1 C-1 G-1
DT-T
JCE (Black) 8 Joint connector X4 K-7 B-1 A-2 C-1 G-1
JCF DT-T
(Black) 8 Joint connector S9 J-8 D-1 A-3 E-1 H-1
JCG DT-T 8 Joint connector V3 K-8 A-3 F-1 F-1 I-1

(Black)
JT1 DT-T 6 Joint connector AD7 J-1
HD465-7, HD605-7 20-351

➄
Address
JT2 DT-T 6 Joint connector AD7 J-1
LINK DT 6 Data link crossover AJ6 F-7 J-3 K-7
LKO DT-T 2 Intermediate connector U3 D-1
LKO DT-T 2 Lever kick-out solenoid V3 D-1
LP DT (Gray) 12 Intermediate connector I2 H-8 K-2
LS M 3 Rheostat M1 D-9
M Terminal 1 Emergency steering motor K-9
MON1 One-pin
connector 1 Rear view monitor (Optional) N7 I-9
MON2 One-pin 1 Rear view monitor (Optional) N7 I-9

connector
MON3 One-pin 1 Rear view monitor (Optional) O7 I-9
connector
MS11 M 1 Model selection connector U9 A-4
(Transmission controller)
MS32 M 1 Model selection connector V3 A-4
OLPR PACKARD 3 Engine oil pressure sensor AE5 B-1
OP1 M 1 Machine monitor setting connector M8, A-5

N9
N9
O9
M8,
OP4 M 1 Machine monitor setting connector O9 A-5
OP5 M 1 M8,
Machine monitor setting connector O9 A-5
OP6 M 1 Machine monitor setting connector N8, A-5

O8
OP7 M 1 Machine monitor setting connector N8, A-4
O8
OPS DT-T 2 Seat heater T2
PL01 M 2 Left head lamp (LOW) D1 J-1
PL02 M 2 Left head lamp (HIGH) D2 J-1
PL03 One-pin 1 Clearance lamp E1 K-1

connector
PL04 One-pin 1 Clearance lamp E1 K-1
connector
PL05 One-pin 1 Turn signal E1 K-1
connector
PL06 One-pin 1 Fog lamp (Optional) D1 J-1
connector
PL07 Terminal 1 Grounding C2 K-1
PM1 MIC 21 VHMS wiring harness T9 D-8, F-7,

E-9 D-7 H-7
PM3 DT-T 3 Pitch angle sensor X7 A-4
PM4 S (Natural 16 VHMS wiring harnes T9 I-8 E-7 D-8 C-8 F-6,
color) H-6
20-352 HD465-7, HD605-7

➄
Address
PM5 MIC 13 Payload meter controller T9 E-9 A-9 G-8
PM6 AMP040 12 Payload meter controller U9 I-8 E-9 D-9 A-9 G-8
PM7 AMP 9 VHMS wiring harnes H-8
PM7 AMP 9 Payload meter controller N7
PM8 BENDIX 5 Connector N7 K-5
PM9 MIC 21 VHMS wiring harness T9 E-9 H-7
PM10 S (Natural 16 VHMS wiring harnes T9 E-9 H-6

color)
PM11 MIC 21 Intermediate connector V9
PMLA DT-T 12 Intermediate connector H9 I-3

(Gray)
PMPR PACKARD 3 Fuel pump pressure sensor AF5 C-1 I-7
PMRA DT-T 6 Intermediate connector D8
POW HD30 21 Intermediate connector AJ7 F-4 H-4 J-7
PR01 M 2 Right head lamp (LOW) A5 K-9
PR02 M 2 Right head lamp (HIGH) A4 J-9
PR03 One-pin 1 Clearance lamp A5 K-9

connector
PR04 One-pin 1 Clearance lamp A5 K-9
connector
PR05 One-pin 1 Turn signal A5 K-9
connector
PR06 One-pin 1 Fog lamp (Optional) A6 J-9
connector
PR07 Terminal 1 Grounding A4 K-8
PSOL DT-T 2 Parking brake solenoid L6 L-3
PSW DT-T 2 Parking brake switch K3 L-3
PUMP PACKARD 3 Fuel pump actuator AF5 D-1

One-pin
PWL connector 1 Power window motor (Left) I2 F-1
PWM M 6 Power mode switch M4 G-9
PWR One-pin 1 Power window motor (Right) C7 F-1

connector
R One-pin
connector 1 Lamp (Optional for payload meter) J-9
R One-pin 1 Lamp (Optional for payload meter) H-1

connector
R01 Relay 5 Engine starting relay AB4 G-7 B-2
R02 Relay 5 Transmission Neutral relay AB3 B-2 A-8
R03 Relay 5 Parking brake relay AB3 A-9
R04 Relay 5 Brake lamp relay (RL) AB3 D-1
R05 Relay 6 Backup lamp, buzzer relay AB2 B-1 D-1
R06 Relay 6 Fog lamp relay AC4 D-1
R07 Relay 5 AISS relay AB4 H-8
R08 Relay 5 Brake lamp relay (CTR) AB3 E-1
HD465-7, HD605-7 20-353

➄
Address
R09 Relay 5 Brake lamp timer relay AB2 A-9 E-1
R10 Relay 5 PLM GDL relay AC4 A-7
R11 Relay 5 Horn relay AC4 D-1
R14 Relay 5 Brake cutting relay AB4 A-8
R15 Relay 5 Transmission cutting relay A2 B-2
R16 Relay 6 Hazard relay 1 AB1 C-1
R17 Relay 5 Hazard relay 2 AC1 C-1
R19 Relay 5 Parking brake safety relay AC4 A-8
R21 Relay 6 Side lamp relay AC4 A-6
R22 Relay 5 Rotary lamp relay AD3 B-1
R25 YAZAKI 11 Power window relay AC1 B-1
R29 Relay 5 Head lamp Hi relay AD2 C-1
R30 Relay 5 Head lamp Lo relay AD1 B-1
R32 Relay 5 Dust indicator relay AC1 B-3
R33 Relay 6 Parking brake manual switch R9 E-8
R34 YAZAKI 7 Power window switch (Left) S1 H-9
R35 YAZAKI 7 Power window switch (Right) S9 H-9
R37 Relay 5 Auto preheater relay AD3 G-8 B-3
R40 Relay 6 Payload meter relay (Optional) AD2 A-6
R43 Relay 5 Green outside pilot lamp relay of AD2 A-5

payload meter
Yellow outside pilot lamp relay of
R44 Relay 5 payload meter AD2 A-5
R45 Relay 5 Red outside pilot lamp relay of

payload meter AD1 A-5
RAD YAZAKI 9 AM/FM radio O2
RAIL PACKARD 3 Fuel rail actuator AF5 D-1
RDC YAZAKI 9 Cassette stereo O2
RE1 YAZAKI 2 Resistor S9 C-9 A-8
RE2 YAZAKI 2 Resistor S9 A-7
RE3 YAZAKI 2 Resistor P8 F-9
RE4 YAZAKI 2 Resistor P8 F-9
RESW DT-T 2 Retarder switch L4 L-1 N-1
RETV DT-T 2 Retarder valve L4 L-1
RL YAZAKI 2 Room lamp E9
RL2 One-pin 1 Room lamp 2 G9

connector
RP DT-T 6 Intermediate connector A6 K-8
RPR PACKARD 3 Fuel rail pressure sensor AI6 C-1
20-354 HD465-7, HD605-7

➄
Address
Con- Type Num-
3-dimen-
RT2 Terminal 1 Emergency steering timer M4
RTL DT-T 6 Retarder potentiometer P8 C-9 C-8
S01 DT-T 2 Service brake switch B7 G-2 N-2
S02 DT-T 2 Secondary brake switch E9 G-2 N-2
S03 DT-T 2 Front brake cutting solenoid (Optional) E9 G-2
S04 DT-T 2 Auto suspension solenoid 1 (Optional) F9 H-2
S05 DT-T 2 Auto suspension solenoid 2 (Optional) F9 H-1
SBS DT-T 2 Seat belt switch U2 F-1
SDE M 6 Side lamp switch (Optional) N2 A-7
SF1 DT-T 12 Shift lever R9 B-9 B-2 H-9

(Green)
SF2 DT-T 2 Shift lever Q9
SIG HD30 31 Intermediate connector AJ7 F-6 H-4 J-7 J-5 B-3
SLG Terminal 1 Grounding C8 I-8
SLG Terminal 1 Grounding J2 I-2
SLL M 1 Side lamp (Optional) J2 G-2
SLR M 1 Side lamp (Optional) C7 J-9
S-NET MS3102A
14S 5 S-NET monitor T1 A-9
SP1 PACKARD 2 Engine speed sensor (Master) AJ8 A-1
SP2 PACKARD 2 Engine speed sensor (Backup) AJ8 A-1
SPA1 DT-T 4 Spare connector 1 C-6
SPA2 DT-T 12 Spare connector 2 C-5
SPA3 DT-T 6 Spare connector 3 F1
SPL YAZAKI 2 Speaker (Left) G9
SPR YAZAKI 2 Speaker (Right) F9
SR2 X 3 Steering speed sensor P1 F-9
SR3 X 2 Pitch angle sensor X7 B-1
SUFL DT-T 3 Suspension oil pressure sensor(FL) H1 H-1 K-5

(Optional)
SUFR DT-T 3 Suspension oil pressure sensor(FR) B7 G-9 K-6
(Optional)
SURL DT-T 3 Suspension oil pressure sensor(RL) L8 K-5 K-5
(Optional)
SURR DT-T 3 Suspension oil pressure sensor(RR) J9 K-5 K-5
(Optional)
T01 DT-T 2 Fuel level gauge sensor G9 I-9
T02 DT-T 6 Retarder oil temperature sensor H9 J-8
HD465-7, HD605-7 20-355

➄
Address
Con- Type Num-
3-dimen-
T05 Terminal 1 Grounding I9 K-1
T1 Terminal 1 Grounding AC9 I-3
TEST One-pin 1 TEST switch V8 F-5

connector
TG One-pin 1 Tachograph S9
connector
TG2 One-pin 1 Tachograph S9
connector
TIMG PACKARD 3 Timing rail actuator AG9 D-1
TM2 HD30 21 Intermediate connector AD8 H-5 J-4
TM3 HD30 31 Intermediate connector AD8 H-5
TMF DT-T 2 Transmission oil filter sensor J3 I-9
TPR PACKAR 3 Timing rail pressure sensor AI6 C-1

D
TR — 6 Brake lamp timer X7 E-1
VHM DT-T 8 Intermediate connector C2

(Black)
WFM M 6 Front wiper motor Q1 A-4
WFR Relay 6 Front wiper relay R1 A-3
WPS DT-T
(Black) 12 Wiper switch Q8 B-3
WSRL DT-T 2 Wheel speed sensor (RL) K1 B-9
WSRR DT-T 2 Wheel speed sensor (RR) K1 C-9
VHMS controller related
CAN1 DT-T 3 VHMS intermediate connector AU2 E-5
DLSW Terminal 1 Ground level download box A01 A-7
EG4 DT-T 12 VHMS intermediate connector AV3 E-6
GDL DT-T 12 Ground level download box inter- AP4 A-6

mediate connector
GR1 Terminal 1 Ground level download box AP2 A-7
GR2 Terminal 1 Ground level download box AP2 A-7
HM-12 DT-T 3 Blow-by sensor AM6 B-4
HM-21A DT 2 Exhaust temperature sensor AN8 B-2
HM-21B DT 2 Exhaust temperature sensor AN7 B-2
HM-22A DT 2 Exhaust temperature sensor - amp AR8 J-2

intermediate connector
HM-22B DT 2 Exhaust temperature sensor - amp AQ7 J-2
HM-23A DT-T 3 VHMS - exhaust temperature amp AR8 J-2
VHMS - exhaust temperature amp
HM-23B DT-T 3 intermediate connector AQ7 J-2
HM-31 DT 2 Engine oil temperature sensor AN1 B-4
HM-35 DT 2 Ambient temperature sensor AM1 B-8
HM50 DT-T 3 Short connector AU2 H-8
HM55 DT-T 3 Short connector AQ6 I-8
20-355-1 HD465-7, HD605-7

➄
Address
Con- Type Num-
3-dimen-
HM81 M 8 VHMS - Orbcomm controller inter- AT2 L-3
mediate connector
HM-2130 Yasaki 2 Resistor AQ2 H-8
HM-2140 Yasaki 2 Resistor AR2 H-8
HM-CN1 AMP070 20 VHMS controller AS8 I-8
HM-CN2A AMP070 18 VHMS controller AT7 J-8
HM-CN2B AMP070 12 VHMS controller AU7 J-8
HM-CN3A AMP070 18 VHMS controller AT8 J-8
HM-CN3B AMP070 12 VHMS controller AS8 K-8
HM-CN4A AMP070 14 VHMS controller AU7 K-8
HM-CN4B AMP070 10 VHMS controller AT8 L-8
LM1 Terminal 1 Ground level download box lamp

terminal AP3 B-7
LM2 Terminal 1 Ground level download box lamp AP3 B-7

terminal
ORB-A AMP070 14 Orbcomm controller AS2 K-2
ORB-B AMP070 10 Orbcomm controller AS2 L-2
PDL MS 5 Ground level download box PLM AP2 A-7

connector
PLM MS 5 PLM II download connector AQ6 K-4
PM1 MIC 21 PLM II intermediate connector AV3 F-7,

H-7
PM4 S 16 PLM II intermediate connector AU7 F-6,
H-6
PM11 MIC 21 VHMS intermediate connector AV6 E-5
Ambient temperature sensor
SPA1 DT-T 4 intermediate connector AO6 C-6
SPA2 DT-T 12 Ground level download box AO6 C5

VDL MS 5 Ground level download box VHMS AP3 A-7
connector
VHM DT-T 8 Blow-by, oil temperature sensor in- AM6 B-4
termediate connector
VHMS MS 5 VHMS download connector AT2 K-4
WAKE Terminal 1 Ground level download box AP2 A-7
HD465-7, HD605-7 20-355-2

➄
TROUBLESHOOTING CONNECTOR ARRANGMENT LOCATION
CONNECTOR ARRANGEMENT LOCATION
20-356 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-357

➄
VHMS control related

(1/2)
20-362 HD465-7, HD605-7

➁
(2/2)
HD465-7, HD605-7 20-363

➁
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(ENG MODE)
Electrical system diagram related engine control ...................................................................................... 20-404

Information in troubleshooting table ............................................................................................................ 20-406
[C111KT] Abnormality in engine controller memory ............................................................................ 20-408
[C112LK] Abnormality in timing rail actuator ....................................................................................... 20-408
[C113KZ] Abnormal current in timing rail actuator system .................................................................. 20-409
[C115KZ] Abnormality in engine speed sensor 2 systems .................................................................. 20-410
[C116KX] Abnormally high level in timing rail pressure sensor system ............................................... 20-412
[C117KX] Abnormally low level in timing rail pressure sensor system ................................................ 20-413
[C118KX] Abnormally high level in fuel pump pressure sensor system ............................................... 20-414
[C119KX] Abnormally low level in fuel pump pressure sensor system ................................................ 20-415
[C121LC] Abnormality in engine speed sensor 1 systems .................................................................. 20-415
[C122KX] Abnormally high level in boost pressure sensor system ...................................................... 20-416
[C123KX] Abnormally low level in boost pressure sensor system ....................................................... 20-417
[C131KX] Abnormally high level in throttle sensor system .................................................................. 20-418
[C132KX] Abnormally low level in throttle sensor system .................................................................... 20-420
[C135KX] Abnormally high level in engine oil pressure sensor system ............................................... 20-421
[C141KX] Abnormally low level in engine oil pressure sensor system ................................................ 20-422
[C143ZG] Lowering of engine oil pressure ........................................................................................... 20-422
[C144KX] Abnormally high level in engine coolant temperature sensor system .................................. 20-423
[C145KX] Abnormally low level in engine coolant temperature sensor system ................................... 20-424
[C148KX] Abnormality in FM throttle: Out of input signal range .......................................................... 20-425
[C151NS] Rise of engine coolant temperature ..................................................................................... 20-426
[C153KX] Abnormally high level in air intake temperature sensor system .......................................... 20-427
[C154KX] Abnormally low level in air intake temperature sensor system ............................................ 20-428
[C221KX] Abnormally high level in atmospheric pressure sensor system ........................................... 20-429
[C222KX] Abnormally low level in atmospheric pressure sensor system ............................................ 20-430
[C234NI] Over-speed .......................................................................................................................... 20-430
[C254KZ] Abnormal voltage of fuel shut-off valve ................................................................................ 20-431
[C259FS] Abnormality in fuel shut-off valve ......................................................................................... 20-432
[C261NS] Abnormal rise of fuel temperature ....................................................................................... 20-432
[C263KX] Abnormally high level in fuel temperature sensor system ................................................... 20-433
[C265KX] Abnormally low level in fuel temperature sensor system ..................................................... 20-434
[C316KZ] Abnormal current of fuel pump actuator .............................................................................. 20-435
[C318LK] Abnormality in fuel pump actuator ....................................................................................... 20-436
[C346KT] Abnormality in power-down unit of engine controller ........................................................... 20-437
[C423L6] Abnormality in in-range of timing rail pressure sensor system ............................................ 20-439
[C431L4] Abnormality in idling validation switch system: See separate list (L4)
(Both signal voltages of 2 systems are sensed) ................................................................. 20-441
[C432L5] Error in idling validation process ( See separate list (L5)) ................................................ 20-443
[C441KK] Abnormally low level in battery voltage system .................................................................. 20-445
[C442KG] Abnormally high level in battery voltage system .................................................................. 20-445
[C451KX] Abnormally high level in fuel rail pressure sensor system ................................................... 20-446
[C452KX] Abnormally low level in fuel rail pressure sensor system .................................................... 20-447
[C455KZ] Abnormal current of fuel rail actuator .................................................................................. 20-448
HD465-7, HD605-7 20-401

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

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
20-404 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ENGINE CONTROL
HD465-7, HD605-7 20-405

➁
TROUBLESHOOTING [C132KX]
[C132KX] ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM
Action code Error code Controller code Abnormally low level in throttle sensor system
Trouble
E03 C132KX ENG (Engine controller system)
Contents of trouble • Signal voltage of throttle sensor (throttle potentiometer) circuit is below 0.30 V.
• Flashes caution lamp and turns on caution buzzer.
Action of controller
• Keeps engine speed at constant level.
Problem that
• Engine speed and output lower suddenly.
appears on machine
• Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring
mode.
Related information
(Code 31701: throttle potentiometer voltage)
• Method of reproducing error code: Turn starting switch ON.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard value
in normal state Carry out troubleshooting for erroe code [C131KX].
20-420 HD465-7, HD605-7

➁
[C135KX] ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM
Action code Error code Controller code Abnormally high level in engine oil pressure sensor system
Trouble
E01 C135KX ENG (Engine controller system)
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Action of controller • Flashes caution lamp and turns on caution buzzer.
Problem that
appears on machine
• Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information
• Method of reproducing error code: Start engine.
Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective engine oil pres-
1 sure sensor OLPR Voltage
(Internal trouble) Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har-
Wiring harness between ECMA (female) –
ness Resistance Max. 10 Ω
OLPR (female)
2 (Disconnection in wiring or
defective contact in connec- Resistance Max. 10 Ω
OLPR (female)
tor)
Resistance Max. 10 Ω
Possible causes OLPR (female)
and standard value ★ Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
Short circuit of wiring harness between ECMA
Short circuit in wiring har- (female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
ness
3 Short circuit of wiring harness between ECMA
(with another wiring har-
ness) (female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
Short circuit of wiring harness between ECMA
(female) – OLPR (female) with wiring Resistance Min. 1 MΩ
harness around it
4 Defective engine controller ECMA Voltage
Between – 4.75 – 5.25 V
Between – 0.42 – 0.58 V
Circuit diagram related to engine oil pressure sensor
HD465-7, HD605-7 20-421

➁
[C148KX] ABNORMALITY IN FM THROTTLE: OUT OF INPUT SIGNAL RANGE
Action code Error code Controller code

Trouble Abnormality in FM throttle: Out of input signal range
E03 C148KX ENG
Contents of trouble • The frequency of the FM throttle is below 150 Hz or above 400 Hz.
• The controller turns the alarm lamp and alarm buzzer on.
• The throttle sensor signal is conformed to the idling validation switch (In idling: 0%, Off idling: 35%).
Problem that
• The engine speed is kept at low idling or 1,500 rpm (Throttle: 35%).
appears on machine
Related information

1) Turn the starting switch OFF.
Disconnection in wiring har- 2) Disconnect connector ECM.
ness 3) Connect T-adapter.
1
(Disconnection or defective
Wiring harness between ECMB (female)
contact) Resistance Max. 10 Ω
and ATC3A (female)
2) Disconnect connectors ECMB and ATC3A.
3) Connect T-adapter.
Grounding fault in wiring
2 Resistance value between
harness Wiring harness between
ECMB (female) , ATC3A
Possible causes ECMB (female) and Min. 1 MΩ
(female) and chassis
and standard value ATC3A (female)
ground
in normal state
2) Disconnect connector ATC3A.
3) Insert T-adapter.
Transmission controller de- 4) Connect the connector.
3
fective 5) Turn the starting switch ON.
Between ATC3A (male) and chassis
Frequency 170 – 380Hz
ground
1) Connect all the connectors.
2) Turn the starting switch ON.
4 Engine controller defective
• Check that the error code disappears.
★ If the error code does not disappear, replace the engine controller.
Circuit diagram related to engine abnormality in FM throttle
HD465-7, HD605-7 20-425

➁
TROUBLESHOOTING [C346KT]
[C346KT] ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER
Action code Error code Controller code Abnormality in power-down unit of engine controller
Trouble
E03 C346KT ENG (Engine controller system)
Contents of trouble • Data recorded in power-down unit of engine controller has error.
Action of controller • Flashes caution lamp and turns on caution buzzer.
Problem that • Power-down data (maintenance information, current controller information, engine operating hours,
appears on machine etc.) are lost.
• Charge level of battery can be checked in monitoring mode.
Related information (Code: 04301)
• Method of reproducing error code: Turn starting switch ON.

If fusible link is broken, circuit probably has short circuit with chassis
1 Defective fusible link (34 A)
ground.
Defective fuse
2 If fuse is broken, circuit probably has short circuit with chassis ground.
(FS1-1, FS1-4)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between ECMB (female) –
BT2- outlet
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between ECMA (female) , Resistance Max. 10 Ω
tor) – BT2- outlet
Wiring harness between FS1 inlet – fusible link
(FUA) – battery relay terminal B
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard value without turning starting switch ON.
in normal state
Short circuit of wiring harness between ECMB
(female) – BT2- outlet with wiring har- Resistance Min. 1 MΩ
Short circuit in wiring harness around it
ness
4 Short circuit of wiring harness between ECMA
(with another wiring har-
ness) (female) , – BT2- outlet with wiring Resistance Min. 1 MΩ
harness around it
Wiring harness between FS1 inlet – fusible link
– battery relay terminal B with wiring harness Resistance Min. 1 MΩ
around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB , , –
17.3 – 34.7 V
ECMA ,
HD465-7, HD605-7 20-437

➁
TROUBLESHOOTING ENG-2
b) Preheating is actuated even under non-actuation conditions for preheating
Action code Error code Controller code Failure in preheating

Trouble b) Preheating is actuated even under non-actuation conditions
Not set Not set ENG for preheating
Contents of trouble • Preheating is actuated even under non-actuation conditions for preheating.
Action of controller • None in particular.
Problem that
• Preheating is actuated even under non-actuation conditions for preheating.
appears on machine
• If any error code related to the engine controller or transmission controller is indicated, perform trou-
Related information
bleshooting for it.

2) Disconnect connectors E11A, E12A, E11B, and E12B.
3) Check the disconnected connectors.
Between E11A and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12A and opposite ON
Intake air heater relay defec- terminal of relay switch
1 When relay is
tive Resistance Min. 1 MΩ
OFF
Between E11B and chassis ground Resistance 19 – 25 Ω
When relay is
Between E12B and opposite ON
terminal of relay switch When relay is
Resistance Min. 1 MΩ
OFF
2) Disconnect the connector.
Possible causes Wiring harness between Voltage between ECMA (fe-
and standard value ECMA (female) and R37 male) , R37 (female) Max. 1 V
in normal state Short circuit with power (female) and chassis ground
2
source in wiring harness Wiring harness between Voltage between R37 (fe-
R37 (female) and E11A, male) , E11A, E11B and Max. 1 V
E11B chassis ground
Wiring harness between Voltage between AC5A (fe-
AC5A (female) and HES male) , HES and chassis Max. 1 V
(★) ground
Measure only on E12A side for wiring harness marked with (★).
2) Disconnect connector ECMB.
4) Connect the connector.
6) Engine water temperature: Max. 0 °C
3 Engine controller defective
In __ seconds after starting switch
is turned ON (During preheating Voltage 20 – 30V
Between time)
ECMA
and , __ seconds or more after starting
switch is turned ON (After preheat- Voltage Max. 1 V
ing time)
20-462 HD465-7, HD605-7

➁
TROUBLESHOOTING FOR TRANSMISSION
CONTROLLER SYSTEM
(TM MODE)
Electrical system diagram related to transmission control .......................................................................... 20-503

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

(7)
TESTING AND ADJUSTING INVERTED TYPE
TROUBLESHOOTING REAR SUSPENSION CYLINDER
[DDTGKA] Lockup clutch fill switch: Disconnection (KA) .................................................................... 20-557

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

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL

★ For details of this page, see page 90-19.
HD465-7, HD605-7 20-503

➁
TROUBLESHOOTING [1380MW]
[1380MW] LOCKUP CLUTCH • SLIP (MW)
Action code Error code Controller code Lockup clutch • Slip (MW)
Trouble (Command is Holding pressure, fill switch is ON, and slip is
E03 1380MW TM sensed)
• When a signal is output to the lockup clutch ECMV, the value calculated from the signals of the engine
Contents of trouble speed sensor, transmission input shaft speed sensor, transmission intermediate shaft speed sensor,
and transmission output shaft speed sensor is abnormal.
• The controller keeps the current gear speed and turns the lockup operation OFF.
• If the shift lever is set in the "N" position, the controller keeps the gear in Neutral.
Problem that • The lockup operation is reset and the gear cannot be shifted.
appears on machine • If the shift lever is set in the "N" position, the machine cannot start until it is stopped.
• This failure can be checked in the monitoring function (Code: 31519, 31609, 31619).
Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

2) Disconnect connector CN20.
Lockup clutch ECMV defec- 3) Connect T-adapter.
1
tive Between CN20 (male) and Resistance 5 – 15 z
Between CN20 (male) , and chassis
Resistance Min. 1 Mz
ground
2) Disconnect connector ATC2 and CN10.
Disconnection in wiring har- 3) Connect T-adapter.
Possible causes
ness
and standard value 2 Wiring harness between ATC2 (female) and
(Disconnection or defective Resistance Max. 1 z
in normal state CN20 (female)
contact)
Wiring harness between ATC2 (female) and
Resistance Max. 1 z
CN20 (female)
Defective sensing by speed
3 • Troubleshooting by the error codes of DL**KA, and DL**LC.
sensor
2) Disconnect connector ATC2.
Transmission controller de- 3) Connect T-adapter.
4
fective
Wiring harness between ATC2 (female)
Resistance 5 – 15 z
and ATC2 (female)
Related electrical circuit diagram
20-506 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15B0NX]
[15B0NX] CLOGGING OF TRANSMISSION OIL FILTER • CLOGGING (NX)

Trouble Clogging of transmission oil filter • Clogging (NX)
E01 15B0NX TM
• When the torque converter oil temperature is above 50°C, the signal circuit of the transmission clogging
Contents of trouble
sensor is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, dust may enter the transmission circuit.
appears on machine
• This failure can be checked in the monitoring function (Code: 33300).
Related information • After repairing the failure and confirming resetting of the machine, perform the initial learning of the
transmission controller, referring to TESTING AND ADJUSTING, "Inspection of machine monitor".

Clogging of transmission fil-
1 • Clean or replace.
ter
2) Disconnect connectors ATC5A and CN10.
Transmission filter clogging 3) Connect T-adapter.
2
sensor defective
Between TMF (male) Filter is normal. Resistance Max. 1 z
and Filter is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC5A, TNF, and CN-10.
Possible causes Disconnection in wiring har- 3) Connect T-adapter.
and standard value ness
3 Wiring harness between ATC5A (female)
in normal state (Disconnection or defective Resistance Max. 1 z
and TMF (female)
contact)
Wiring harness between CJH1 (female)
Resistance Max. 1 z
and TMF (female)
2) Disconnect connectors ATC5A and ATC3A.
Transmission controller de- 4) Connect conector.
4
Between ATC5A Filter is normal. Voltage Max. 1 V
and chassis ground Filter is clogged. Voltage 20 – 30 V
20-508 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15G0MW]
[15G0MW] R CLUTCH • SLIP (MW)
Action code Error code Controller code R clutch • Slip (MW)

E03 15G0MW TM sensed)
• When a signal is output to the R clutch ECMV, the value calculated from the signals of the transmission
Contents of trouble input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output shaft
speed sensor is abnormal.
Action of controller • The controller sets the gear in Neutral.
Problem that
• The gear is set in Neutral suddenly during travel and the machine cannot start again.
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure
control valve for a defect.

1 R clutch ECMV defective
Between CN10 (male) and Resistance 5 – 15 z
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-510 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15H0MW]
[15H0MW] HI CLUTCH • SLIP (MW)
Action code Error code Controller code Hi clutch • Slip (MW)

E03 15H0MW TM sensed)
• When a signal is output to the Hi clutch ECMV, the value calculated from the signals of the transmission
Problem that
• The gear is set in Neutral suddenly during travel.
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

1 Hi clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN18 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-511

(7)
TROUBLESHOOTING [15H0MW]
20-512 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15J0MW]
[15J0MW] LO CLUTCH • SLIP (MW)
Action code Error code Controller code Lo clutch • Slip (MW)

E03 15J0MW TM sensed)
• When a signal is output to the Lo clutch ECMV, the value calculated from the signals of the transmission
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

1 Lo clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN16 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-513

(7)
TROUBLESHOOTING [15J0MW]
20-514 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15K0MW]
[15K0MW] 1ST CLUTCH • SLIP (MW)
Action code Error code Controller code 1st clutch • Slip (MW)
E03 15K0MW TM sensed)
• When a signal is output to the 1st clutch ECMV, the value calculated from the signals of the transmis-
Contents of trouble sion input shaft speed sensor, transmission intermediate shaft speed sensor, and transmission output
shaft speed sensor is abnormal.
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

1 1st clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN6 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-515

(7)
TROUBLESHOOTING [15L0MW]
[15L0MW] 2ND CLUTCH • SLIP (MW)
Action code Error code Controller code 2nd clutch • Slip (MW)
E03 15L0MW TM sensed)
• When a signal is output to the 2nd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

1 2nd clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-516 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15M0MW]
[15M0MW] 3RD CLUTCH • SLIP (MW)
Action code Error code Controller code 3rd clutch • Slip (MW)
E03 15M0MW TM sensed)
• When a signal is output to the 3rd clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

1 3rd clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN12 (female)
sensor
4
fective
and ATC2 (female)
HD465-7, HD605-7 20-517

(7)
TROUBLESHOOTING [15N0MW]
[15N0MW] 4TH CLUTCH • SLIP (MW)
Action code Error code Controller code 4th clutch • Slip (MW)
E03 15N0MW TM sensed)
• When a signal is output to the 4th clutch ECMV, the value calculated from the signals of the transmis-
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

1 4th clutch ECMV defective
ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-518 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SBL1]
[15SBL1] R CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code R clutch solenoid • See separate list (L1)
Trouble
E03 15SBL1 TM (Command is OFF and fill switch is ON)
• When the output to the R clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
clutch is not disengaged.
Problem that
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 31516, 31606, 31616).

1 R clutch fill switch defective When dis-
Between CN11 (male) and engaged
chassis ground When en-
Resistance Max. 1 z
gaged
Possible causes
and standard value Grounding fault in wiring
in normal state 2 Resistance value be-
harness
Wiring harness between ATC5A tween ATC5A (female)
Min. 1 Mz
(female) and CN11 (female) , CN11 (female)
and chassis ground
Transmission controller de-
3 When dis-
fective Resistance Min. 1 Mz
Between ATC5A (female) and engaged
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-519

(7)
TROUBLESHOOTING [15SBMA]
[15SBMA] R CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code R clutch solenoid • Malfunction (MA)
E03 15SBMA TM sensed)
• When a signal is output to the R clutch ECMV, 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, transmission intermediate
shaft speed sensor, and transmission output shaft speed sensor is abnormal.
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the R clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN10 (female)
sensor
4
fective
and ATC2 (female)
20-520 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SCL1]
[15SCL1] HI CLUTCH SOLENOID • SEE SEPARATE LIST (L1)

Action code Error code Controller code Hi clutch solenoid • See separate list (L1)
Trouble
E03 15SCL1 TM (Command is OFF and fill switch is ON)
• When the output to the Hi clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Hi clutch fill switch defective When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-521

(7)
TROUBLESHOOTING [15SCMA]
[15SCMA] HI CLUTCH SOLENOID • MALFUNCTION (MA)

Action code Error code Controller code Hi clutch solenoid • Malfunction (MA)
E03 15SCMA TM sensed)
• When a signal is output to the Hi clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Hi clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN18 (female)
sensor
4
fective
and ATC2 (female)
20-522 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SDL1]
[15SDL1] LO CLUTCH SOLENOID • SEE SEPARATE LIST (L1)

Action code Error code Controller code Lo clutch solenoid • See separate list (L1)
Trouble
E03 15SDL1 TM (Command is OFF and fill switch is ON)
• When the output to the Lo clutch ECMV is turned OFF, the signal from the fill switch is kept ON and the
Contents of trouble
Problem that
appears on machine

1 Lo clutch fill switch defective When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-523

(7)
TROUBLESHOOTING [15SDMA]
[15SDMA] LO CLUTCH SOLENOID • MALFUNCTION (MA)

Action code Error code Controller code Lo clutch solenoid • Malfunction (MA)
E03 15SDMA TM sensed)
• When a signal is output to the Lo clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the Lo clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN16 (female)
sensor
4
fective
and ATC2 (female)
20-524 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SEL1]
[15SEL1] 1ST CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 1st clutch solenoid • See separate list (L1)
Trouble
E03 15SEL1 TM (Command is OFF and fill switch is ON)
• When the output to the 1st clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
the clutch is not disengaged.
Problem that
appears on machine

1 1st clutch fill switch defective When dis-
Between CN7 (male) and chas- engaged
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-525

(7)
TROUBLESHOOTING [15SEMA]
[15SEMA] 1ST CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 1st clutch solenoid • Malfunction (MA)
E03 15SEMA TM sensed)
• When a signal is output to the 1st clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 1st clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN6 (female)
sensor
4
fective
and ATC2 (female)
20-526 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SFL1]
[15SFL1] 2ND CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 2nd clutch solenoid • See separate list (L1)
Trouble
E03 15SFL1 TM (Command is OFF and fill switch is ON)
• When the output to the 2nd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

2nd clutch fill switch defec-
1 When dis-
tive Resistance Min. 1 Mz
Between CN9 (male) and chas- engaged
sis ground When en-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-527

(7)
TROUBLESHOOTING [15SFMA]
[15SFMA] 2ND CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 2nd clutch solenoid • Malfunction (MA)
E03 15SFMA TM sensed)
• When a signal is output to the 2nd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 2nd clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN8 (female)
sensor
4
fective
and ATC2 (female)
20-528 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SGL1]
[15SGL1] 3RD CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 3rd clutch solenoid • See separate list (L1)
Trouble
E03 15SGL1 TM (Command is OFF and fill switch is ON)
• When the output to the 3rd clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
Problem that
appears on machine

3rd clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-529

(7)
TROUBLESHOOTING [15SGMA]
[15SGMA] 3RD CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 3rd clutch solenoid • Malfunction (MA)
E03 15SGMA TM sensed)
• When a signal is output to the 3rd clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 3rd clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN12 (female)
sensor
4
fective
and ATC2 (female)
20-530 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SHL1]
[15SHL1] 4TH CLUTCH SOLENOID • SEE SEPARATE LIST (L1)
Action code Error code Controller code 4th clutch solenoid • See separate list (L1)
Trouble
E03 15SHL1 TM (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
Contents of trouble
Problem that
appears on machine

4th clutch fill switch defec-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-531

(7)
TROUBLESHOOTING [15SHMA]
[15SHMA] 4TH CLUTCH SOLENOID • MALFUNCTION (MA)
Action code Error code Controller code 4th clutch solenoid • Malfunction (MA)
E03 15SHMA TM sensed)
• When a signal is output to the 4th clutch ECMV, the signal from the fill switch is kept OFF and the value
Problem that
appears on machine
Related information • If the electric system is normal, check the hydraulic/mechanical system of the 4th clutch and pressure

ground
Possible causes
ness
contact)
Resistance Max. 1 z
CN14 (female)
sensor
4
fective
and ATC2 (female)
20-532 HD465-7, HD605-7

(7)
TROUBLESHOOTING [15SJL1]
[15SJL1] LOCKUP CLUTCH SOLENOID • 15SJ (L1)
Action code Error code Controller code Lockup clutch solenoid • 15SJ (L1)
Trouble
E03 15SJL1 TM (Command is OFF and fill switch is ON)
• When the output to the lockup clutch ECMV is turned OFF, the signal from the fill switch is kept ON and
Contents of trouble
• If the shift lever is set in the "N" position, the controller keeps the gear in neutral.

Lockup clutch fill switch de-
1 When dis-
Resistance Max. 1 z
gaged
Possible causes
harness
Min. 1 Mz
and chassis ground
3 When dis-
Resistance Max. 1 z
gaged
HD465-7, HD605-7 20-533

(7)
TROUBLESHOOTING [15SJMA]
[15SJMA] LOCKUP CLUTCH SOLENOID • 15SJ (MA)
Action code Error code Controller code Lockup clutch solenoid • 15SJ (MA)
Trouble
E03 15SJMA TM (Command is OFF, fill switch is ON, and slip is sensed)
• When a signal is output to the lockup clutch ECMV, the signal from the fill switch is kept OFF and the
Contents of trouble value calculated from the signals of the engine speed sensor, transmission intermediate shaft speed
sensor, and transmission output shaft speed sensor is abnormal.
Related information • If the electric system is normal, check the hydraulic/mechanical system of the lockup clutch and pres-
sure control valve for a defect.

Lockup clutch ECMV 3) Connect T-adapter.
1
defective Between CN20 (male) and Resistance 5 – 15 z
ground
2) Disconnect connector ATC5A and CN20.
Possible causes
ness
contact)
Resistance Max. 1 z
CN20 (female)
sensor
4
fective
and ATC2 (female)
20-534 HD465-7, HD605-7

(7)
TROUBLESHOOTING [AA10NX]
[AA10NX] AIR CLEANER ELEMENT • CLOGGING (NX)

Trouble Air cleaner element • Clogging (NX)
E01 AA10NX TM
Contents of trouble • The air cleaner clogging signal circuit is opened (disconnected from GND).
Problem that
• If the machine is used without repairing, the suction performance of the engine may be lowered.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 33200).

The dust indicator is not red. Air cleaner is normal.
1 Clogging of air cleaner
The dust indicator is red. Air cleaner is clogged.
2) Replace R32 with normal one.
Relay (R32)
No
When the dust indicator relay (R32) is re- is normal.
placed, is failure repaired? Relay (R32)
Yes
is defective.
2) Disconnect connector R32.
Dust indicator relay (R32) 3) Check the relay.
2
defective
Between R32 (male) and Resistance 200 – 400 z
3) Check the relay.
4) Apply voltage between R32 (male) and .
Apply 24 V between
Between R32 (male) and .
and Do not apply 24 V be-
Resistance Max. 1 z
tween and .
Possible causes 1) Turn the starting switch OFF.
and standard value 2) Disconnect connectors FR01.
in normal state Air cleaner clogging sensor 3) Connect T-adapter.
3
defective
Between FR01 (male) Air cleaner is normal. Resistance Max. 1 z
and Air cleaner is clogged. Resistance Min. 1 Mz
2) Disconnect connectors ATC3A and R32.
ness Wiring harness between ATC3A (female)
4 Resistance Max. 1 z
and R32 (female)
contact)
Wiring harness between ATC3A (female)
Resistance Max. 1 z
and R32 (female)
2) Disconnect connector R32 and FR01.
Grounding fault of wiring 3) Connect T-adapter.
5
harness Resistance value be-
Wiring harness between R32
tween R32 (female) Min. 1 Mz
(female) and FR01 (female) , FR01 (female)
2) Disconnect connectors ATC3A.
Transmission controller de- 4) Connect connector.
6
Between ATC3A Air cleaner is normal. Voltage 20 – 30 V
and Air cleaner is clogged. Voltage Max. 1 V
HD465-7, HD605-7 20-539

(7)
TROUBLESHOOTING [AB00MA]
[AB00MA] ALTERNATOR • MALFUNCTION (MA)
Action code Error code Controller code Alternator • Malfunction (MA)

Trouble
E03 AB00MA TM (Failure in battery charging circuit)
Contents of trouble • A generation signal is not input from the alternator while the engine is running.
Problem that • If the machine is used without repairing, the source voltage may lower so much that the machine cannot
appears on machine travel.

2) Disconnect connector alternator terminal R.
1 Alternator defective
Between alternator R and E Voltage 20 – 30 V
★ If the battery is deteriorated or used in a cold district, the voltage may
not rise for a while after the engine is started.
2) Disconnect connector ATC3B.
Disconnection in wiring har- Wiring harness between Voltage between ATC3B (fe-
20 – 30 V
Possible causes ness ATC3B (female) and al- male) and chassis ground
and standard value 2 (Disconnection or defective ternator terminal R Resistance Max. 1 Ω
in normal state contact) ★ If the battery is deteriorated or used in a cold district, the voltage may
Wiring harness between battery relay terminal
M and alternator terminal R
2) Disconnect connector ATC3B.
Transmission controller de- 4) Connect the connector.
3 5) Start the engine.
fective
Between ATC3B and chassis ground Voltage 20 – 30 V
★ If the battery is deteriorated or used in a cold district, the voltage may
HD465-7, HD605-7 20-541

➁
TROUBLESHOOTING [DDTPKA]
[DDTPKA] 4TH CLUTCH FILL SWITCH : DISCONNECTION (KA)
Action code Error code Controller code 4th clutch fill switch : Disconnection (KA)
Trouble (Command is Holding pressure, fill switch is OFF, and slip is not
E03 DDTPKA TM sensed)
• When the output to the 4th clutch EPOCV is turned ON, the clutch is engaged but the signal from the
Contents of trouble
fill switch is not turned ON.
• The controller keeps the current gear speed.
Problem that • The gear cannot be shifted.

4th clutch fill switch defec-
1 When dis-
tive Resistance Min. 1 MΩ
gaged
Possible causes Disconnection in wiring har- 2) Disconnect connectors ATC5A and CN15.
and standard value ness
2 3) Connect T-adapter.
in normal state (Disconnection or defective
Wiring harness between ATC5A (female)
and CN15 (female)
3 When dis-
fective Resistance Min. 1 MΩ
gaged
20-564 HD465-7, HD605-7

➁
TROUBLESHOOTING [DXH1KA]
[DXH1KA] DISCONNECTION IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of lockup clutch solenoid: Discon-
Trouble
E01 DXH1KA TM nection (KA)
Contents of trouble • When a signal is output to the lockup clutch ECMV, any current does not flow.
Action of controller • The controller turns the lockup operation OFF.
Problem that
• The lockup system does not operate.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 31519, 31609, 31619)

1
ground
2) Disconnect connectors ATC2 and CN20.
Possible causes
and standard value
in normal state ness Wiring harness between ATC2 (female)
and CN20 (female)
contact)
Resistance Max. 1 z
and CN20 (female)
3
fective
and ATC2 (female)
20-590 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DXH1KB]
[DXH1KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LOCKUP CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of lockup clutch solenoid: Short cir-
Trouble
E01 DXH1KB TM cuit (KB)
• When a signal is output to the lockup clutch ECMV, an abnormally large current flows, or some current
Contents of trouble
is flowing while the signal is OFF.
• The lockup system is reset and the gear cannot be shifted.
Problem that
• If the shift lever is set in the "N" position, the machine cannot start until it is stopped. (The machine
appears on machine
cannot start again, depending on the failure condition.)

1
ground
Possible causes Resistance value be-
and standard value Wiring harness between ATC2 (fe- tween ATC2 (female)
in normal state Short circuit in wiring har- Min. 1 Mz
2 male) and CN20 (female) , CN20 (female)
ness
and chassis ground
Between wiring harness between ATC2 (fe-
male) and CN20 (female) and wiring har-
ness between ATC2 (female) and CN20
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-591

(7)
[DXH2KA] DISCONNECTION IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of Hi clutch solenoid: Disconnec-
Trouble
E03 DXH2KA TM tion (KA)
Contents of trouble • When a signal is output to the Hi clutch ECMV, any current does not flow.
Problem that • The gear is set in neutral during travel.
appears on machine • The machine cannot start again until it is stopped.

ground
Possible causes 2) Disconnect connectors ATC2 and CN18.
and standard value Disconnection in wiring har- 3) Connect T-adapter.
in normal state ness Wiring harness between ATC2 (female)
and CN18 (female)
contact)
Resistance Max. 1 z
and CN18 (female)
3
fective
and ATC2 (female)
20-592 HD465-7, HD605-7

(7)
[DXH2KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HI CLUTCH SOLENOID:

SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of Hi clutch solenoid: Short circuit
Trouble
E03 DXH2KB TM (KB)
• When a signal is output to the Hi clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
flowing while the signal is OFF.
• The gear is set in Neutral during travel.
Problem that
• The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-593

(7)
20-594 HD465-7, HD605-7

(7)
[DXH3KA] DISCONNECTION IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of Lo clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the Lo clutch ECMV, any current does not flow.
Problem that • The gear is set in Neutral during travel.

ground
in normal state ness
2 Wiring harness between ATC2 (female) and
CN16 (female)
contact)
Resistance Max. 1 z
male) and CN16 (female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-595

(7)
[DXH3KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF LO CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of Lo clutch solenoid: Short circuit
Trouble
E03 DXH3KB TM (KB)
• When a signal is output to the Lo clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
• The machine cannot start until it is stopped.
appears on machine
(The machine cannot start again, depending on the failure condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
20-596 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-597

(7)
[DXH4KA] DISCONNECTION IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 1st clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 1st clutch ECMV, any current does not flow.

ground
CN6 (female)
contact)
Resistance Max. 1 z
CN6 (female)
3
fective
ATC2 (female)
20-598 HD465-7, HD605-7

(7)
[DXH4KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 1ST CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 1st clutch solenoid: Short circuit
Trouble
E03 DXH4KB TM (KB)
• When a signal is output to the 1st clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-599

(7)
[DXH5KA] DISCONNECTION IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 2nd clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 2nd clutch ECMV, any current does not flow.

ground
CN8 (female)
contact)
Resistance Max. 1 z
CN8 (female)
3
fective
ATC2 (female)
20-600 HD465-7, HD605-7

(7)
[DXH5KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 2ND CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 2nd clutch solenoid: Short circuit
Trouble
E03 DXH5KB TM (KB)
• When a signal is output to the 2nd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-601

(7)
[DXH6KA] DISCONNECTION IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 3rd clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the 3rd clutch ECMV, any current does not flow.

ground
CN12 (female)
contact)
Resistance Max. 1 z
CN12 (female)
3
fective
ATC2 (female)
20-602 HD465-7, HD605-7

(7)
[DXH6KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 3RD CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 3rd clutch solenoid: Short circuit
Trouble
E03 DXH6KB TM (KB)
• When a signal is output to the 3rd clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
• The machine cannot start until it is stopped. (The machine cannot start again, depending on the failure
appears on machine
condition.)

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-603

(7)
[DXH7KA] DISCONNECTION IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of R clutch solenoid: Disconnec-
Trouble
Contents of trouble • When a signal is output to the R clutch ECMV, any current does not flow.

ground
CN10 (female)
contact)
Resistance Max. 1 z
CN10 (female)
3
fective
ATC2 (female)
20-604 HD465-7, HD605-7

(7)
[DXH7KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF R CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of R clutch solenoid: Short circuit
Trouble
E03 DXH7KB TM (KB)
• When a signal is output to the R clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female)
HD465-7, HD605-7 20-605

(7)
TROUBLESHOOTING [DXHHKA]
[DXHHKA] DISCONNECTION IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID:

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of 4th clutch solenoid: Disconnec-
Trouble
E03 DXHHKA TM tion (KA)
Contents of trouble • When a signal is output to the 4th clutch ECMV, any current does not flow.

ground
CN14 (female)
contact)
Resistance Max. 1 z
CN14 (female)
3
fective
ATC2 (female)
20-606 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DXHHKB]
[DXHHKB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF 4TH CLUTCH SOLENOID: SHORT

CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of 4th clutch solenoid: Short circuit
Trouble
E03 DXHHKB TM (KB)
• When a signal is output to the 4th clutch ECMV, an abnormally large current flows, or some current is
Contents of trouble
Problem that
appears on machine

ground
ness
and chassis ground
(female)
3
fective
ATC2 (female) ,
HD465-7, HD605-7 20-607

(7)
TROUBLESHOOTING FOR RETARDER
CONTROLLER SYSTEM
(BK MODE)
Electrical system diagram related to retarder control .................................................................................. 20-704

Information in troubleshooting table ....................................................................................................... 20-706
Trouble code table ................................................................................................................................. 20-707
[2G42ZG] Accumulator (front): lowering of oil pressure (ZG).............................................................. 20-708
[2G43ZG] Accumulator (rear): lowering of oil pressure (ZG) .............................................................. 20-708
[D1C0KZ] Brake cutout relay: disconnection or short circuit (KZ) ....................................................... 20-709
[D5ZNKZ] Failure of front brake cutout output system (disconnection, grounding fault, short circuit)
(OPT): disconnection or short circuit (KZ) .......................................................................... 20-711
[DB10KK] Retarder controller: lowering of source/input voltage (KK) ................................................. 20-713
[DB11KK] Main power line of retarder controller: lowering of source/input voltage (KK) .................... 20-715
[DB12KK] Retarder controller load power line: lowering of source/input voltage (KK) ........................ 20-717
[DB13KK] Direct line of retarder controller battery: lowering of source/input voltage (KK).................. 20-719
[DB19KM] Retarder controller wiring harness: mistake in operation or setting (KM) ........................... 20-720
[DB1SKQ] Wrong information on model selection: disagreement of model selection signals (KQ)..... 20-721
[DDD7KX] Failure in travel speed set switch system (OPT): out of input signal range (KX)................ 20-722
[DDD8KA] ARSC system switch system: disconnection (KA).............................................................. 20-724
[DDD8KB] ARSC system switch system: short circuit (KB) ................................................................. 20-725
[dGR2L8] Failure In retarder oil temperature sensor system: see separate list (L8) ...................... 20-726
[DGR2L8] Brake oil temperature sensor (rear): see separate list (L8) ............................................ 20-727
[dHP4KX] Failure in suspension pressure sensor (FR) system (OPT): out of input signal range (KX) ... 20-728
[DHP4KX] Failure in suspension pressure sensor (FR) system (OPT): out of input signal range (KX) ... 20-730
[dHP5KX] Failure in suspension pressure sensor (FL) system (OPT): out of input signal range (KX).... 20-732
[DHP5KX] Failure in suspension pressure sensor (FL) system (OPT): out of input signal range (KX).... 20-734
[DHU2KX] Accumulator oil pressure sensor (front): out of input signal range (KX) ............................. 20-736
[DHU3KX] Accumulator oil pressure sensor (rear): out of input signal range (KX).............................. 20-738
[dK11KX] Failure in acceleration sensor system (OPT): out of input signal range (KX) ..................... 20-740
[DK11KX] Failure in acceleration sensor system (OPT): out of input signal range (KX) ..................... 20-741
[DK51L5] Retarder lever potentiometer: see separate list (L5) ...................................................... 20-742
[DK52KX] Dump lever potentiometer 1: out of input signal range (KX)............................................... 20-745
[DK53L8] Dump lever potentiometer 2: see separate list (L8) ....................................................... 20-747
[DK54KX] Body positioner sensor: out of input signal range (KX) ...................................................... 20-748
[DKD0L6] Failure in steering speed sensor (OPT): see separate list (L6) ...................................... 20-750
[dLt3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-752
[dLT3KA] Transmission output shaft speed sensor: disconnection (KA)............................................ 20-753
[DW35KZ] Failure in output system of auto suspension solenoid 1 (OPT) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-754
[DW36KZ] Failure in output system of auto suspension solenoid 2 (OPT) (disconnection,
grounding fault, short circuit): disconnection or short circuit (KZ)....................................... 20-755
[DW72KZ] Failure in kick-out solenoid output system (D_OUT3) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-756
[DW73KZ] Failure in hoist select valve output system (D_OUT5) (disconnection, grounding fault,
short circuit): disconnection or short circuit (KZ) ................................................................ 20-758
[DK11K4] Proportional solenoid pressure reducing valve of rear wheel: Uncontrollable (K4) ......... 20-759-1
[DX11KA] Disconnection in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): disconnection (KA) ..................................................................... 20-760
[DX11KB] Short circuit in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): short circuit (KB)......................................................................... 20-761
[DX11KY] Grounding fault in output circuit of electromagnetic proportional pressure reducing valve
of rear wheel (A_OUT2): short circuit with power line (KY) ................................................ 20-762
HD465-7, HD605-7 20-701

➄
[DX11MA] Proportional solenoid pressure reducing valve of rear wheel: Malfunction (MA)............. 20-762-1
[DX13KA] Disconnection in output circuit of hoist EPC valve (A_OUT3): disconnection (KA)............ 20-763
[DX13KB] Grounding fault in output circuit of hoist EPC valve (A_OUT3): short circuit (KB) ............. 20-764
[DX13KY] Short circuit in output circuit of hoist EPC valve (A_OUT3): short circuit with power line (KY).. 20-765
BK-1 Parking brake does not operate normally........................................................................... 20-767
a) When the parking brake switch is set in the OFF position, the parking brake
is not released............................................................................................................... 20-767
b) When the parking brake switch is set in the PARK position, the parking brake
does not work................................................................................................................ 20-769
BK-2 Retarder brake oil temperature gauge does not operate normally ..................................... 20-771
BK-3 Inclination alarm is turned ON when dump body is raised (when machine is not inclined
more than 15°).................................................................................................................... 20-772
BK-4 Touch up/down and cancellation cannot be performed ...................................................... 20-773
20-702 HD465-7, HD605-7

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER

CONTROL
20-704 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO RETARDER CONTROL
HD465-7, HD605-7 20-705

➄
TROUBLESHOOTING [dHP4KX]
[dHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (OPT): OUT

OF INPUT SIGNAL RANGE (KX)
Action code Error code Controller code Failure in suspension pressure sensor (FR) system (OPT): Out
Trouble of input signal range (KX)
E03 dHP4KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Action of controller • When ARSC operates, the controller releases the brake gradually.
Problem that
• This failure does not have a serious effect on the machine.
appears on machine
• This failure can be checked in the monitoring function (Code: 32802, 32803)
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "DHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
Disconnection in wiring har- Wiring harness between BRC3A (female) (20)
1 and SUFR (female) (C)
Wiring harness between BRC3A (female) (16)
and SUFR (female) (A)
Wiring harness between PM6 (female) (2) and
SUFR (female) (B)
2) Disconnect connectors BRC3A SUFR and PM6.
Wiring harness between Resistance between BRC3A
2 BRC3A (female) (20) and (female) (20), SUFR (female) Min. 1 M Ω
harness
SUFR (female) (C) (C) and chassis ground
Wiring harness between Resistance between PM6
PM6 (female) (14) and (female) (2), SUFR (female) Min. 1 M Ω
Possible causes SUFR (female) (B) (B) and chassis ground
and standard value 1) Turn the starting switch OFF.
in normal state 2) Disconnect connectors BRC3A and SUFR.
Short circuit with power 4) Turn the starting switch ON.
3
source in wiring harness
Wiring harness between Voltage between BRC3A (fe-
BRC3A (female) (20) and male) (9), SUFR (female) Max. 1 V
2) Disconnect connector SUFR.
Suspension pressure sensor 4) Connect the connector.
4
(FR) defective 5) Turn the starting switch ON.
Between SUFR (B) and (A) Voltage 20 – 30 V
Between SUFR (C) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors BRC3A.
5 Retarder controller defective 4) Connect the connector.
BRC3A (20) and (16) Voltage 1.0 – 4.6 V
20-728 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-729

➄
TROUBLESHOOTING [DHP4KX]
[DHP4KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FR) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FR) system (OPT): Out
Trouble of input signal range (KX)
E03 DHP4KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Right) is below 1.0 V or above 4.6 V.
Action of controller • Auto suspension system does not operate.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, error code "dHP4KX" is displayed.

2) Disconnect connectors, BRC3A, SUFR and PM6.
1 and SUFR (female) (C)
and SUFR (female) (A)
Wiring harness between PM6 (female) (14)
and SUFR (female) (B)
2) Disconnect connectors BRC3A, SUFR and PM6.
2 BRC3A (female) (20) and (female) (20), SUFR (female) Min. 1 M Ω
harness
PM6 (female) (2) and SUFR (female) (2), SUFR (female) Min. 1 M Ω
Possible causes (female) (B) (B) and chassis ground
in normal state 2) Disconnect connectors BRC3A and SUFR.
3
BRC3A (female) (20) and male) (9), SUFR (female) Max. 1 V
4
Between SUFR (B) and (A) Voltage 18 ± 3 V
2) Disconnect connectors BRC1 and BRC3A.
20-730 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-731

➄
[dHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FL) system (OPT): Out of
Trouble input signal range (KX)
E03 dHP5KX BK (When ARSC is set and the ARSC system switch is ON)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Action of controller • When ARSC operates, the controller releases the brake gradually.
Problem that
appears on machine
Related information
• When ARSC is not set or the ARSC system switch is OFF, error code "DHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 and SUFL (female) (C)
and SUFL (female) (A)
SUFL (female) (B)
2) Disconnect connectors BRC3A SUFLand PM6.
2 BRC3A (female) (19) and (female) (19), SUFL (female) Min. 1 M Ω
harness
SUFL (female) (C) (C) and chassis ground
PM6 (female) (2) and SUFL (female) (2), SUFL (female) Min. 1 M Ω
in normal state 2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) (20) and male) (9), SUFL (female) (C) Max. 1 V
SUFL (female) (C) and chassis ground
2) Disconnect connector SUFL.
4
Between SUFL (B) and (A) Voltage 18 ± 3 V
Between SUFL (C) and (A) Voltage 1.0 – 4.6 V
20-732 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-733

➄
[DHP5KX] FAILURE IN SUSPENSION PRESSURE SENSOR (FL) SYSTEM (OPT): OUT

Action code Error code Controller code Failure in suspension pressure sensor (FL) system (OPT): Out of
Trouble input signal range (KX)
E03 DHP5KX BK (When ARSC is not set or the ARSC system switch is OFF)
Contents of trouble • The input signal circuit voltage of the suspension pressure sensor (Left) is below 1.0 V or above 4.6 V.
Action of controller • ARSC does not operate.
Problem that
appears on machine
Related information
• When ARSC is set and the ARSC system switch is ON, error code "dHP5KX" is displayed.

2) Disconnect connectors, BRC3A, SUFL and PM6.
1 and SUFL (female) (C)
and SUFL (female) (A)
SUFL (female) (B)
2) Disconnect connectors BRC3A, SUFL and PM6.
2 BRC3A (female) (19) and (female) (19), SUFL (female) Min. 1 M Ω
harness
PM6 (female) (2) and SUFL (female) (2), SUFL (female) Min. 1 M Ω
in normal state 2) Disconnect connectors BRC3A and SUFL.
3
BRC3A (female) (20) and male) (9), SUFL (female) (B) Max. 1 V
SUFL (female) (C) and chassis ground
4
Between SUFL (B) and (A) Voltage 18 ± 3 V
20-734 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-735

➄
TROUBLESHOOTING [DW35KZ]
[DW35KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 1 (OPT)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Error code Controller code Failure in output system of auto suspension solenoid 1 (OPT)
Trouble (Disconnection, grounding fault, short circuit): Disconnection or
E01 DW35KZ BK short circuit (KZ)
• When the output to the auto suspension solenoid 1 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to auto suspension solenoid 1 OFF.
Problem that
• The auto suspension system does not operate.
appears on machine

2) Disconnect connector S04.
Auto suspension solenoid 1 3) Insert T-adapter.
1
defective Between S04 (female) (1) and (2) Resistance 15 – 35 Ω
Between S04 (female) (1), (2) and chassis
Resistance Min. 1 M Ω
ground
Possible causes 2) Disconnect connectors BRC1 and S04.
2 Wiring harness between BRC1 (female) (1)
(Disconnection or defective Resistance Max. 1 Ω
and S04 (female) (1)
contact)
Wiring harness between S04 (female) (2) and
chassis ground
2) Disconnect connector BRC1.
3 Retarder controller defective 3) Insert T-adapter.
Between BRC1 (female) (1) and chassis
Resistance 15 – 20 Ω
ground
20-754 HD465-7, HD605-7

➄
TROUBLESHOOTING [DW36KZ]
[DW36KZ] FAILURE IN OUTPUT SYSTEM OF AUTO SUSPENSION SOLENOID 2 (OPT)

(DISCONNECTION, GROUNDING FAULT, SHORT CIRCUIT):
DISCONNECTION OR SHORT CIRCUIT (KZ)
Action code Error code Controller code Failure in output system of auto suspension solenoid 2 (OPT)
Trouble (Disconnection, grounding fault, short circuit): Disconnection or
E01 DW36KZ BK short circuit (KZ)
• When the output to the auto suspension solenoid 2 circuit is ON, a too large current flows or any current
Contents of trouble
does not flow. Or, some current is flowing while the output is OFF.
Action of controller • The controller turns the output to auto suspension solenoid 2 OFF.
Problem that
• The auto suspension system does not operate.
appears on machine

2) Disconnect connector S05.
Auto suspension solenoid 2 3) Insert T-adapter.
1
defective Between S05 (female) (1) and (2) Resistance 15 – 35 Ω
Between S05 (female) (1), (2) and chassis
ground
Possible causes 2) Disconnect connectors BRC1 and S05.
and S05 (female) (1)
contact)
Wiring harness between S05 (female) (2) and
chassis ground
Between BRC1 (female) (2) and chassis
Resistance 15 – 20 Ω
ground
HD465-7, HD605-7 20-755

➄
TROUBLESHOOTING [DK11K4]
[DK11K4] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: UNCONTROLLABLE (K4)
Action code Error code Controller code Proportional solenoid pressure reducing valve of rear wheel: Un-
Trouble
E03 DK11K4 BK controllable (K4)
Contents of trouble • The proportional solenoid pressure reducing valve does not return (does not move).
Action of controller • Resets the retarder solenoid output.
Problem that
• The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
• The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional
• Check proportional solenoid pressure reducing valve of rear wheel
1 solenoid pressure reducing
and repair or replace it, if it has abnormality (mechanical failure).
valve of rear wheel
1) Turn starting switch OFF.
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 Ω
male) (1) and (2) Oil pressure OFF Resistance Min. 1 M Ω
2) Disconnect connector BRC5A and RESW.
Grounding fault in wiring 4) Connect connector.
3 5) Turn starting switch ON.
harness
Possible causes
and standard value Wiring harness between Resistance between BRC5A
in normal state BRC5A (female) (4) and (female) (4), RESW (female) Max. 1 Ω
RESW (female) (1) (1) and chassis ground
2) Disconnect connector BRC5A and RESW.
Short circuit with power 4) Connect connector.
BRC5A (female) (4) and male) (4), RESW (female) Max. 1 V
2) Disconnect connector BRC5A and BRC3A.
5 Defective retarder controller 4) Connect connector.
5) Turn starting switch ON.
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
and BRC3A (16) Oil pressure OFF Voltage 20 – 30 V
20-759-1 HD465-7, HD605-7

➄
TROUBLESHOOTING [DK11K4]
HD465-7, HD605-7 20-759-2

➄
TROUBLESHOOTING [DX11KA]
[DX11KA] DISCONNECTION IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

PROPORTIONAL PRESSURE REDUCING VALVE OF REAR WHEEL
(A_OUT2): DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Disconnection
E03 DX11KA BK (KA)
• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, any current does not
Contents of trouble
flow.
Action of controller • The controller turns the output to the rear brake pressure reducing valve solenoid OFF.
Problem that
• The retarder (rear brake) does not operate.
appears on machine
Related information • This failure can be checked in the monitoring function (Code: 33800, 33801).

2) Disconnect connector RETV.
Rear brake pressure reduc- 3) Insert T-adapter.
1
ing valve solenoid defective Between RETV (female) (1) and (2) Resistance 10 – 30 Ω
Between RETV (female) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and RETV.
and RETV (female) (1).
contact)
Wiring harness between BRC2 (female) (17)
and RETV (female) (1).
2) Disconnect connector BRC.
Between BRC2 (female) (7) and (17) Resistance 10 – 30 Ω
20-760 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX11KB]
[DX11KB] SHORT CIRCUIT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

(A_OUT2): SHORT CIRCUIT (KB)
Action code Error code Controller code Short circuit in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KB BK (KB)
• When the output to the rear wheel pressure reducing valve solenoid circuit is ON, a too large current
Contents of trouble
flows.
Problem that
appears on machine

1
ground
2) Disconnect connectors BRC2 and RETV.
Possible causes 3) Connect T-adapter.
and standard value Resistance value be-
in normal state Wiring harness between BRC2
Grounding fault or short cir- tween BRC2 (female)
2 (female) (7) and RETV (female) Min. 1 M Ω
cuit in wiring harness (9), RETV (female) (1)
(1).
and chassis ground.
Wiring harness between BRC (female) (7) and RETV (fe-
male) (1) and wiring harness between BRC (female) (17) Min. 1 M Ω
and RETV (female) (2)
HD465-7, HD605-7 20-761

➄
TROUBLESHOOTING [DX11KY]
[DX11KY] GROUNDING FAULT IN OUTPUT CIRCUIT OF ELECTROMAGNETIC

(A_OUT2): SHORT CIRCUIT WITH POWER LINE (KY)
Action code Error code Controller code Grounding fault in output circuit of electromagnetic proportional
Trouble pressure reducing valve of rear wheel (A_OUT2): Short circuit
E03 DX11KY BK with power line (KY)
• While the output to the rear wheel pressure reducing valve solenoid circuit is OFF, some current is flow-
Contents of trouble
ing.
Problem that
appears on machine

1
ground

and standard value 2) Disconnect connectors BRC2 and RETV.
in normal state 3) Connect T-adapter.
Short circuit with power
2 Voltage between
source in wiring harness Wiring harness between BRC2
BRC2 (female) (7),
(female) (7) and RETV (female) Max. 1 V
RETV (female) (1) and
(1).
chassis ground.
20-762 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX11MA]
[DX11MA] PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE OF REAR

WHEEL: MALFUNCTION (MA)
Action code Error code Controller code Proportional solenoid pressure reducing valve of rear wheel:
Trouble
E03 DX11MA BK Malfunction (MA)
Contents of trouble • The proportional solenoid pressure reducing valve does not operate (does not move).
Action of controller • Resets the retarder solenoid output.
Problem that
• The retarder (rear brake), ARSC, and overrun prevention system do not operate.
appears on machine
• The state of the retarder oil pressure switch can be checked with the monitoring function
Related information
(Code: 34100).

Defective proportional sole- • Check the proportional solenoid pressure reducing valve of rear
1 noid pressure reducing wheel and repair or replace it, if it has abnormality (mechanical fail-
valve of rear wheel ure).
2) Disconnect connector RESW.
Defective retarder oil pres- 4) Connect connector.
2
sure switch 5) Turn starting switch ON.
Between RESW (fe- Oil pressure ON Resistance Max. 1 Ω
male) (1) and (2) Oil pressure OFF Resistance Min. 1 M Ω
Possible causes
and standard value 1) Turn starting switch OFF.
in normal state 2) Disconnect connector BRC5A and RESW.
3
ness Wiring harness between Resistance between BRC5A
BRC5A (female) (4) and (female) (4), RESW (female) Max. 1 Ω
2) Disconnect connector BRC5A.
Between BRC5A (4) Oil pressure ON Voltage Max. 1 V
and BRC3A (16) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-762-1

➄
[DX13KA] DISCONNECTION IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

DISCONNECTION (KA)
Action code Error code Controller code Disconnection in output circuit of hoist EPC valve (A_OUT3):
Trouble
E03 DX13KA BK Disconnection (KA)
Contents of trouble • When the output to the dump EPC solenoid circuit is ON, any current does not flow.
• The controller turns the output to the dump select valve solenoid OFF.
• The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
• The dump body does not operate.
appears on machine

2) Disconnect connector HEPC.
Dump EPC valve solenoid
1
defective Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
Between HEPC (female) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC2 and HEPC.
and standard value
in normal state
ness
and HEPC (female) (1).
contact)
and HEPC (female) (1).
19. Between BRC2 (female) (10) and (20) Resistance 15 – 20 Ω
HD465-7, HD605-7 20-763

➄
[DX13KB] GROUNDING FAULT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT (KB)
Action code Error code Controller code Grounding fault in output circuit of hoist EPC valve (A_OUT3):
Trouble Short circuit (KB)
E03 DX13KB BK
Contents of trouble • When the output to the dump EPC valve solenoid circuit is ON, a too large current flows.
Action of controller • The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid
1 Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
defective
ground
and standard value
Resistance value be-
Grounding fault or short cir- (female) (10) and HEPC (female) tween BRC2 (female) Min. 1 M Ω
2 (10), HEPC (female)
cuit in wiring harness (1).
(1) and chassis ground.
Wiring harness between BRC (female) (10) and HEPC (fe-
male) (1) and wiring harness between BRC (female) (20) Min. 1 M Ω
and HEPC (female) (2)
20-764 HD465-7, HD605-7

➄
[DX13KY] SHORT CIRCUIT IN OUTPUT CIRCUIT OF HOIST EPC VALVE (A_OUT3):

SHORT CIRCUIT WITH POWER LINE (KY)
Action code Error code Controller code Short circuit in output circuit of hoist EPC valve (A_OUT3): Short
Trouble
E03 DX13KY BK circuit with power line (KY)
Contents of trouble • While the output to the dump EPC valve solenoid circuit is OFF, some large current is flowing.
• The controller turns the output to the dump EPC valve solenoid OFF.
Problem that
appears on machine

Dump EPC valve solenoid 3) Insert T-adapter.
1
defective Between HEPC (female) (1) and (2) Resistance 15 – 20 Ω
ground
Possible causes 4) Turn the starting switch ON.
and standard value Short circuit with power Voltage between
source in wiring harness BRC2 (female) (10),
2 (female) (10) and HEPC (female) Max. 1 V
(Contact with power source HEPC (female) (1) and
(1).
wiring harness) chassis ground.
Voltage between
Wiring harness between BRC2
BRC2 (female) (20),
(female) (20) and HEPC (female) Max. 1 V
HEPC (female) (2) and
(2).
chassis ground.
HD465-7, HD605-7 20-765

➄
TROUBLESHOOTING FOR PAYLOAD
METER SYSTEM (CARD TYPE)
(LC MODE)
Electrical system diagram related to payload meter ................................................................................... 20-802

Service codes of payload meter (card type) and contents of self-diagnosis ....................................... 20-804
Information in troubleshooting table........................................................................................................ 20-807
Trouble code table .................................................................................................................................. 20-808
LC- 1 When starting switch is turned ON, any item is not displayed.................................................... 20-809
LC- 2 After starting switch is turned ON, all external pilot lamps do not light up.................................. 20-811
LC- 3 External lamps light up while condition for lighting is not set...................................................... 20-814
LC- 4 Lighting level of external pilot lamps is abnormal ....................................................................... 20-816
LC- 5 Cycle data and engine ON/OFF data not recorded
(charge level signal system: judges that engine is stopped) ...................................................... 20-818
LC- 6 Calibration cannot be performed and displayed clock does not conform to condition
(shift lever "N" position signal system) ....................................................................................... 20-819
LC- 7 Displayed logic is abnormal........................................................................................................ 20-821
a) When loaded dump truck starts traveling, "0" is kept displayed ........................................... 20-821
b) After loaded dump truck start traveling, display of odometer does not increase .................. 20-821
c) When travel speed exceeds limit speed, "SP:SP" does not go off........................................ 20-821
d) Integrated pay load is not displayed ..................................................................................... 20-822
e) Displayed and saved pay load is not correct ........................................................................ 20-823
LC- 8 Payload meter keeps displaying "b:FL" (body "FLOAT" signal system: dump lever is not in
"FLOAT" position while truck is not dumping)............................................................................. 20-824
LC- 9 Payload meter displays "F:09" (lowering of internal backup battery voltage) ............................. 20-826
LC-10 Payload meter displays " :FULL" (data saving memory is full) ................................................ 20-826
LC-11 Payload meter displays "F-20" : failure in power source of suspension pressure sensor and
clinometer system....................................................................................................................... 20-827
LC-12 Payload meter displays "F-21" – "F-24" : disconnection or grounding fault in suspension
sensor signal system .................................................................................................................. 20-829
LC-13 Payload meter displays "F-25" – "F-28" : short circuit with power source in suspension
sensor signal system .................................................................................................................. 20-832
LC-14 Payload meter displays "F-CAL" (negligence of calibration or internal damage of payload meter) ... 20-834
LC-15 Payload meter displays "F:43" – "F:45" (short circuit with power source in external pilot lamp
relay system) .............................................................................................................................. 20-835
LC-16 Payload meter displays "L-bad" (cycle data were saved while truck body was pitching) ........... 20-837
LC-17 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 ............................................................................ 20-839
LC-18 Payload meter displays "F-31" : grounding fault or disconnection in clinometer sensor signal
system ........................................................................................................................................ 20-840
LC-19 Payload meter displays "F-32" : short circuit with power source in clinometer sensor signal
system ........................................................................................................................................ 20-842
LC-20 Payload meter displays "F:18" (disconnection in charge level signal system) ........................... 20-844
HD465-7, HD605-7 20-801

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
20-802 HD465-7, HD605-7

➁
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO PAYLOAD METER
HD465-7, HD605-7 20-803

➁
TROUBLESHOOTING FOR
MONITOR SYSTEM
(MON MODE)
Electrical system diagram related to monitor .............................................................................................. 20-904

Information in troubleshooting table........................................................................................................ 20-905
Trouble code table .................................................................................................................................. 20-906
[B@C7NS] Rear brake oil: overheating (NS) ........................................................................................ 20-907
[B@CENS] Torque converter: overheating (NS) ................................................................................... 20-907
[DAF0KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-908
[DAF9KM] Monitor panel: mistake in operation or setting (KM) ........................................................... 20-911
[DAFSKQ] Monitor panel: disagreement of model selection signals (KQ) ........................................... 20-912
[DAQSKR] S-NET communication defective
(between transmission controller and machine monitor) (KR)............................................ 20-913
[DASRKR] CAN communication • Communication defective: abnormality in objective component (KR) .. 20-916
[DB1SKR] S-NET communication defective (between retarder controller and machine monitor) (KR)..... 20-918
[DV00KB] Short circuit in alarm buzzer output • short circuit (KB) ...................................................... 20-921
MON- 1 When starting switch is turned ON, machine monitor does not display any item ............... 20-922
MON- 2 When starting switch is turned OFF and machine monitor does not operate normally ...... 20-923
MON- 3 Alarm buzzer defective ....................................................................................................... 20-925
a) Alarm buzzer does not sound ....................................................................................... 20-925
b) Alarm buzzer does not stop sounding........................................................................... 20-926
MON- 4 Items displayed by gauges, caution lamps, and character display of machine monitor
are abnormal ...................................................................................................................... 20-927
a) Items displayed by gauges are different from machine condition ................................. 20-927
b) Items displayed by caution lamps are different from machine condition ....................... 20-928
c) Character display does not display any item or it displays abnormally ......................... 20-928
MON- 5 Operation of machine monitor cannot be checked normally .............................................. 20-929
MON- 6 Display of character display cannot be selected normally.................................................. 20-930
a) Machine monitor mode select switch 1 system is abnormal ......................................... 20-930
b) Machine monitor mode select switch 2 system is abnormal ......................................... 20-932
MON- 7 Power mode select function does not work normally ......................................................... 20-934
MON- 8 Seat belt caution lamp does not operate normally ............................................................. 20-935
a) Lamp lights up while seat belt is fastened..................................................................... 20-935
b) Lamp does not light up while seat belt is unfastened.................................................... 20-936
MON- 9 Turn signals and hazard lamp do not operate normally...................................................... 20-937
a) When turn signal lever and hazard lamp switch are operated, any turn signal lamp
does not flash................................................................................................................ 20-937
b) When turn signal lever and hazard lamp switch are operated, the turn signal lamps
do not flash but light up ................................................................................................. 20-938
c) When turn signal lever is operated, turn signal lamps on either or both sides do not flash
(When hazard lamp switch is operated, however, turn signal lamps flash normally) ......... 20-939
d) When hazard lamp switch is turned ON, any turn signal lamp does not flash
(When turn signal lever is operated, however, turn signal lamps flash normally) ......... 20-940
e) When hazard lamp switch is turned OFF, turn signal lamps continue flashing
(When turn signal lever is operated, however, turn signal lamps flash normally) ......... 20-942
f) Turn signal pilot lamps do not flash normally
(Turn signal lamps flash normally, however) ................................................................. 20-943
HD465-7, HD605-7 20-901

➁
MON-10 Night lighting is abnormal ................................................................................................... 20-945
a) When lamp switch is set in 1st or 2nd position, any of small lamp, night lamp,
and head lamp does not light up. .................................................................................. 20-945
b) When lamp switch is set in 1st position, small lamp and night lamp do not light up ..... 20-946
c) When lamp switch is OFF, small lamp and night lamp light up ..................................... 20-947
d) When dimmer switch is operated, brightness of night lighting does not change........... 20-948
e) Head lamp "Hi" beam does not light up ........................................................................ 20-949
f) Head lamp "Lo" beam does not light up........................................................................ 20-950
g) Head lamp cannot be set to "Hi" or "Lo" ....................................................................... 20-951
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up ... 20-952
MON-11 Power window does not operate normally.......................................................................... 20-954
a) Operating left side does not .......................................................................................... 20-954
b) Operating right side does not ........................................................................................ 20-955
MON-12 Defective air conditioner ..................................................................................................... 20-957
a) Air conditioner does not operate ................................................................................... 20-957
b) Air does not come out or air flow cannot be adjusted ................................................... 20-958
c) Air is not cooled or temperature cannot be adjusted (Electric system) ......................... 20-960
d) Recirculated air and fresh air cannot be selected ......................................................... 20-962
e) Air outlets cannot be selected ....................................................................................... 20-963
f) Air is not cooled (Mechanical system)........................................................................... 20-965
g) Air is not heated (Defective hot water circuit)................................................................ 20-966
h) Abnormal sound comes out .......................................................................................... 20-966
i) Water leaks ................................................................................................................... 20-967
★ For abnormality of the fuel level gauge, see troubleshooting for the transmission controller system (TM
Mode).
20-902 HD465-7, HD605-7

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR

★ For details of this page, see page 90-21.
20-904 HD465-7, HD605-7

➁
TROUBLESHOOTING [DAQSKR]
HD465-7, HD605-7 20-915

➁
TROUBLESHOOTING [DB1SKR]
20-920 HD465-7, HD605-7

➁
TROUBLESHOOTING MON-10
e) Head lamp "Hi" beam does not light up
Action code Error code Controller code Night lighting is abnormal

Trouble
Not set Not set Not set e) Head lamp "Hi" beam does not light up
Contents of trouble • The head lamp cannot be set to "Hi" or "Lo".
Problem that
• The head lamp cannot be set to "Hi" or "Lo".
appears on machine
• Before performing troubleshooting, check that fuses BT1 , BT1 , BT1 , BT1 , and BT1
are not broken. (If any of them is broken, there is a grounding fault. Accordingly, check the related
wiring harness.)
• The lamps and night lighting are branched at the switch and relay to the related devices. Accordingly,
Related information
if only 1 device is defective, the possible causes of the failure are breakage of the bulb, defect of the
wiring harness on the signal side (between the branching point and lamp), and defect of the wiring har-
ness on the GND side.
• Error code is not displayed.

2) Disconnect connector CM.
3) Check the switch.
Between Set the lamp switch in OFF position. Resistance Min. 1 M Ω

1 Lamp switch defective CM (male) Set the lamp switch in 1st position. Resistance Max. 1 Ω
and Set the lamp switch in 2nd position. Resistance Max. 1 Ω
CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M Ω
When head lamp "Lo" relay (R30) is No Relay R30
replaced, is failure repaired? Yes Relay R30
3) Check the relay.
Possible causes Head lamp "Hi" relay (R30)
and standard value 2 defective Between R30 (male) and Resistance 200 – 400 Ω
in normal state 1) Turn the starting switch OFF.
3) Check the relay.
4) Apply voltage between R30 (male) and .
Apply 24 V between
tween and .
2) Disconnect connectors DPC2B, CM, fuse BT1 and , Switch,
and Tachograph
4) Connect the connectors.
ness
3
(Disconnection or defective Wiring harness between R30 (female) , Resistance Max. 1 Ω
contact) and branching point of wiring harness
Wiring harness between R30 (female) and
DCP1 (female)
branching point of wiring harness
HD465-7, HD605-7 20-949

➁
f) Head lamp "Lo" beam does not light up

Trouble
Not set Not set Not set f) Head lamp "Lo" beam does not light up
Contents of trouble • The head lamp "Lo" beam does not light up.
Problem that
• The head lamp "Lo" beam does not light up.
appears on machine
wiring harness.)
Related information


1 Lamp switch defective CM (male) Set the lamp switch in 1st position. Resistance Max. 1 Ω
CM (male) Set the lamp switch in 1st position. Resistance Min. 1 M Ω
Possible causes
2) Disconnect connectors DPC2A, PL1, PR1, R29, CM, and fuse BT1
and standard value
terminals and
in normal state
Wiring harness between PL1 (female) and
chassis ground
Disconnection in wiring har- Wiring harness between PR1 (female) and
2 chassis ground
contact) Wiring harness between battery relay terminal
M (CN-02), fuse BT1 terminals and , and Resistance Max. 1 Ω
CM (female)
Wiring harness between CM (female) and
fuse BT1 terminal
Wiring harness fuse BT1 terminal and PL1
(female) , PR1 (female)
20-950 HD465-7, HD605-7

➁
g) Head lamp cannot be set to "Hi" or "Lo"

Trouble
Not set Not set Not set g) Head lamp cannot be set to "Hi" or "Lo"
Contents of trouble • The head lamp "Hi" beam does not light up.
Problem that
• The head lamp "Hi" beam does not light up.
appears on machine
wiring harness.)
Related information

1 Passing switch defective Set the passing switch in RAISE
Between (PASS) position. Resistance Max. 1 Ω
CM (male)
Set the passing switch in RETURN
and Resistance Min. 1 M Ω
(OFF) position.
When head lamp "Hi" relay (R29) No Relay R29
is replaced, is failure repaired? Yes Relay R29
3) Check the relay.
Head lamp "Passing" relay
2
(R29) defective Between R29 (male) and Resistance 200 – 400 Ω
3) Check the relay.
Possible causes 4) Apply voltage between R29 (male) and .
and standard value Apply 24 V between
in normal state Resistance Max. 1 Ω
tween and .
2) Disconnect connectors DPC2A, PL2, PR2, R29, CM, and fuse BT1
terminals and
Wiring harness between PL2 (female) and
chassis ground
Wiring harness between PR2 (female) and
chassis ground
ness Wiring harness between fuse BT1 terminal
3 Resistance Max. 1 Ω
(Disconnection or defective and PL2 (female) , PR2 (female)
contact) Wiring harness between R29 (female) and
chassis ground
R29 (female)
HD465-7, HD605-7 20-951

➁
h) When head lamp is set to "Hi" beam, pilot lamp of machine monitor does not light up

Trouble h) When head lamp is set to "Hi" beam, pilot lamp of machine
Not set Not set Not set monitor does not light up
Contents of trouble • When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
Problem that
• When the head lamp is set to "Hi" beam, the pilot lamp of the machine monitor does not light up.
appears on machine
wiring harness.)
Related information

Disconnection in wiring har- 2) Disconnect connectors DPC2A, CM, and R29.
ness 3) Connect T-adapter.
1
Wiring harness between DPC2A (female) ,
CM (female) , and R29 (female)
and standard value 2) Disconnect connector DPC2A.
in normal state 3) Insert T-adapter.
4) Connect the connector.
2 Machine monitor defective 5) Turn the starting switch ON.
Set the passing switch
Voltage Max. 1 V
Between DPC2A in "Lo".
and chassis ground Set the passing switch
Voltage 20 – 30 V
in "Hi".
20-952 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-953

➁
MON-11 POWER WINDOW DOES NOT OPERATE NORMALLY

a) Operating left side does not
Action code Error code

Controller code Power window does not operate normally
Trouble
Not set Not set Not set a) Operating left side does not
Contents of trouble • The power window does not operate normally. (Operating left side does not)
Problem that
• The power window does not operate normally. (Operating left side does not)
appears on machine
• Before performing troubleshooting, check that fuses BT2 are not broken. (If any of them is broken,
Related information
there is a grounding fault. Accordingly, check the related wiring harness.)

Power window switch (L.H.) "Left
Between Resistance Min. 1 M Ω
up"
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M Ω
Power window switch (L.H.) (male)
1 and Power window switch (L.H.) "Left
defective Resistance Max. 1 Ω
down"
Power window switch (L.H.) "Left
Between Resistance Max. 1 Ω
up"
R34
Power window switch (L.H.) "OFF" Resistance Min. 1 M Ω
(male)
and Power window switch (L.H.) "Left
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R34, PWL, and fuse BT2 terminal .
Possible causes 3) Insert T-adapter.
and standard value 4) Connect the connectors.
in normal state 5) Turn the starting switch ON.
Wiring harness between fuse BT2 terminal
and R34 (female)
Disconnection in wiring har- and R25 (female)
ness Wiring harness between R25 (female) and
(Disconnection or defective R34 (female)
contact)
Wiring harness between R25 (female) ,
CAB1 and PWL (female)
CAB1 and PWL (male)
R34 (female)
chassis ground
2) Replace power window motor (L.H.) with motor normal one.
Power window motor (L.H.) ★ If the results of 1 – 3 above are normal, perform the following test.
4
defective
When power window motor (L.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
20-954 HD465-7, HD605-7

➁
b) Operating right side does not
Action code Error code Controller code Power window does not operate normally
Trouble
Not set Not set Not set b) Operating right side does not
Contents of trouble • The power window does not operate normally. (Operating right side does not)
Problem that
• The power window does not operate normally. (Operating right side does not)
appears on machine
• Before performing troubleshooting, check that fuses BT2 are not broken. (If any of them is broken,
Related information
there is a grounding fault. Accordingly, check the related wiring harness.)

Power window switch (R.H.) "Right
Between Resistance Min. 1 M Ω
up"
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M Ω
Power window switch (R.H.) (male)
1 and Power window switch (R.H.) "Right
defective Resistance Max. 1 Ω
down"
Power window switch (R.H.) "Right
Between Resistance Max. 1 Ω
up"
R35
Power window switch (R.H.) "OFF" Resistance Min. 1 M Ω
(male)
and Power window switch (R.H.) "Right
down"
Power window relay (R25) 3) Turn the starting switch ON.
2
defective
When power window relay (R25) is No Relay R25 is normal
replaced, is failure repaired? Yes Relay R25 is defective
2) Disconnect connectors R25, R35, PWR, and fuse BT2 terminal .
Possible causes 3) Insert T-adapter.
and standard value 4) Connect the connectors.
in normal state 5) Turn the starting switch ON.
and R35 (female)
Disconnection in wiring har- and R25 (female)
ness Wiring harness between R25 (female) and
(Disconnection or defective R35 (female)
contact)
CAB1 and PWR (female)
CAB1 and PWR (male)
R35 (female)
chassis ground
2) Replace power window motor (R.H.) with motor normal one.
Power window motor (R.H.) ★ If the results of 1 – 3 above are normal, perform the following test.
4
defective
When power window motor (R.H.) No Motor is normal
is motor replaced, is failure re-
placed ? Yes Motor is defective
HD465-7, HD605-7 20-955

➁
20-956 HD465-7, HD605-7

➁
MON-12 DEFECTIVE AIR CONDITIONER

a) Air conditioner does not operate
Action code Error code Controller code Defective air conditioner

Trouble
None None None a) Air conditioner does not operate
Contents of trouble • The air conditioner does not operate.
Problem that
• The air conditioner does not operate.
appears on machine
• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information
grounding fault.

2) Disconnect connector ACP1 and fuse BT3 (4) terminal.
Possible causes ness
1 Wiring harness between fuse BT3 (4) and
and standard value (Disconnection or defective Resistance Max. 1 Ω
ACP1 (female) (1)
in normal state contact)
Wiring harness between ACP1 (female) (14)
and chassis ground
a Check the control panel and repair or replace it, if it has abnormality.
Defective air conditioner
2
control panel
HD465-7, HD605-7 20-957

➄
b) Air does not come out or air flow cannot be adjusted

Trouble
None None None b) Air does not come out or air flow cannot be adjusted
Contents of trouble • Air does not come out or air flow cannot be adjusted
Problem that
• Air does not come out or air flow cannot be adjusted
appears on machine
Related information

2) Disconnect connectors ACR1, ACR2, ACR3, and ACR4 and fuse
terminals BT1 (18) and BT3 (4).
Wiring harness between fuse BT3 (4) and
ACR1 (female) (1)
Disconnection in power
supply wiring harness Wiring harness between fuse BT3 (4) and
(Disconnection or defective ACR2 (female) (1)
contact) Wiring harness between fuse BT3 (4) and
ACR3 (female) (1)
ACR4 (female) (1)
ACR1 (female) (3)
2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
and ACR1 (female) (2)
Possible causes
and standard value Wiring harness between ACP1 (female) (5)
in normal state and ACR2 (female) (2)
Wiring harness between ACR1 (female) (4)
Disconnection in wiring Resistance Max. 1 Ω
harness and ACBM (female) (1)
2
(Disconnection or defective Wiring harness between ACR2 (female) (3)
contact) and ACBM (female) (2), ACRE (female) (1)
and ACRE (female) (2)
and ACRE (female) (3)
wiring harness between ACR2 (female) (4)
and chassis ground
and chassis ground
and chassis ground)
wiring harness between ACRE (female) (4)
and chassis ground
20-958 HD465-7, HD605-7

➄

2) Disconnect connectors ACP1, ACR1, ACR2, ACR3, ACR4, ACR5,
ACBM, and ACRE.
Wiring harness between Resistance between ACR1
ACR1 (female) (4) and (female) (4), ACBM (female) Min. 1 M Ω
ACBM (female) (1) (1) and chassis ground
3 ACR2 (female) (3) and (female) (3), ACBM (female)
harness Min. 1 M Ω
ACBM (female) (2), ACRE (2), ACRE (female) (1) and
(female) (1) chassis ground
ACR3 (female) (3) and (female) (3), ACRE (female) Min. 1 M Ω
ACRE (female) (2) (2) and chassis ground
ACR4 (female) (3) and (female) (3), ACRE (female) Min. 1 M Ω
ACRE (female) (3) (3) and chassis ground
2) Replace relay.
4 Defective blower main relay 4) Start air conditioner.
Replace relay Condition becomes normal. Relay is defective.
with normal one. Condition does not become normal. Relay is normal.
2) Replace relay.
5 Defective blower Hi relay 4) Start air conditioner.
Possible causes Condition becomes normal. Relay is defective.
Replace relay
and standard value
in normal state
2) Replace relay.
6 Defective blower M2 relay 4) Start air conditioner.
2) Replace relay.
7 Defective blower M1 relay 4) Start air conditioner.
2) Replace motor.
8 Defective blower motor 4) Start air conditioner.
Replace motor Condition becomes normal. Relay is defective.
2) Disconnect connector ACRE.
3) Check resistor unit.
9 Defective blower resistor Between ACRE (female) (1) and (2) Resistance 2.8 Ω
Between ACRE (female) (1) and (3) Resistance 4.8 Ω
Between ACRE (female) (1) and (4) Resistance 4.0 Ω
10
control panel
HD465-7, HD605-7 20-959

➄
c) Air is not cooled or temperature cannot be adjusted (Electric system)

Trouble c) Air is not cooled or temperature cannot be adjusted (Electric
None None None system)
Contents of trouble • Air is not cooled or temperature cannot be adjusted (Electric system)
Problem that
• Air is not cooled or temperature cannot be adjusted (Electric system)
appears on machine
• If fuse BT3 (4) is broken, check the wiring harness between fuse BT3 (4) and ACP1 (female) (1) for
Related information grounding fault. If fuse BT1 (18) is broken, check the wiring harness between fuse BT1 (18) and ACR5
(female) (3) for grounding fault.

2) Disconnect connectors ACR5 and fuse terminals BT1 (18) and BT3 (4).
Disconnection in power 3) Connect T-adapter.
supply wiring harness
1 Wiring harness between fuse BT3 (4) and
ACR5 (female) (1)
contact)
ACR5 (female) (3)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
and ACPS (female) (2)
and ACTH (female) (1)
and ACM1(female) (4)
Disconnection in wiring har- and ACTH (female) (2) Resistance Max. 1 Ω
2 ness (Disconnection or de-
fective contact) Resistance Max. 1 Ω
Possible causes and ACM1 (female) (3)
and standard value Wiring harness between ACP1 (female) (16)
in normal state Resistance Max. 1 Ω
and ACM1 (female) (1)
and ACPS (female) (1)
and E07 (female) (1)
2) Disconnect connectors ACP1, ACP2, ACM1, ACM2, ACM3, ACTH,
ACPS, and E07.
Wiring harness between Resistance between ACP1
ACP1 (female) (6) and (female) (6), ACPS (female) Min. 1 M Ω
Grounding fault in wiring ACPS (female) (2) (2) and chassis ground
3
harness
ACP1 (female) (9) and (female) (9), ACTH (female) Min. 1 M Ω
ACTH (female) (1) (1) and chassis ground
ACP1 (female) (10) and (female) (10), ACM1 (female) Min. 1 M Ω
ACM1 (female) (4) (4) and chassis ground
20-960 HD465-7, HD605-7

➄

ACP1 (female) (13) and (female) (13), ACTH (female) Min. 1 M Ω
ACTH (female) (2) (2) and chassis ground
ACP1 (female) (13) and (female) (13), ACM1(female) Min. 1 M Ω
Grounding fault in wiring ACM1 (female) (2) (2) and chassis ground
3
harness
ACR5 (female) (2) and (female) (2), ACPS (female) Min. 1 M Ω
ACPS (female) (1) (1) and chassis ground
ACR5 (female) (4) and E07 (female) (4), E07 (female) Min. 1 M Ω
(female) (1) (1) and chassis ground
2) Replace relay.
Defective compressor clutch
4 4) Start air conditioner.
Possible causes relay
and standard value Replace relay Condition becomes normal. Relay is defective.
in normal state with normal one. Condition does not become normal. Relay is normal.
2) Disconnect connector ACPS.
5 Defective pressure switch
Between ACPS Air conditioner switch OFF Resistance Min. 1 M Ω
(male) (1) and Air conditioner switch ON in
(2) Resistance Max. 1 Ω
cooling mode
2) Disconnect connector ACTH.
6 Defective thermistor 4) Start air conditioner.
Between ACTH (male) Temperature: 25°C Resistance 37 – 50 k Ω
(1) and (2) Temperature: 100°C Resistance 3.5 – 4.0 k Ω
2) Replace motor.
Defective temperature ad-
7 4) Start air conditioner.
justment servomotor
Replace motor Condition becomes normal. Motor is defective.
with normal one. Condition does not become normal. Motor is normal.
2) Replace air conditioner compressor.
Defective air conditioner 4) Start air conditioner.
8
compressor Replace air Condition becomes normal. Compressor is defective.
conditioner
compressor with Condition does not become Compressor is normal.
normal one. normal.
HD465-7, HD605-7 20-961

➄

2) Replace diode (E08).
Possible causes
9 Defective diode (E08) Replace diode Condition becomes normal. Diode (E08) is defective.
and standard value
in normal state (E08) with Condition does not become
normal one. Diode (E08) is normal.
normal.
10
control panel
d) Recirculated air and fresh air cannot be selected

Trouble
None None None d) Recirculated air and fresh air cannot be selected
Contents of trouble • Recirculated air and fresh air cannot be selected because of a defect in the air conditioner system.
Problem that
• Recirculated air and fresh air cannot be selected.
appears on machine
Related information

2) Disconnect connectors ACP2 and ACM3.
Disconnection in wiring 3) Connect T-adapter.
harness
1 Wiring harness between ACP2 (female) (5)
contact)
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors ACP2 and ACM3.
2 ACP2 (female) (5) and (female) (5), ACM3 (female) Min. 1 M Ω
harness
3
control panel
20-962 HD465-7, HD605-7

➄
e) Air outlets cannot be selected

Trouble
None None None e) Air outlets cannot be selected
Contents of trouble • Air outlets cannot be selected
Problem that
• Air outlets cannot be selected
appears on machine
Related information

2) Disconnect connectors ACP1, ACP2, and ACM2.
Disconnection in wiring Wiring harness between ACP1 (female) (13)
harness Resistance Max. 1 Ω
1 and ACM2 (female) (3)
2) Disconnect connectors ACP1, ACP2, and ACM2.
and standard value
in normal state
Grounding fault in wiring ACM2 (female) (3) (3) and chassis ground
2
harness Wiring harness between Resistance between ACP2
3
control panel
HD465-7, HD605-7 20-963

➄
20-964 HD465-7, HD605-7

➄
f) Air is not cooled (Mechanical system)

Trouble
None None None f) Air is not cooled (Mechanical system)
Contents of trouble • Air is not cooled because of abnormality in mechanical system.
Problem that
• Air is not cooled because of abnormality in mechanical system.
appears on machine
Related information

Gas leakage through pipe
1 • Check and repair or replace, if abnormal.
joints or parts
Natural leakage through
hose, etc. (Refrigerant has • Check refrigerant level and add new refrigerant to proper level, if nec
2
not been added for long essary.
time)
3 Insufficient refrigerant level • Add new refrigerant to proper level.
a Check the valve for excessive opening and defective contact of

• Check and repair or replace, if abnormal.
4 Defective expansion valve
heat-sensor tube, too.
Clogging of low-pressure
5 • Check and remove clogging material, if there is any, or replace.
circuit and evaporator
• Check and remove clogging material, if there is any, and clean evap-
Possible causes 6 Clogging of evaporator fins
orator.
and standard value
in normal state 7 Clogging of filter • Check and clean, or replace.
Defective installation of ther-
mistor
Air leakage through air con-
9 • Check and repair or replace leaking part.
ditioner unit and duct
10 Insufficient set air flow • Increase set air flow.
11 Excessive refrigerant • Check refrigerant level and reduce it to proper level, if necessary.
• Evacuate system and fill it with refrigerant to proper level and replace
12 Entry of air
receiver drier.
13 Clogging of condenser fins • Check fins for clogging and clean them, if necessary.
Insufficient compression by
14 • Check and repair or replace, if necessary.
compressor
Entry of water in refrigerant • Evacuate system and fill it with refrigerant to proper level and replace
15
circuit receiver drier.
HD465-7, HD605-7 20-965

➄
g) Air is not heated (Defective hot water circuit)

Trouble
None None None g) Air is not heated (Defective hot water circuit)
Contents of trouble • Air is not heated (Defective hot water circuit).
Problem that
• Air is not heated (Defective hot water circuit).
appears on machine
• Check that water is not leaking through the hot water circuit.
Related information
• Check that air is flowing out of the air outlets.
1 Clogging of heater core fins a If this is the cause, the temperature at the hot water inlet and outlet
• Check heater core fins for clogging and clean them, if necessary.
of the heater core becomes high.
a If this is the cause, the temperature at the hot water inlet and outlet
• Check and repair or replace leaking part.
Air leakage through air con-
2
ditioner unit
of the heater core becomes high.
a If this is the cause, the temperature at the hot water inlet of the heat-
Possible causes • Check and remove clogging material, or replace valve.
and standard value 3 Defective water valve
in normal state (Clogging or defective valve)
er core becomes high but that at the hot water outlet becomes low.
4 Clogging of heater core
er core becomes high but that at the hot water outlet becomes low.
Clogging up to hot water
5
inlet of heater core
er core becomes low.
h) Abnormal sound comes out
Action code Controller code

Error code Defective air conditioner
Trouble
None None None h) Abnormal sound comes out
Contents of trouble • Abnormal sound comes out.
Problem that
• Abnormal sound comes out.
appears on machine
Related information

Defective installation of bolts
1 • Check and repair, if abnormal.
(screws) related to case
Interference of fan case, etc.
or breakage of fan
Entry of foreign matter in
Possible causes 3 blower motor or defective • Check and remove foreign matter, if there is any, and repair or replace
and standard value blower motor
in normal state • Check and replace, if abnormal sound (peep or gas leakage sound)
4 Defective expansion valve
comes out.
Loosened or worn
5 • Check and repair or replace, if loosened or worn.
compressor V-belt
Insufficient or excessive • Check refrigerant level and reduce or increase it to proper level, if
6
refrigerant necessary.
7 Defective compressor • Check and repair or replace, if abnormal.
20-966 HD465-7, HD605-7

➄
i) Water leaks

Trouble
None None None i) Water leaks
Contents of trouble • Water leaks.
Problem that
• Water leaks.
appears on machine
Related information

Clogging of water drain hole
1 • Check and repair, if abnormal.
in air conditioner unit
Clogging, bend, defective
installation, or breakage of
drain hose of air conditioner
unit
Possible causes Breakage (Cracking) of air
and standard value 3 conditioner unit case • Check and repair or replace, if broken (cracked).
in normal state
Defective installation of bolts
4 (screws) related to air • Check and repair or replace, if abnormal.
conditioner unit case
Defective joints of hot water
circuit piping
6 Defective heater core • Check and repair or replace, if abnormal.
7 Defective water valve • Check and repair or replace, if abnormal.
HD465-7, HD605-7 20-967

➄
TROUBLESHOOTING OF VHMS CONTROLLER
SYSTEM (VHMS MODE)
Electrical system diagram related VHMS controller .................................................................................. 20-1002
Information given in troubleshooting chart ................................................................................................ 20-1004
Failure type code list ................................................................................................................................. 20-1005
[A000N1] (or VHMS_LED displays [n201]) Engine overrun ............................................................. 20-1006
[DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage.................................. 20-1006-1
[DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.... 20-1006-3
[DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24V) system... 20-1006-5
[DBB7KP] (or VHMS_LED indicates "n903") Abnormality in sensor power source (12V) system... 20-1006-7
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications:
Defective communications (KR)
(between engine controller and VHMS controller)............................................................ 20-1007
[DBBSKR] (or VHMS_LED displays [n803]) Defective S-NET communications: (KR) ...................... 20-1009
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground
in engine oil temperature sensor system (KB) {30 min (at 500 rpm or above) after
starting engine}..................................................................................................................20-1011
[DGE1KY] (or VHMS_LED displays [n241]) Short circuit with power source in engine
oil temperature sensor system (KY) ................................................................................. 20-1012
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system:
Input signal outside range (KX) ........................................................................................ 20-1013
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground
in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ........................................ 20-1014
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source in No. 1, 2, 3 (front)
exhaust temperature sensor system (KB) ........................................................................ 20-1016
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground
in No. 4, 5, 6 (rear) exhaust temperature sensor system (KA) ......................................... 20-1018
[DGT5KB] (or VHMS LED displays [n321]) Short circuit with power source in No. 4, 5, 6 (rear)
exhaust temperature sensor system (KB) ........................................................................ 20-1020
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground
in engine blow-by pressure sensor system (KA) .............................................................. 20-1022
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source in engine
blow-by pressure sensor system (KY).............................................................................. 20-1023
[DhP4KX] Suspension pressure sensor (Front right): Out of input signal range (KX).................... 20-1023-1
[DhP5KX] Suspension pressure sensor (Front left): Out of input signal range (KX) ...................... 20-1023-3
[DhP6KX] Suspension pressure sensor (Rear right): Out of input signal range (KX) .................... 20-1023-5
[DhP7KX] Suspension pressure sensor (Rear left): Out of input signal range (KX)....................... 20-1023-7
[DKH1KX] Pitch angle sensor: Out of input signal range (KX)........................................................ 10-1023-9
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .......................... 20-1024
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (front) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1025
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (front) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1026
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (rear) exhaust temperature is high
(2):(NR)............................................................................................................................. 20-1027
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (rear) exhaust temperature is high
(1):(NS)............................................................................................................................. 20-1028
VHMS-1 VHMS-1 Abnormality in satellite data communication
a) Satellite communication data are not transmitted ......................................................... 20-1029
b) Abnormality in downloading into PC or setting of PC ................................................... 20-1032
VHMS-2 Abnormality in saving data in VHMS controller ................................................................. 20-1034
VHMS-3 Engine blow-by pressure indicated by monitor is low........................................................ 20-1036
HD465-7, HD605-7 20-1001

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
ELECTRICAL SYSTEM DIAGRAM RELATED VHMS CONTROLLER
20-1002 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1003

➄
20-1003-1 HD465-7, HD605-7

➄
TROUBLESHOOTING INFORMATION GIVEN IN TROUBLESHOOTING CHART
INFORMATION GIVEN IN TROUBLESHOOTING CHART

★ The following type of information is given in the troubleshooting charts and related circuit diagrams, so make
sure that you understand the content fully before starting troubleshooting.
Shown on panel Shown on Shown on Trouble Problem that appeared on machine
display panel display panel display
Contents of trouble Condition when monitor panel or controller detected failure.
Action of controller Action taken to protect system or equipment when monitor panel or controller detected failure.
Problem that
Problem that appeared on machine when monitor panel or controller took above action.
appears on machine
Related information Information related to troubleshooting or failure that occurred.

<Content of information>
• Standard value when condition is normal (used to judge status of
probable failure).
1 • Remarks used to judge status of probable failure.
<Problems with wiring harness>

• Disconnection
Defective connection of connector or disconnection in wiring har-
ness.
2 • Short circuit with chassis ground
Wiring harness not connected to GND (ground) circuit is in contact
with GND circuit.
• Short circuit with power source
Wiring harness not connected to power source (24V) circuit is in
contact with power source circuit.
Probable cause Probable cause of existing • Short circuit
and standard value 3 failure (the numbers are Wiring harnesses of independent circuits are in abnormal contact.
when normal index numbers and do not
indicate the order of priority) <Precautions when troubleshooting>
Method of displaying connector No. and method of handling T-
adapter
If there are no special instructions, insert or connect the T-adapter
as follows.
4 • If there is no indication of (male) or (female) with the connector
No., disconnect the connector and insert the T-adapter into both
the male and female sides.
• If (male) or (female) is indicated with the connector No., discon-
nect the connector and insert the T-adapter into only the side indi-
cated (either male or female).
Order of listing pin No. and method of handling test lead
5 If there are no special instructions, connect the (+) lead and (–) lead
of the tester as follows.
• Connect the (+) lead to the pin No. or wiring harness given first.
• Connect the (–) lead to the pin No. or wiring harness given last.
20-1004 HD465-7, HD605-7

➁
TROUBLESHOOTING FAILURE TYPE CODE LIST
This is the section of the circuit diagram that shows the parts related to the failure.
• Connector No.: (type – No. of pins) (color).
• Arrows (⇔): Shows approximate mounting position on machine.
FAILURE TYPE CODE LIST

★ For failure type codes marked "See list", refer to this list.
Failure type Failure type
code Details of problem code Details of problem
Fill signal for non-existent combination of clutches ON simulta-

KA Disconnection L0 neously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
Drop in power source volt-
KK age, input L2 Fuel pressure is higher than max. specified value.
Mismatch in model selec-

KQ tion signal L3 Target components cannot be controlled.
KR Defective communications L4 ON/OFF signals from 2 systems do not match.

Engine speed signal, C terminal signal, oil pressure switch,
KT Abnormality inside con- L6 water temperature sensor signals do not match operating con-
troller dition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
KY source LC Speed signals of 2 systems do not match.
Disconnection or short cir- Switch remains pressed for length of time unthinkable for nor-
KZ cuit LD mal operations .
Fill signal is turned OFF when command current to ECMV is
MA Defective function LH ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
HD465-7, HD605-7 20-1005

➁
TROUBLESHOOTING [A000N1]
[A000N1] (OR VHMS_LED DISPLAYS [n201]) ENGINE OVERRUN

Trouble Engine overrun
None A000N1 None
Contents of trouble • Engine speed of more than 2,625 rpm is detected when engine is running.
Action of controller • Carries out control for default mode.
Problem that
• If machine continues to be used as it is, engine may be damaged.
appears on machine
• Engine speed can be checked with monitoring function (code: 01001)
• LED display is [n201]
Related information
• If failure codes [C115KZ] or [C121LC] related to engine controller are displayed, carry out troubleshoot-
ing first for the applicable code.

1 Engine overrun Inspect engine and repair if any abnormality is found.
Defective engine speed
Probable cause 2 Carry out troubleshooting for failure code [C115KZ] or [C121LC].
sensor
and standard value
when normal 1) Start engine.
2) Check with monitoring function (code: 01001).
3 Defective VHMS controller
Monitoring code:
High idling speed Power mode 2,270 ± 50 rpm
01001
20-1006 HD465-7, HD605-7

➁
TROUBLESHOOTING [DBB0KK]
[DBB0KK] (OR VHMS_LED INDICATES "n901") ABNORMALITY IN SOURCE

VOLTAGE

Trouble Abnormality source voltage
None DBB0KK None
Contents of trouble • The switch source voltage is below 9.5(± 2.5)V or above 42.4(± 6)V.
Problem that
• The system may not operate normally.
appears on machine
Related information • VHMS controller LED indicates "n901".

• If the circuit breaker is turned OFF, the circuit probably has ground-
1 Defective circuit breaker
ing fault (See cause 3).
2) Disconnect connector HM-CN1 and battery relay terminal CN-02
(Terminal M).
Disconnection in wiring har- Wiring harness between HM-CN1 (female) (8),
2 ness (Disconnection or de- (9) and battery relay CN-02 (Terminal M) Resistance Max. 1 Ω
fective contact)
Wiring harness between HM-CN1 (female)
(11), (12) and ER
Probable cause Resistance Max. 1 Ω
(19), (20) and ER
and standard value
when normal
2) Disconnect connector HM-CN1, battery relay terminal CN-02
(Terminal M), and connectors related to them.
3 Wiring harness between Resistance between HM-
harness
HM-CN1 (female) (8), (9) CN1 (female) (8), (9) and
and battery relay CN-02 chassis ground Min. 1 M Ω
(Terminal M) and wiring har-
nesses related to it
2) Disconnect HM-CN1.
4 Defective VHMS controller 3) Connect T-adapter.
Between HM-CN1 (8), (9) and chassis ground Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-1

➄
TROUBLESHOOTING [DBB0KK]
20-1006-2 HD465-7, HD605-7

➄
TROUBLESHOOTING [DBB5KP]
[DBB5KP] (OR VHMS_LED INDICATES "n904") ABNORMALITY IN SENSOR POWER

SOURCE (5 V) SYSTEM

Trouble Abnormality in sensor power source (5 V) system
None DBB5KP None
Contents of trouble • Sensor power source (5 V) voltage is out of the normal range (4.5 – 5.5 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and HM-12.
harness
HM-CN1 (female) (4), (5) CN1 (female) (4), (5), HM-
Min. 1 M Ω
and HM-12 (female) (B) CN12 (female) (B) and chas-
sis ground
Probable cause 2) Disconnect connectors HM-CN1 and HM-12.
and standard value 3) Connect T-adapter.
when normal Short circuit with power 4) Turn starting switch ON.
2
source in wiring harness Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (4), (5) (female) (4), (5), HM-12 (fe-
Max. 1 V
and HM-12 (female) (B) male) (B) and chassis
ground
Between HM-CN1 (4), (5) and (11), (12) Voltage 4.5 – 5.5 V
HD465-7, HD605-7 20-1006-3

➄
20-1006-4 HD465-7, HD605-7

➄

SOURCE (24 V) SYSTEM

None DBB6KP None
Contents of trouble • Sensor power source (24 V) voltage is out of the normal range (20 - 30V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1, HM-23A, HM-23B, SUFR, SUFL,
SURR, and SURL.
Wiring harness between Resistance between HM-
HM-CN1 (female) (2) and CN1 (female) (2), HM-23A
Min. 1 M Ω
HM-23A (female) (A), HM- (female) (A), HM-23B (fe-
23B (female) (A) male) and chassis ground
harness
HM-CN1 (female) (2) and CN1 (female) (2), HM-SUFL
HM-SUFL (female) (B), HM- (female) (B), HM-SUFR (fe- Min. 1 M Ω
SUFR (female) (B) male) (B) and chassis
ground
Wiring harness between HM- Resistance between HM-
CN1 (female) (2) and HM- CN1 (female) (2), HM-SURL
Min. 1 M Ω
SURL (female) (B), HM- (female) (B), HM-SURR (fe-
SURR (female) (B) male) (B) and chassis ground
Probable cause 2) Disconnect connectors HM-CN1, GR-2, HM-23A, HM-23B, SUFR,
and standard value SUFL, SURR, and SURL.
when normal 3) Connect T-adapter.
Wiring harness between Voltage between HM-CN1
HM-CN1 (female) (2) and (female) (2), HM-23A (fe-
Max. 1 V
HM-23A (female) (A), HM- male) (A), HM-23B (female)
Short circuit with power 23B (female) (A) (A) and chassis ground
2
source in wiring harness Voltage between HM-CN1
Wiring harness between
(female) (2), HM-SUFL (fe-
HM-CN1 (female) (2) and
male) (B), HM-SUFR (fe- Max. 1 V
HM-SUFL (female) (B), HM-
male) (B) and chassis
SUFR (female) (B)
ground
HM-CN1 (female) (2) and (female) (2), HM-SURL (fe-
Max. 1 V
HM-2SURL (female) (B), male) (B), HM-SURR (fe-
HM-SURR (female) (B) male) (B) and chassis ground
Between HM-CN1 (2) and (11), (12) Voltage 20 – 30 V
HD465-7, HD605-7 20-1006-5

➄
20-1006-6 HD465-7, HD605-7

➄

SOURCE (12 V) SYSTEM

None DBB7KP None
Contents of trouble • Sensor power source (12 V) voltage is out of the normal range (10 – 15 V).
Problem that
appears on machine

2) Disconnect connectors HM-CN1 and GDL.
1 Resistance between HM-
harness Wiring harness between
CN1 (female) (3), GDL
HM-CN1 (female) (3) and Min. 1 M Ω
(male) (1) and chassis
GDL (male) (1)
ground
Probable cause
2) Disconnect connectors HM-CN1 and GDL.
and standard value
when normal Short circuit with power
HM-CN1 (female) (3) and (female) (3), GDL (male) (1) Max. 1 V
GDL (male) (1) and chassis ground
3 Defective VHMS controller 3) Insert T-adapter.
Between HM-CN1 (3) and (11), (12) Voltage 10 – 15V
HD465-7, HD605-7 20-1006-7

➄
20-1006-8 HD465-7, HD605-7

➄
TROUBLESHOOTING [DBBRKR]
[DBBRKR] (OR VHMS_LED DISPLAYS [n801]) DEFECTIVE CAN COMMUNICATIONS:

DEFECTIVE COMMUNICATIONS (KR)
(BETWEEN ENGINE CONTROLLER AND VHMS CONTROLLER)
Action code Error code Controller code Defective CAN communications: Defective communications (KR)
Trouble
None DBBRKR None (between engine controller and VHMS controller)
Contents of trouble • Communications (CAN) data from engine controller cannot be obtained.
Action of controller • Maintains condition existing when abnormality occurred.
Problem that
• VHMS function for obtaining data from engine controller not working.
appears on machine
Related information • If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first
for the applicable code.

2) Disconnect connectors HM-CN4A and CAN1.
harness
1 Wiring harness between HM-CN4A (female)
(disconnection, defective Resistance Max. 1 Ω
and CAN1 (female)
contact)
Wiring harness between HM-CN4A (female)
and CAN1 (female)
2) Disconnect connectors HM-CN4A and CAN1.
Resistance value between
HM-CN4A (female) ,
Short circuit with chassis HM-CN4A (female) and Max. 1 Ω
2 CAN1 (female) – chassis
ground in wiring harness CAN1 (female)
ground
HM-CN4A (female) ,
Probable cause HM-CN4A (female) and Max. 1 Ω
CAN1 (female) – chassis
and standard value CAN1 (female)
ground
when normal
2) Disconnect connector HM-CN4A.
Short circuit with power Wiring harness between Voltage between HM-CN4A
3
source in wiring harness HM-CN4A (female) and (female) , CAN1 (female) Max. 1 V
CAN1 (female) – chassis ground
Wiring harness between Voltage between HM-CN4A
HM-CN4A (female) and (female) , CAN1 (female) Max. 1 V
CAN1 (female) – chassis ground
2) Replace VHMS controller.
4 Defective VHMS controller Does not communicate VHMS controller
Is communication normally normal
normal when VHMS
controller is replaced? Communicates VHMS controller
normally defective
HD465-7, HD605-7 20-1007

➁
TROUBLESHOOTING [DBBRKR]
20-1008 HD465-7, HD605-7

➁
TROUBLESHOOTING [DBBSKR]
[DBBSKR] (OR VHMS_LED DISPLAYS [n803]) DEFECTIVE S-NET COMMUNICATIONS:

(KR)

Trouble Defective S-NET communications: (KR)
E03 DBBSKR None
Contents of trouble • Communications data from controller cannot be obtained.
Action of controller • Machine monitor shows abnormal display screen (red) to warn operator of abnormality.
Problem that
• In some cases, system does not work normally.
appears on machine
• If failure code [DAQSKR], [DBISKR] related to S-NET of other controllers is displayed, carry out trou-
Related information bleshooting first for the applicable code.

2) Disconnect connectors HM-CN3A, JCB, JCC, and JCD.
Disconnection in wiring Wiring harness between HM-CN3A (female)
1 and JCB (female)
(disconnection, defective
and JCD (female)
, – JCC (female) , JCE (female)
2) Disconnect connectors HM-CN3A, JCB, and JCD.
HM-CN3A (female) , JCB
Short circuit with chassis HM-CN3A (female) and Min. 1 MΩ
2 (female) – chassis
ground in wiring harness JCB (female)
ground
Probable cause Resistance value between
and standard value Wiring harness between
HM-CN3A (female) , JCD
when normal HM-CN3A (female) and Min. 1 MΩ
(female) – chassis
JCD (female)
ground
2) Disconnect connector HM-CN3A, JCB, and JCD.
3 HM-CN3A (female) and (female) , JCB (female) Max. 1 V
JCB (female) – chassis ground
HM-CN3A (female) and (female) , JCD (female) Max. 1 V
JCD (female) – chassis ground
4 Defective VHMS controller 4) Connect connector.
Between HM-CN3A and Voltage Max. 6 – 9 V
Between HM-CN3A and Voltage Max. 6 – 9 V
HD465-7, HD605-7 20-1009

➁
TROUBLESHOOTING [DBBSKR]
20-1010 HD465-7, HD605-7

➁
TROUBLESHOOTING [DGE1KB]
[DGE1KB] (OR VHMS_LED DISPLAYS [n242]) DISCONNECTION, SHORT CIRCUIT WITH

CHASSIS GROUND IN ENGINE OIL TEMPERUTURE SENSOR SYSTEM (KB)
{30 MIN (AT 500 RPM OR ABOVE) AFTER STARTING ENGINE}
Action code Error code Controller code Disconnection, short circuit with chassis ground in engine oil
Trouble temperature sensor system (KB)
None DGE1KB None {30 min (at 500 rpm or above) after starting engine}
Contents of trouble • Signal voltage of engine oil temperature sensor has dropped below 0.3V.
Action of controller • Takes no particular action.
Problem that
• Engine oil temperature cannot be monitored with monitoring function.
appears on machine
• Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

2) Disconnect connector HM-31.
Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
Between HM-31 (male) 25 °C Resistance Approx. 35 – 50 kΩ
and 100 °C Resistance Approx. 3.3 – 4.3 kΩ
2) Disconnect connectors HM-CN2A and HM-31.
harness
Probable cause and HM-31 (female)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 Ω
and HM-31 (female)
2) Disconnect connector HM-CN2A and HM-31.
Short circuit with chassis
ground in wiring harness Wiring harness between
HM-CN2A (female) , HM-
HM-CN2A (female) and Min. 1 MΩ
HM-31 (female)
ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kΩ
HD465-7, HD605-7 20-1011

➁
TROUBLESHOOTING [DGE1KY]
[DGE1KY] (OR VHMS_LED DISPLAYS [n241]) SHORT CIRCUIT WITH POWER

SOURCE IN ENGINE OIL TEMPERATURE SENSOR SYSTEM (KY)
Action code Error code Controller code Short circuit with power source in engine oil temperature sensor
Trouble
None DGE1KY None system (KY)
Contents of trouble • Signal voltage of engine oil temperature sensor has risen above 4.9V.
Problem that
• Engine oil temperature cannot be monitored with monitoring function.
appears on machine
• Engine oil temperature can be checked with monitoring function (code: 42700).
Related information

Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch OFF.
Between HM-31 (male) 25 °C Resistance Approx. 35 – 50 kΩ
Probable cause 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors HM-CN2A and HM-31.
when normal Short circuit with power 3) Connect T-adapter.
2
source in wiring harness Wiring harness between Voltage between HM-CN2A
HM-CN2A (female) and (female) , HM-31 (female) Max. 1 V
HM-31 (female) – chassis ground
Between HM-CN2A (female) 25 °C Resistance Approx. 35 – 50 kΩ
20-1012 HD465-7, HD605-7

➁
TROUBLESHOOTING [DGE5KX]
[DGE5KX] (OR VHMS_LED DISPLAYS [n401]) FAILURE IN AMBIENT TEMPERATURE

SENSOR SYSTEM: INPUT SIGNAL OUTSIDE RANGE (KX)
Action code Error code Controller code Failure in ambient temperature sensor system: Input signal out-
Trouble
None DGE5KX None side range (KX)
Contents of trouble • Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.
Problem that
• Ambient temperature cannot be monitored with monitoring function.
appears on machine
• Ambient temperature can be checked with monitoring function (code: 37501).
Related information

4) Connect connector.
Defective ambient
temperature sensor
0 °C Resistance Approx. 10 – 15 kΩ
Between HM-35 (male)
and
harness
Probable cause and HM-35 (female)
contact)
and standard value Wiring harness between HM-CN2A (female)
when normal Resistance Max. 1 Ω
and HM-35 (female)
Short circuit with chassis
ground in wiring harness Wiring harness between
HM-35 (female)
ground
4 Defective VHMS controller 0 °C Resistance Approx. 10 – 15 kΩ
Between HM-CN2A (female)
and
HD465-7, HD605-7 20-1013

➁
TROUBLESHOOTING [DGT4KA]
[DGT4KA] (OR VHMS_LED DISPLAYS [n312])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 1, 2, 3
(FRONT) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in No. 1, 2, 3
Trouble
None DGT4KA None (front) exhaust temperature sensor system (KA)
Contents of trouble • Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
• No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function.
appears on machine
• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
Related information
• LED display is [n312].

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor.
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
1 Does not become normal when replaced
exhaust temperature sensor normal
Exhaust temperature sensor
Becomes normal when replaced
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
2 exhaust temperature sensor 5) Start engine.
amp
Between and Voltage 20 – 30 V
HM-23A Between and 20 °C Voltage Approx. 0.9 – 1.2 V
500 °C Voltage Approx. 2.6 – 3.5 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Probable cause 3) Connect T-adapter.
and standard value
when normal Disconnection in wiring Resistance Max. 1 Ω
harness and HM-23A (female)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
and HM-23A (female)
Wiring harness between HM-22A (female)
and HM-21A (female)
Wiring harness between HM-22A (female)
and HM-21A (female)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21A, HM-22A, and
HM-23A.
Short circuit with chassis HM-CN1 (female) , HM-
4 HM-CN1 (female) and Min. 1 MΩ
ground in wiring harness 23A (female) – chassis
HM-23A (female)
ground
23A (female) – chassis
HM-23A (female)
ground
20-1014 HD465-7, HD605-7

➁

2) Disconnect connectors HM-CN1 and HM-CN2A.
Probable cause
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
Between HM-CN1 and HM-CN2A Voltage 20 – 30 V
Between HM-CN2A and 20 °C Voltage Approx. 0.9 – 1.2V
HD465-7, HD605-7 20-1015

➁
TROUBLESHOOTING [DGT4KB]
[DGT4KB] (OR VHMS_LED DISPLAYS [n311])

SHORT CIRCUIT WITH POWER SOURCE IN NO. 1, 2, 3 (FRONT) EXHAUST
TEMPERATURE SENSOR SYSTEM (KB)
Action code Error code Controller code Short circuit with power source in No. 1, 2, 3 (front) exhaust tem-
Trouble
None DGT4KB None perature sensor system (KB)
Contents of trouble • Signal voltage of more than 4.9V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
Problem that
• No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function
appears on machine
Related information

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor
Defective No. 1, 2, 3 (front) Exhaust temperature sensor
defective
2) Disconnect connector HM-23A.
Defective No. 1, 2, 3 (front) 4) Connect connector.
amp
HM-23A Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21A and HM-22A.
Probable cause Short circuit with chassis
and standard value 3 ground in wiring harness Resistance value between
when normal HM-22A (female) ,
HM-22A (female) and Min. 1 MΩ
HM-21A (female) – chas-
HM-21A (female)
sis ground
2) Disconnect connectors HM-CN2A and HM-23A.
Short circuit with chassis 4) Turn starting switch ON.
4
ground in wiring harness Resistance value between
HM-CN2 (female) ,
HM-23A (female) – chas-
HM-23A (female)
sis ground
5 Defective VHMS controller 5) Start engine.
Between HM-CN2A and 20 °C Voltage Approx. 0.9 – 1.2 V
20-1016 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-1017

➁
[DGT5KA] (OR VHMS_LED DISPLAYS [n322])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN NO. 4, 5, 6
(REAR) EXHAUST TEMPERATURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in No. 4, 5, 6
Trouble
None DGT5KA None (rear) exhaust temperature sensor system (KA)
Contents of trouble • Signal voltage of less than 0.3V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
• No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function
appears on machine
• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601).
Related information

2) Replace No. 4, 5, 6 (ear) exhaust temperature sensor
Defective No. 4, 5, 6 (ear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (ear) 4) Connect connector.
amp
HM-23B Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Probable cause 3) Connect T-adapter.
and standard value
when normal Disconnection in wiring Resistance Max. 1 Ω
harness and HM-23B (female)
3
(disconnection, defective Wiring harness between HM-CN2A (female)
and HM-23B (female)
Wiring harness between HM-22B (female)
and HM-21B (female)
Wiring harness between HM-22B (female)
and HM-21B (female)
2) Disconnect connectors HM-CN1, HM-CN2A, HM-21B, HM-22B, and
HM-23B.
Short circuit with chassis HM-CN1 (female) , HM-
4 HM-CN1 (female) and Min. 1 MΩ
ground in wiring harness 23B (female) – chassis
HM-23B (female)
ground
23B (female) – chassis
HM-23B (female)
ground
20-1018 HD465-7, HD605-7

➁

Probable cause 3) Insert T-adapter.
and standard value 4) Connect connector.
when normal 5 Defective VHMS controller 5) Start engine.
HD465-7, HD605-7 20-1019

➁
[DGT5KB] (OR VHMS_LED DISPLAYS [n321])

SHORT CIRCUIT WITH POWER SOURCE IN NO. 4, 5, 6 (REAR) EXHAUST
TEMPERATURE SENSOR SYSTEM (KB)
Action code Error code Controller code Short circuit with power source in No. 4, 5, 6 (rear) exhaust tem-
Trouble
None DGT5KB None perature sensor system (KB)
Contents of trouble • Signal voltage of more than 4.9V detected from No. 4, 5, 6 (rear) exhaust temperature sensor.
Problem that
• No. 4, 5, 6 (rear) exhaust temperature cannot be monitored with monitoring function.
appears on machine
Related information

2) Replace No. 4, 5, 6 (rear) exhaust temperature sensor
Defective No. 4, 5, 6 (rear) Exhaust temperature sensor
defective
2) Disconnect connector HM-23B.
Defective No. 4, 5, 6 (rear) 4) Connect connector.
amp
HM-23B Between and 20 °C Voltage Approx. 0.9 – 1.2 V
2) Disconnect connectors HM-21B and HM-22B.
Probable cause Short circuit with chassis
and standard value 3 ground in wiring harness Resistance value between
when normal HM-22B (female) ,
HM-22B (female) and Min. 1 MΩ
HM-21B (female) – chas-
HM-21B (female)
sis ground
2) Disconnect connectors HM-CN2A and HM-23B.
Short circuit with chassis 4) Turn starting switch ON.
4
ground in wiring harness Resistance value between
HM-CN2 (female) ,
HM-23B (female) – chas-
HM-23B (female)
sis ground
20-1020 HD465-7, HD605-7

➁
HD465-7, HD605-7 20-1021

➁
TROUBLESHOOTING [DHE5KB]
[DHE5KB] (OR VHMS_LED DISPLAYS [n332])

DISCONNECTION, SHORT CIRCUIT WITH CHASSIS GROUND IN ENGINE
BLOW-BY PRESSURE SENSOR SYSTEM (KA)
Action code Error code Controller code Disconnection, short circuit with chassis ground in engine blow-
Trouble
None DHE5KB None by pressure sensor system (KA)
Contents of trouble • Signal voltage of blow-by pressure sensor has dropped below 0.1V.
Problem that
• Blow-by pressure cannot be monitored with monitoring function.
appears on machine
• Blow-by pressure can be checked with monitoring function (code: 42800).
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 and Voltage 4.5 – 5.5V
Between HM-12 and Voltage 0.3 – 0.7V
2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
2 ness (disconnection, defec- Wiring harness between HM-CN1 (female)
tive contact) , – HM-12 (female)
and HM-12 (female)
Probable cause
and standard value 2) Disconnect connectors HM-CN1, HM-CN2A, and HM-12.
when normal
HM-CN1 (female) , ,
Short circuit with chassis HM-CN1 (female) , – Min. 1 MΩ
3 HM-12 (female) – chas-
ground in wiring harness HM-12 (female)
sis ground
12 (female) - chassis
HM-12 (female)
ground
4 Defective VHMS controller
5) Start engine.
Between HM-CN1 and HM-CN2A Voltage 4.5 – 5.5V
Between HM-CN2A and Voltage 0.3 – 0.7V
20-1022 HD465-7, HD605-7

➁
TROUBLESHOOTING [DHE5KY]
[DHE5KY] (OR VHMS_LED DISPLAYS [n331]) SHORT CIRCUIT WITH POWER

SOURCE IN ENGINE BLOW-BY PRESSURE SENSOR SYSTEM (KY)
Action code Error code Controller code Short circuit with power source in engine blow-by pressure sen-
Trouble
None DHE5KY None sor system (KY)
Contents of trouble • Signal voltage of blow-by pressure sensor has risen above 4.7V.
Problem that
• Blow-by pressure cannot be monitored with monitoring function.
appears on machine
Related information

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between HM-12 and Voltage 4.5 – 5.5 V
Between HM-12 and Voltage 0.3 – 0.7 V
Probable cause
and standard value
when normal Short circuit with chassis
ground in wiring harness
HM-CN2A (female) and (female) , HM-12 (female) Max. 1 V
HM-12 (female) – chassis ground
Between HM-CN1 and HM–CN2A Voltage 4.5 – 5.5 V
Between HM-CN2A and Voltage 0.3 – 0.7 V
HD465-7, HD605-7 20-1023

➁
TROUBLESHOOTING [DhP4KX]
[DhP4KX] SUSPENSION PRESSURE SENSOR (FRONT RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Front right): Out of input signal
Trouble
E01 DhP4KX PLM range (KX)
• The voltage of the signal circuit of the suspension pressure sensor (Front right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
• The payload is not indicated and saved correctly.
appears on machine
• The suspension pressure (Front right) signal can be checked with the monitoring function (Code:
Related information 32804).
• This failure occurs only when the built-in PLM function is installed.

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 z
1 ness (Disconnection or de- (1) and SUFR (female) (C)
fective contact) Wiring harness between HM-CN1 (female) (2)
Resistance Max. 1 z
and SUFR (female) (B)
Wiring harness between HM-CN2B (female)
Resistance Max. 1 z
(9) and SUFR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFR.
Resistance between HM-
CN2B (female) (1), SUFR
Grounding fault in wiring HM-CN2B (female) (1) and Min. 1 M z
2 (female) (C) and chassis
harness SUFR (female) (C)
ground
Resistance between HM-
CN1 (female) (2), SUFR
HM-CN1 (female) (2) and Min. 1 M z
(female) (B) and chassis
Probable cause SUFR (female) (B)
ground
and standard value
when normal 1) Turn starting switch OFF.
2) Disconnect connectors HM-CN2B and SUFR.
Short circuit with power 4) Turn starting switch ON.
3
Wiring harness between Voltage between HM-CN2B
HM-CN2B (female) (1) and (female) (1), SUFR (female) Max. 1 V
3) Insert connect T-adapter.
Defective suspension pres- 4) Connect connector.
4
sure sensor (Front right) 5) Turn starting switch ON.
Between SUFR (B) and (A) Voltage 20 – 30 V
2) Disconnect connectors HM-CN1 and HM-CN2B.
Defective VHMS & PLM 4) Connect connector.
5
controller 5) Turn starting switch ON.
Between HM-CN1 (2) and HM-CN2B (9) Voltage 20 – 30 V
Between HM-CN2B (1) and (9) Voltage 1.0 – 4.6 V
20-1023-1 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-1023-2

➄
[DhP5KX] SUSPENSION PRESSURE SENSOR (FRONT LEFT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Front left): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Front left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Front left) signal can be checked with the monitoring function (Code:
Related information 32805).

2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
1 ness (Disconnection or de- (2) and SUFL (female) (C)
Resistance Max. 1 z
and SUFL (female) (B)
Resistance Max. 1 z
(9) and SUFL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SUFL.
HM-CN2B (female) (2) and CN2B (female) (2), SUFL
Grounding fault in wiring Min. 1 M z
2 SUFL (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), SUFL (fe-
Min. 1 M z
SUFL (female) (B) male) (B) and chassis
Probable cause ground
and standard value
2) Disconnect connectors HM-CN2B and SUFL.
3
HM-CN2B (female) (2) and (female) (2), SUFL (female) Max. 1 V
4
sure sensor (Front left) 5) Turn starting switch ON.
Between SUFL (B) and (A) Voltage 20 – 30 V
5
20-1023-3 HD465-7, HD605-7

(7)
HD465-7, HD605-7 20-1023-4

➄
[DhP6KX] SUSPENSION PRESSURE SENSOR (REAR RIGHT): OUT OF INPUT SIG-

NAL RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Rear right) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32806).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 Ω
1 ness (Disconnection or de- (7) and SURR (female) (C)
and SURR (female) (B)
(9) and SURR (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURR.
HM-CN2B (female) (7) and CN2B (female) (7), SURR
Grounding fault in wiring Min. 1 M Ω
2 SURR (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (7), SURR
Min. 1 M Ω
SURR (female) (B) (female) (C) and chassis
and standard value
2) Disconnect connectors HM-CN2B and SURR.
3
HM-CN2B (female) (7) and (female) (7), SURR (female) Max. 1 V
SURR (female) (C) (C) and chassis ground
2) Disconnect connector SURR.
4
sure sensor (Rear right) 5) Turn starting switch ON.
Between SURR (B) and (A) Voltage 20 – 30 V
Between SURR (C) and (A) Voltage 1.0 – 4.6 V
5
20-1023-5 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1023-6

➄
[DhP7KX] SUSPENSION PRESSURE SENSOR (REAR LEFT): OUT OF INPUT SIGNAL

RANGE (KX)
Action code Error code Controller code Suspension pressure sensor (Rear right): Out of input signal
Trouble
• The voltage of the signal circuit of the suspension pressure sensor (Rear left) is below 0.3 V or above
Contents of trouble
4.9 V.
Problem that
appears on machine
• The suspension pressure (Rear left) signal can be checked with the monitoring function (Code: 32807).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
Disconnection in wiring har- Wiring harness between HM-CN2B (female) Resistance Max. 1 Ω
1 ness (Disconnection or de- (8) and SURL (female) (C)
and SURL (female) (B)
(9) and SURL (female) (A)
2) Disconnect connectors HM-CN1, HM-CN2B, and SURL.
HM-CN2B (female) (8) and CN2B (female) (8), SURL
Grounding fault in wiring Min. 1 M Ω
2 SURL (female) (C) (female) (C) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), SURL (fe-
Min. 1 M Ω
SURL (female) (B) male) (B) and chassis
and standard value
2) Disconnect connectors HM-CN2B and SURL.
3
HM-CN2B (female) (8) and (female) (8), SURL (female) Max. 1 V
SURL (female) (C) (C) and chassis ground
2) Disconnect connector SURL.
4
sure sensor (Rear left) 5) Turn starting switch ON.
Between SURL (B) and (A) Voltage 20 – 30 V
Between SURL (C) and (A) Voltage 1.0 – 4.6 V
5
20-1023-7 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1023-8

➄
TROUBLESHOOTING [DKH1KX]
[DKH1KX] PITCH ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Pitch angle sensor: Out of input signal range (KX)
E01 DKH1KX PLM
Contents of trouble • The voltage of the signal circuit of the pitch angle sensor is below 0.3 V or above 4.9 V.
Problem that
appears on machine
• The pitch angle sensor signal [Angle (rad)] can be checked with the monitoring function (Code: 32901).
Related information

2) Disconnect connectors HM-CN1, HM-CN2B, and PM3.
1 ness (Disconnection or de- (3) and PM3 (female) (B)
Resistance Max. 1 z
and PM3 (female) (C)
Resistance Max. 1 z
(9) and PM3 (female) (A)
2) Disconnect connectors BRCB and PM3.
HM-CN2B (female) (3) and CN2B (female) (3), PM3 (fe-
Grounding fault in wiring Min. 1 M z
2 PM3 (female) (B) male) (B) and chassis
harness
ground
HM-CN1 (female) (2) and CN1 (female) (2), PM3 (fe-
Min. 1 M z
Probable cause PM3 (female) (C) male) (C) and chassis
and standard value ground
2) Disconnect connectors BRC3B and PM3.
3
HM-CN2B (female) (3) – (female) (3), MP3 (female) Max. 1 V
PM3 (female) (B) (B) and chassis ground
2) Disconnect connectors PM3.
4 Defective pitch angle sensor 4) Turn starting switch ON.
Between PM3 (C) and (A) Voltage 20 – 30 V
Between PM3 (B) and (A) Voltage 1.0 – 4.6 V
2) Disconnect connectors PM5 and HM-CN2B
5
20-1023-9 HD465-7, HD605-7

(7)
TROUBLESHOOTING [DKH1KX]
HD465-7, HD605-7 20-1023-10

(6)
TROUBLESHOOTING [F@BBZL]
[F@BBZL] (OR VHMS_LED DISPLAYS [n338])

ENGINE BLOW-BY PRESSURE IS HIGH: (ZL)

Trouble Engine blow-by pressure is high: (ZL)
None F@BBZL None
Contents of trouble • Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.
Problem that
appears on machine
Related information
• If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in blow-by
Probable cause 1 Inspect engine and repair if any abnormality is found
pressure
and standard value
when normal Defective orifice inside
2 Inspect orifice inside breather and repair if any abnormality is found
breather
3 Defective VHMS controller If Items 1 and 2 are normal, defective VHMS controlle
20-1024 HD465-7, HD605-7

➁
TROUBLESHOOTING [F@BYNR]
[F@BYNR] (OR VHMS_LED DISPLAYS [n362])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (2):(NR)
None F@BYNR None
• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
750 °C at more than rated output speed and 800 °C at less than max. torque speed)
Problem that
appears on machine
• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600)
Related information
• If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in exhaust
temperature for No. 1, 2, 3
1 Inspect engine and repair if any abnormality is found
(front)
(When system is normal)
and standard value 2) Disconnect connectors HM-CN1 and HM-CN2A.
when normal 3) Insert T-adapter.
HD465-7, HD605-7 20-1025

➁
TROUBLESHOOTING [F@BYNS]
[F@BYNS] (OR VHMS_LED DISPLAYS [n361])

NO. 1, 2, 3 (FRONT) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 1, 2, 3 (front) exhaust temperature is high (1):(NS)
None F@BYNS None
• Signal circuit of No. 1, 2, 3 (front) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(front)
20-1026 HD465-7, HD605-7

➁
TROUBLESHOOTING [F@BZNR]
[F@BZNR] (OR VHMS_LED DISPLAYS [n372])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (2):(NR)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (2):(NR)
None F@BZNR None
• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
HD465-7, HD605-7 20-1027

➁
TROUBLESHOOTING [F@BZNS]
[F@BZNS] (OR VHMS_LED DISPLAYS [n371])

NO. 4, 5, 6 (REAR) EXHAUST TEMPERATURE IS HIGH (1):(NS)

Trouble No. 4, 5, 6 (rear) exhaust temperature is high (1):(NS)
None F@BZNS None
• Signal circuit of No. 4, 5, 6 (rear) exhaust temperature sensors has detected more than exhaust tem-
Contents of trouble perature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between
Problem that
appears on machine
Related information
code.

(rear)
Between HM-CN2A and 20° C Voltage Approx. 0.9 – 1.2 V
20-1028 HD465-7, HD605-7

➁
TROUBLESHOOTING VHMS-1
VHMS-1 ABNORMALITY IN SATELLITE DATA COMMUNICATION

a) Satellite communication data are not transmitted
Action code Error code Controller code Abnormality in satellite data communication
Trouble
None None None a) Satellite communication data are not transmitted
Contents of trouble • Satellite communication data are not transmitted.
Problem that
• Satellite communication data are not transmitted.
appears on machine
Related information
aMove the machine outdoors.

Machine is in tunnel or build- • Not defective.
1
ing
aMove the machine to a place from where you can look out over the
Machine is behind building • Not defective.
2 or mountain and only a part
of heaven is seen from it heavens.
Abnormality in communica- • Check communication antenna. If it is broken or removed, repair or
3
tion antenna replace it.
Entry of foreign matter in
4 communication antenna • Check inside of communication antenna and remove foreign matter.
connector
Abnormality in communica- • Check communication antenna. If it is broken (or disconnected), re-
5
tion antenna cable pair or replace it.
2) Disconnect connectors HM-CN1, HM-CN2B, HM-CN4B, ORB-A,
and ORB-B.
Wiring harness between ORB-B (female) (1)
and HM-CN4B (female) (4)
Disconnection in wiring har- and HM-CN4B (female) (10) Resistance Max. 1 Ω
Probable cause 6 ness (Disconnection or de-
and standard value fective contact) Resistance Max. 1 Ω
and HM-CN4B (female) (3)
when normal
Wiring harness between ORB-A (female) (7),
(8) and HM-CN1 (female) (6), (7)
Wiring harness between ORB-A (female) (10),
(11) and HM-CN1 (female) (19), (20)
Wiring harness between ORB-A (female) (2)
and HM-CN2 (female) (17)
and ORB-B.
Wiring harness between Resistance between ORB-B
ORB-B (female) (1) and HM- (female) (1), HM-CN4B (fe-
Min. 1M Ω
CN4B (female) (4) male) (4) and chassis
Grounding fault or short cir- ground
7
cuit in wiring harness Wiring harness between Resistance between ORB-B
Min. 1M Ω
ground
Wiring harness between Resistance between ORB-B
Min. 1M Ω
ground
HD465-7, HD605-7 20-1029

➄

Wiring harness between Resistance between ORB-A
ORB-A (female) (7), (8) and (female) (7), (8)HM-CN1 (fe-
Min. 1M Ω
HM-CN1 (female) (6), (7) male) (6), (7) and chassis
ground
ORB-A (female) (10), (11) (female) (10), (11), HM-CN1
Min. 1M Ω
and HM-CN1 (female) (19), (female) (19), (20) and chas-
(20) sis ground
ORB-A (female) (2) and HM- (female) (2), HM-CN2A (fe-
Min. 1M Ω
CN2A (female) (17) male) (17) and chassis
ground
Between wiring harness be- Resistance between wiring
tween ORB-B (female) (1) harness between ORB-B
and HM-CN4B (female) (4) (female) (1) and HM-CN4B
and wiring harness between (female) (4) and wiring har- Min. 1M Ω
ORB-B (female) (2) and HM- ness between ORB-B (fe-
CN4B (female) (10) male) (2) and HM-CN4B
(female) (10)
Grounding fault or short cir- ORB-B (female) (3) and HM- ness between ORB-B (fe-
7
cuit in wiring harness CN4B (female) (3) male) (3) and HM-CN4B
Probable cause (female) (3)
and standard value
when normal
ORB-B (female) (3) and HM- ness between ORB-B (fe-
CN4B (female) (3) male) (3) and HM-CN4B
(female) (3)
tween ORB-A (female) (7), harness between ORB-A
(8) and HM-CN1 (female) (female) (7), (8) and HM-
(6), (7) and wiring harness CN1 (female) (6), (7) and
Min. 1M Ω
between ORB-A (female) wiring harness between
(10), (11) and HM-CN1 (fe- ORB-A (female) (10), (11)
male) (19), (20) and HM-CN1 (female) (19),
(20)
tween ORB-A (female) (2) harness between ORB-A
and HM-CN2A (female) (17) (female) (2) and HM-CN2A
ORB-A (female) (10), (11) ness between ORB-A (fe-
and HM-CN1 (female) (19), male) (10), (11) and HM-
(20) CN1 (female) (19), (20)
Short circuit with power and ORB-B.
8
source in wiring harness 3) Insert connect T-adapter.
20-1030 HD465-7, HD605-7

➄

Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (1) and HM- male) (1), HM-CN4B (fe- Max. 1 V
CN4B (female) (4) male) (4) and chassis ground
Wiring harness between Voltage between ORB-B
Max. 1 V
ground
8 Wiring harness between Voltage between ORB-B (fe-
ORB-B (female) (3) and HM- male) (3), HM-CN4B (fe-
Max. 1 V
CN4B (female) (3) and chas- male) (3) and chassis ground
sis ground
Wiring harness between Voltage between ORB-A (fe-
ORB-A (female) (2) and HM- male) (2), HM-CN2A (fe-
Min. 1 M Ω
CN2A (female) (17) male) (17) and chassis
and standard value
when normal 1) Turn starting switch ON.
About 3 minutes after the VHMS controller is turned ON, judge by
the state of the decimal point of the VHMS controller LED (7 seg-
ments on the right side).
• VHMS controller cannot communicate with
Decimal point goes off ORBCOMM controller (Abnormality in ORB-
COMM controller).
Defective ORBCOMM con- • Communication with VHMS is normal.
9
troller Decimal point lights up • ORBCOMM controller does not have data to
transmit.
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
quickly
and has captured satellite (is transmitting).
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
slowly
but has not captured satellite.
HD465-7, HD605-7 20-1031

➄
b) Abnormality in downloading into PC or setting of PC
Action code Error code Controller code Abnormality in satellite data communication
Trouble
None None None b) Abnormality in downloading into PC or setting of PC
Contents of trouble • PC cannot download or cannot be set.
Problem that
• PC cannot download or cannot be set.
appears on machine
Related information

2) Disconnect connectors HM-CN4A and VHMS.
ness (Disconnection or de- Wiring harness between HM-CN4A (female)
aWiring harness for down-

1 fective contact) (9) and VHMS (female) (B)
loading in cab Resistance Max. 1 Ω
(10) and VHMS (female) (C)
(11) and VHMS (female) (D)
2) Disconnect connectors HM-CN4A and VHMS.
HM-CN4A (female) (9) and CN4A (female) (9), VHMS
Min. 1M Ω
VHMS (female) (B) (female) (B) and chassis
ground
Min. 1M Ω
VHMS (female) (C) (female) (C) and chassis
Probable cause
ground
and standard value
when normal Wiring harness between Resistance between HM-
Min. 1M Ω
VHMS (female) (D) (female) (D) and chassis
ground
Grounding fault or short cir-
aWiring harness for down- tween HM-CN4A (female)

cuit in wiring harness Between wiring harness be- Resistance between wiring
2 harness between HM-CN4A
loading inside cab (9) and VHMS (female) (B) (female) (9) and VHMS (fe-
Min. 1M Ω
and wiring harness between male) (B) and wiring harness
HM-CN4A (female) (10) and between HM-CN4A (female)
VHMS (female) (C) (10) and VHMS (female) (C)
tween HM-CN4A (female) harness between HM-CN4A
(9) and VHMS (female) (B) (female) (9) and VHMS (fe-
Min. 1M Ω
and wiring harness between male) (B) and wiring harness
HM-CN4A (female) (11) and between HM-CN4A (female)
VHMS (female) (D) (11) and VHMS (female) (D)
Between wiring harness be- Resistance between HM-
tween HM-CN4A (female) CN4A (female) (10) and
(10) and VHMS (female) (C) VHMS (female) (C) and wir-
Min. 1M Ω
and wiring harness between ing harness between HM-
HM-CN4A (female) (11) and CN4A (female) (11) and
VHMS (female) (D) VHMS (female) (D)
20-1032 HD465-7, HD605-7

➄

2) Disconnect connectors VHMS and VDL.
ness (Disconnection or de- Wiring harness between VHMS (male) (B) and
aWiring harness for down-

3 fective contact) VDL (female) (B)
Wiring harness between VHMS (male) (C)
loading inside cab Resistance Max. 1 Ω
and VDL (female) (C)
Wiring harness between VHMS (male) (D) and
VDL (female) (D)
2) Disconnect connectors VHMS and VDL.
Wiring harness between Resistance between wiring
VHMS (male) (B) and VDL harness between VHMS
Min. 1M Ω
(female) (B) (male) (B) and VDL (female)
(B) and chassis ground
Wiring harness between Resistance between wiring
VHMS (male) (C) and VDL harness between VHMS
Min. 1M Ω
(female) (C) (male) (C) and VDL (female)
Probable cause
(C) and chassis ground
and standard value
when normal Wiring harness between Resistance between wiring
VHMS (male) (D) and VDL harness between VHMS
Min. 1M Ω
(female) (D) (male) (D) and VDL (female)
(D) and chassis ground
Grounding fault or short cir-
aWiring harness for down- tween VHMS (male) (B) and

cuit in wiring harness Between wiring harness be- Resistance between wiring
4 harness between VHMS
loading outside cab VDL (female) (B) and wiring (male) (B) and VDL (female)
Min. 1M Ω
harness between VHMS (B) and wiring harness be-
(male) (C) and VDL (female) tween VHMS (male) (C) and
(C) VDL (female) (C)
tween VHMS (male) (B) and harness between VHMS
VDL (female) (B) and wiring (male) (B) and VDL (female)
Min. 1M Ω
harness between VHMS (fe- (B) and wiring harness be-
male) (D) and VDL (male) tween VHMS (male) (D) and
(D) VDL (female) (D)
tween VHMS (male) (C) and harness between VHMS
VDL (female) (C) and wiring (male) (C) and VDL (female)
Min. 1M Ω
harness between VHMS (C) and wiring harness be-
(male) (D) and VDL (female) tween VHMS (male) (D) and
(D) VDL (female) (D)
HD465-7, HD605-7 20-1033

➄
VHMS-2 ABNORMALITY IN SAVING DATA IN VHMS CONTROLLER

(DATA ARE NOT SAVED)
Action code Error code Controller code Abnormality in saving data in VHMS controller
a LED of VHMS counts up and operates normally

Trouble (Data are not saved)
None None None
aPower is kept turned off.

• Data are not saved in the VHMS controller.
Contents of trouble

Problem that
• None in particular.
appears on machine
• If fuse BT-2 (29) is broken, check the wiring harness between fuse and HM-CN1 (6), (7) for grounding
Related information
fault.

2) Disconnect connector HM-CN1 and fuse terminal BT-2 (29).
Wiring harness between HM-CN1 (female) (6),
Probable cause Resistance Max. 1 Ω
(7) and fuse terminal BT-2 (29)
and standard value Disconnection in wiring har-
1 ness (Disconnection or de- 1) After the starting switch is turned to the OFF position, the LED of
when normal
fective contact) the VHMS displays SH (Processing time of memory), and then
the all operation is finished (the power for the VHMS is turned
OFF), if the all system is normal.
2) If the power for the VHMS is turned OFF immediately after the
starting switch is turned to the OFF position, the power is not ap-
plied constantly.
20-1034 HD465-7, HD605-7

➄
HD465-7, HD605-7 20-1035

➄
VHMS-3 ENGINE BLOW-BY PRESSURE INDICATED BY MONITOR IS LOW

(WHEN BLOW-BY PRESSURE MEASURED WITH MEASURING INSTRUMENT
IS NORMAL)
Action code Error code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring instrument
None None None is normal)
Contents of trouble • The engine blow-by pressure indicated by the monitor is low.
Problem that • The engine blow-by pressure indicated by the monitor is low.
appears on machine (The blow-by pressure measured with a measuring instrument is normal.)
• The blow-by pressure can be checked with the monitoring function (Code: 42800).
Related information
• If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
Probable cause Cause Standard value in normal state/Remarks on troubleshooting

and standard value 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal.
when normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.
20-1036 HD465-7, HD605-7

➄
TROUBLESHOOTING OF ASR
CONTROLLER SYSTEM
(ASR MODE)
Electrical system diagram related ASR control ........................................................................................ 20-1052

Information in troubleshooting table...................................................................................................... 20-1053
Trouble code table ................................................................................................................................ 20-1054
[DDDAKA] ASR system switch system: Disconnection (KA).............................................................. 20-1055
[DDDAKB] ASR system switch system: Short circuit (KB) ................................................................. 20-1056
[DK30KX] Steering angle sensor: Out of input signal range (KX) .................................................... 20-1057
[DLF8KA] Wheel speed sensor (RR): Disconnection (KA) ............................................................... 20-1059
[DLF8LC] Wheel speed sensor (RR): See separate list (LC) ...................................................... 20-1060
[DLF9KA] Wheel speed sensor (RL): Disconnection (KA) ................................................................ 20-1061
[DLF9LC] Wheel speed sensor (RL): See separate list (LC) ........................................................ 20-1062
[dLT3LC] Transmission output shaft speed sensor: See separate list (LC) ................................ 20-1063
[DWNBK4] Shut-off solenoid valve: Uncontrollable (K4) .................................................................... 20-1065
[DWNBKA] Shut-off solenoid valve: Disconnection (KA) .................................................................... 20-1067
[DWNBKB] Shut-off solenoid valve: Short circuit (KB) ....................................................................... 20-1068
[DWNBKY] Shut-off solenoid valve: Short circuit with power source (KY) .......................................... 20-1069
[DWNBMA] Shut-off solenoid valve: Malfunction (MA) ........................................................................ 20-1070
[DX17K4] ASR proportional solenoid pressure reducing valve (Right): Uncontrollable (K4) ............ 20-1071
[DX17KA] ASR proportional solenoid pressure reducing valve (Right): Disconnection (KA) ............ 20-1073
[DX17KB] ASR proportional solenoid pressure reducing valve (Right): Short circuit (KB)................ 20-1074
[DX17KY] ASR proportional solenoid pressure reducing valve (Right): Short circuit with
power source (KY)............................................................................................................ 20-1075
[DX17MA] ASR proportional solenoid pressure reducing valve (Right): Malfunction (MA)................ 20-1076
[DX18K4] ASR proportional solenoid pressure reducing valve (Left): Uncontrollable (K4) .............. 20-1077
[DX18KA] ASR proportional solenoid pressure reducing valve (Left): Disconnection (KA) .............. 20-1079
[DX18KB] ASR proportional solenoid pressure reducing valve (Left): Short circuit (KB) .................. 20-1080
[DX18KY] ASR proportional solenoid pressure reducing valve (Left): Short circuit with
power source (KY)............................................................................................................ 20-1081
[DX18MA] ASR proportional solenoid pressure reducing valve (Left): Malfunction (MA) .................. 20-1082
HD465-7, HD605-7 20-1051

➄
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
ELECTRICAL SYSTEM DIAGRAM RELATED ASR CONTROL
20-1052 HD465-7, HD605-7

➄
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

★ The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Display on Display on Display on Trouble Trouble in machine
panel panel panel
Contents of trouble Condition at the time when the monitor panel or controller detects the trouble
The action taken by the monitor panel or controller to protect the system or devices when the monitor-
panel or controller detects the trouble
Problem that The problem that appears on the machine as a result of the action taken by the monitor panel or controller
appears on machine (shown above)
Related information Information related to the detected trouble or troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in harness>
• Disconnection
Connector is connected imperfectly or harness is broken.
• Grounding fault
Harness which is not connected to chassis ground circuit is in con-
2 tact with chassis ground circuit.
• Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
• Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes 3 Possible causes of trouble <Precautions for troubleshooting>

and standard value (Given numbers are refer- (1) Method of indicating connector No. and handling of T-
in normal state ence numbers, which do not adapter
indicate priority) Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
• If connector No. has no marks of "male" and "female", disconnect
connector and insert T-adapters in both male side and female
4
side.
• If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
5 • Connect positive (+) lead to pin No. or harness entered on front
side.
• Connect negative (–) lead to pin No. or harness entered on rear
side.
HD465-7, HD605-7 20-1053

➄
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
This a circuit diagram of the part related to the failure.

• Connector No.: Shows the "Type – Number of pin" and " Color".
• Arrow (⇔): Roughly shows the location on the machine.
TROUBLE CODE TABLE

a Regarding trouble code provided with instruction "Refer to table", check it against table below.
Trouble code Contents of trouble Trouble code Contents of trouble
Fill signals at two or more channels which are not set as combi-
KA Disconnection in wiring L0 nation are turned ON at the same time.
KB Short circuit L1 Fill signal is ON when command current to ECMV is OFF.
Source voltage reduction/
KK input L2 Fuel pressure is above maxim specified value.
Type select signal incon-

KQ sistency L3 Object part is uncontrollable.
KR Defective communication L4 ON and OFF signals at two systems are inconsistent.

Engine rotation signal, terminal C signal, oil pressure switch
KT Abnormality in controller L6 signal, water temperature sensor signal, etc. are inconsistent
with operation state or stop state.
KX Outside input signal range L8 Analog signals in two systems are inconsistent.
KY source LC rpm signals in two systems are inconsistent.
Disconnection or short cir-

KZ cuit LD Switch is pressed for usually unthinkable long time.
MA Malfunction LH Fill signal is OFF when command current to ECMV is ON.

MB Performance reduction
MW Sliding
NS Overheat
ZG Oil pressure reduction
ZK Coolant level reduction
20-1054 HD465-7, HD605-7

➄
TROUBLESHOOTING [DDDAKA]
[DDDAKA] ASR SYSTEM SWITCH SYSTEM: DISCONNECTION (KA)

Trouble ASR system switch system: Short circuit (KA)
E01 DDDAKA BK
Contents of trouble • The ASR system switch ON input and system switch OFF input are turned OFF.
Action of controller • Resets the ASR control.
Problem that • The machine is not affected badly.
appears on machine • The ASR system cannot be controlled.
Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
Disconnection in wiring Wiring harness between DPC2B (female) (3)
harness and ASR (female) (3)
1
(Disconnection or defective 1) Turn starting switch OFF.
contact) 2) Disconnect connectors ASR and DPC2B.
Wiring harness between DPC2B (female) (9)
and ASR (female) (3)
2) Replace ASR system switch with normal one.
Possible causes
and standard value 3) Turn starting switch ON.
Defective ASR system
in normal state 2 System switch is nor-
switch When ASR system switch is Yes
mal
replaced with normal one, does
condition become normal? System switch is defec-
No
tive
2) Disconnect connector DPC2B.
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON Voltage 20 – 30 V
and chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
and chassis ground ASR system switch OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1055

➄
TROUBLESHOOTING [DDDAKB]
[DDDAKB] ASR SYSTEM SWITCH SYSTEM: SHORT CIRCUIT (KB)

Trouble ASR system switch system: Short circuit (KB)
E01 DDDAKB BK
Contents of trouble • The ASR system switch ON input and system switch OFF input are turned ON.
Related information • The state of the ASR switch can be checked with the monitoring function (Code: 37900).

2) Disconnect connectors ASR and DPC2B.
Short circuit with power Wiring harness between Voltage between DPC2B
1 DPC2B (female) (3) and (female) (3), ASR (female) Max. 1 V
ASR (female) (3) (3) and chassis ground
Wiring harness between Voltage between DPC2B
DPC2B (female) (9) and (female) (9), ASR (female) Max. 1 V
ASR (female) (2) (2) and chassis ground
2) Replace ASR system switch with normal one.
Possible causes
Defective ASR system 3) Turn starting switch ON.
and standard value
in normal state 2 switch System switch is nor-
When ASR system switch is re- Yes
mal
placed with normal one, does con-
dition become normal? System switch is defec-
No
tive
2) Disconnect connector DPC2B.
3 Defective machine monitor
Between DPC2B (3) ASR system switch ON Voltage 20 – 30 V
and chassis ground ASR system switch OFF Voltage Max. 1 V
Between DPC2B (9) ASR system switch ON Voltage Max. 1 V
and chassis ground ASR system switch OFF Voltage 20 – 30 V
20-1056 HD465-7, HD605-7

➄
TROUBLESHOOTING [DK30KX]
[DK30KX] STEERING ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)

Trouble Steering angle sensor: Out of input signal range (KX)
E01 DK30KX BK
Contents of trouble • The voltage of the signal circuit of the steering angle sensor is below 0.5 V or above 4.7 V.
Action of controller • Controls the ASR by setting the steering angle (turning angle) to 20 degrees.
Problem that
• The machine is not affected badly.
appears on machine
Related information • The steering angle can be checked with the monitoring function (Code: 35400).

2) Disconnect connectors BRC2, BRC3A, and ASR1.
Disconnection in wiring Wiring harness between BRC2 (female) (16)
1 and ASR1 (female) (3)
and ASR1 (female) (2)
Wiring harness between Resistance between BRC2
Grounding fault in wiring BRC2 (female) (16) and (female) (16), ASR 1 (female) Min. 1 MΩ
2
harness ASR1 (female) (3) (3) and chassis ground
BRC3A (female) (7) and (female) (7), ASR1 (female) Min. 1 MΩ
ASR1 (female) (2) (2) and chassis ground
Possible causes
and standard value
in normal state
Short circuit with power Voltage between BRC2
3 Wiring harness between
source in wiring harness BRC2 (female) (16) and (female) (16), ASR1 (female) Max. 1 V
Wiring harness between Voltage between BRC3A
BRC3A (female) (7) and (female) (7), ASR1 (female) Max. 1 V
2) Disconnect connector RTL.
Defective steering angle 4) Connect connector.
4
sensor 5) Turn starting switch ON.
Between ASR (3) and (1) Voltage 4.6 – 5.4 V
Between ASR (2) and (1) Voltage 2–3V
2) Disconnect connectors BRC2 and RTL.
5 Defective retarder controller
Between BRC1 (16) and BRC3A (16) Voltage 4.6 – 5.4 V
Between BRC3A (7) and (16) Voltage 2–3V
HD465-7, HD605-7 20-1057

➄
TROUBLESHOOTING [DK30KX]
20-1058 HD465-7, HD605-7

➄
TROUBLESHOOTING [DLF8KA]
[DLF8KA] WHEEL SPEED SENSOR (RR): DISCONNECTION (KA)

Trouble Wheel speed sensor (RR): Disconnection (KA)
E01 DLF8KA BK
Contents of trouble • The signal circuit of the wheel speed sensor (RR) is disconnected and signals are not input.
Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
Defective wheel speed
1
sensor (RR) Between WSRR (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRR (male) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRR.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
2 Wiring harness between BRC3A (female) (3)
(Disconnection or defective and WSRR (female) (1) Resistance Max. 1 Ω
contact)
and WSRR (female) (2)
3 Defective retarder controller 3) Connect T-adapter.
Between BRC3A (female) (3) and (14) Resistance 950 – 1,450 Ω
HD465-7, HD605-7 20-1059

➄
TROUBLESHOOTING [DLF8LC]
[DLF8LC] WHEEL SPEED SENSOR (RR): SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RR): See separate list (LC)
E01 DLF8LC BK
• The wheel speed (RR) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RL) speed sensor signal is different from the signal speed of the wheel (RR) speed sensor.
Related information • The wheel speed (RR) can be checked with the monitoring function (Code: 39701).

2) Disconnect connector WSRR.
1
sensor (RR) Between WSRR (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRR (male) (1), (2) and chassis
ground
Grounding fault in wiring 3) Connect T-adapter.
2
harness Wiring harness between Resistance between BRC3A
Possible causes
and standard value BRC3A (female) (3) and (female) (3), WSRR (female) Min. 1 MΩ
in normal state WSRR (female) (1) (1) and chassis ground
harness
BRC3A (female) (3) and male) (3), WSRR (female) (1) Max. 1 V
WSRR (female) (1) and chassis ground
20-1060 HD465-7, HD605-7

➄
TROUBLESHOOTING [DLF9KA]
[DLF9KA] WHEEL SPEED SENSOR (RL): DISCONNECTION (KA)

Trouble Wheel speed sensor (RL): Disconnection (KA)
E01 DLF9KA BK
Contents of trouble • The signal circuit of the wheel speed sensor (RL) is disconnected and signals are not input.
Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
Defective wheel speed sen- 3) Connect T-adapter.
1
sor (RL) Between WSRL (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRL (male) (1), (2) and chassis
ground
Possible causes
2) Disconnect connectors BRC3A and WSRL.
and standard value Disconnection in wiring 3) Connect T-adapter.
in normal state harness
2 Wiring harness between BRC3A (female) (2)
and WSRL (female) (1)
contact)
and WSRL (female) (2)
HD465-7, HD605-7 20-1061

➄
TROUBLESHOOTING [DLF9LC]
[DLF9LC] WHEEL SPEED SENSOR (RL): SEE SEPARATE LIST (LC)

Trouble Wheel speed sensor (RL): See separate list (LC)
E01 DLF9LC BK
• The wheel speed (RL) calculated from the transmission output shaft speed sensor signal and wheel
Contents of trouble
(RR) speed sensor signal is different from the signal speed of the wheel (RL) speed sensor.
Related information • The wheel speed (RL) can be checked with the monitoring function (Code: 39700).

2) Disconnect connector WSRL.
1
sensor (RL) Between WSRL (male) (1) and (2) Resistance 950 – 1,450 Ω
Between WSRL (male) (1), (2) and chassis
ground
Grounding fault in wiring 3) Connect T-adapter.
2
harness Wiring harness between Resistance between BRC3A
Possible causes
and standard value BRC3A (female) (3) and (female) (3), WSRL (female) Min. 1 MΩ
in normal state WSRL (female) (1) (1) and chassis ground
harness
Wiring harness between Voltage between BRC3A
BRC3A (female) (3) and (female) (3), WSRL (female) Max. 1 V
WSRL (female) (1) (1) and chassis ground
20-1062 HD465-7, HD605-7

➄
TROUBLESHOOTING [dLT3LC]
[dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR:

SEE SEPARATE LIST (LC)
Action code Error code Controller code Transmission output shaft speed sensor: See separate list (LC)
Trouble
E01 dLT3LC BK (ASR is set and ASR system switch is turned ON)
• The travel speed calculated from the transmission output shaft speed sensor signal, wheel (RR) speed
Contents of trouble sensor signal, and wheel (RL) speed sensor signal is different from the signal speed of the wheel (RR)
speed sensor and wheel (RL) speed sensor.
• The transmission output shaft speed can be checked with the monitoring function (Code: 31400).
Related information
The wheel speed can be checked with the monitoring function (Code: 39700, 39701).

Defective transmission
1
output shaft speed sensor Between CN5 (male) (1) and (2) Resistance 500 – 1,000 Ω
Between CN5 (male) (1), (2) and chassis
ground
2) Disconnect connectors ATC3A, BRC3A, PM5, and CN5.
Grounding fault in wiring har-
2 Wiring harness between Resistance between BRC3A
ness
ATC3A (female) (3), BRC3A (female) (13), ATC3A (female)
Min. 1 MΩ
Possible causes (female) (13), PM5 (female) (3), PM5 (female) (7), CN5 (fe-
and standard value (7), and CN5 (female) (1) male) (1) and chassis ground
in normal state
2) Disconnect connectors BRC3A, ATC3A, PM5, and CN5.
3
source in wiring harness Voltage between ATC3A
Wiring harness between (female) (3), BRC3A (female)
ATC3A (female) (3), BRC3A
(13), PM5 (female) (7), CN5 Max. 1 V
(female) (13), PM5 (female)
(7), and CN5 (female) (1) (female) (1) and chassis
ground
Defective transmission con- 2) Disconnect connector BRC3A.
4 3) Connect T-adapter.
troller
HD465-7, HD605-7 20-1063

➄
TROUBLESHOOTING [dLT3LC]
20-1064 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBK4]
[DWNBK4] SHUT-OFF SOLENOID VALVE: UNCONTROLLABLE (K4)

Trouble Shut-off solenoid valve: Uncontrollable (K4)
E01 DWNBK4 BK
Contents of trouble • The shut-off solenoid valve does not return (does not move) or the pressure switch system is defective.
Related information

Defective shut-off solenoid • Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2) Disconnect connector ASR7.
Defective shut-off solenoid 4) Connect connector.
2
valve oil pressure switch 5) Turn starting switch ON.
Between ASR7 (female) (1) Oil pressure ON Resistance Max. 1 Ω
and (2) Oil pressure OFF Resistance Min. 1 MΩ
2) Disconnect connectors BRC5B and ASR7.
Possible causes harness
and standard value Wiring harness between Resistance between BRC5B
in normal state BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 Ω
Wiring harness between Voltage between BRC5B
BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 V
2) Disconnect connectors BRC5B and BRC2.
Between BRC5B (8) and Oil pressure ON Voltage Max. 1 V
BRC2 (21) Oil pressure OFF Voltage 20 – 30 V
HD465-7, HD605-7 20-1065

➄
TROUBLESHOOTING [DWNBK4]
20-1066 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBKA]
[DWNBKA] SHUT-OFF SOLENOID VALVE: DISCONNECTION (KA)

Trouble Shut-off solenoid valve: Disconnection (KA)
E01 DWNBKA BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, any current does not flow.
Related information

1
valve 5) Turn starting switch ON.
Between ASR2 (female) (1) and (2) Resistance 10 – 30 Ω
Between ASR2 (1), (2) and chassis ground Resistance Min. 1 MΩ
Possible causes
and standard value
2) Disconnect connectors BRC2 and ASR2.
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (2)
defective contact) and ASR2 (female) (1)
HD465-7, HD605-7 20-1067

➄
TROUBLESHOOTING [DWNBKB]
[DWNBKB] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT (KB)

Trouble Shut-off solenoid valve: Short circuit (KB)
E01 DWNBKB BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned ON, too much current flows.
Related information

1
and standard value Wiring harness between Resistance between BRC2
in normal state BRC2 (female) (2) and ASR2 (female) (2), ASR2 (female) Max. 1 Ω
Grounding fault or short (female) (1) (1) and chassis ground
2
circuit in wiring harness Between wiring harness be-
tween BRC2 (female) (2) Resistance between BRC2
and ASR2 (female) (1) and (female) (2), ASR2 (female)
Max. 1 Ω
wiring harness between (1) and BRC2 (female) (13),
BRC2 (female) (13) and ASR2 (female) (2)
ASR2 (female) (2)
20-1068 HD465-7, HD605-7

➄
TROUBLESHOOTING [DWNBKY]
[DWNBKY] SHUT-OFF SOLENOID VALVE: SHORT CIRCUIT WITH POWER SOURCE (KY)

Trouble Shut-off solenoid valve: Short circuit with power source (KY)
E01 DWNBKY BK
Contents of trouble • When the output to the shut-off solenoid valve circuit is turned OFF, a current flows.
Related information

1
Possible causes 1) Turn starting switch OFF.
and standard value 2) Disconnect connectors BRC2 and ASR2.
Short circuit with power 4) Connect connector
Wiring harness between Voltage between BRC2
BRC2 (female) (2) and ASR2 (female) (2), ASR2 (female) Max. 1 V
(female) (1) (1) and chassis ground
HD465-7, HD605-7 20-1069

➄
TROUBLESHOOTING [DWNBMA]
[DWNBMA] SHUT-OFF SOLENOID VALVE: MALFUNCTION (MA)

Trouble Shut-off solenoid valve: Malfunction (MA)
E01 DWNBMA BK
• The shut-off solenoid valve does not operate (does not move) or the pressure switch system is
Contents of trouble
defective.
Related information

Defective shut-off solenoid • Check the shut-off solenoid valve and repair or replace it, if it has
1
valve abnormality (mechanical failure).
2
valve oil pressure switch 5) Turn starting switch ON.
Possible causes
in normal state 2) Disconnect connectors BRC5B and ASR7.
3
harness Wiring harness between Resistance between BRC5B
BRC5B (female) (8) and (female) (8), ASR7 (female) Max. 1 Ω
20-1070 HD465-7, HD605-7

➄
TROUBLESHOOTING [DX17K4]
[DX17K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

UNCONTROLLABLE (K4)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Right):
Trouble
E01 DX17K4 BK Uncontrollable (K4)
• The ASR proportional solenoid pressure reducing valve (Right) does not return (does not move) or the
Contents of trouble
pressure switch system is defective.
Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
Defective ASR proportional 3) Insert connect T-adapter.
solenoid pressure reducing 4) Connect connector.
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Wiring harness between Resistance between BRC5B
HD465-7, HD605-7 20-1071

➄
20-1072 HD465-7, HD605-7

➄
[DX17KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

DISCONNECTION (KA)
Trouble
• When the output to the ASR proportional solenoid pressure reducing valve (Right) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

Defective ASR proportional
1 solenoid pressure reducing 4) Connect connector.
valve (Right)
Possible causes
and standard value
in normal state Disconnection in wiring 3) Connect T-adapter.
harness
(Disconnection or defective and ASR3 (female) (1) Resistance Max. 1 Ω
contact)
HD465-7, HD605-7 20-1073

➄
[DX17KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT (KB)
Trouble
E01 DX17KB BK Short circuit (KB)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Right)
Possible causes
and standard value
in normal state
Grounding fault or short
2 BRC2 (female) (9) and (female) (9), ASR3 (female) Min. 1 MΩ
circuit in wiring harness
Between wiring harness between BRC2 (female) (9) and
ASR3 (female) (1) and wiring harness between BRC2 Min. 1 MΩ
(female) (19) and ASR3 (female) (2)
20-1074 HD465-7, HD605-7

➄
[DX17KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

SHORT CIRCUIT WITH POWER SOURCE (KY)
Trouble
E01 DX17KY BK Short circuit with power source (KY)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Right)
Possible causes
and standard value
4) Connect connector
in normal state
2 Wiring harness between Voltage between BRC2
(female) (19) and ASR (female) (2)
HD465-7, HD605-7 20-1075

➄
[DX17MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (RIGHT):

MALFUNCTION (MA)
Trouble
• The ASR proportional solenoid pressure reducing valve (Right) does not operate (does not move) or
Contents of trouble
the pressure switch system is defective.
Related information • The state of the ASR switch (Right) can be checked with the monitoring function (Code: 39605).

Defective ASR proportional • Check the ASR proportional solenoid pressure reducing valve
1 solenoid pressure reducing (Right) and repair or replace it, if it has abnormality (mechanical
valve (Right) failure).
2
valve (Right) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1076 HD465-7, HD605-7

➄
[DX18K4] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

UNCONTROLLABLE (K4)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left):
Trouble
E01 DX18K4 BK Uncontrollable (K4)
• The ASR proportional solenoid pressure reducing valve (Left) does not return (does not move) or the
Contents of trouble
Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

• Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
Wiring harness between Voltage between BRC5B
HD465-7, HD605-7 20-1077

➄
20-1078 HD465-7, HD605-7

➄
[DX18KA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

DISCONNECTION (KA)
Trouble
• When the output to the ASR proportional solenoid pressure reducing valve (Left) circuit is turned ON,
Contents of trouble
any current does not flow.
Related information

valve (Left)
Possible causes
and standard value
in normal state
2 harness (Disconnection or Wiring harness between BRC2 (female) (8)
defective contact) and ASR4 (female) (1)
HD465-7, HD605-7 20-1079

➄
[DX18KB] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT (KB)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KB BK circuit (KB)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned ON, any
Contents of trouble
current does not flow.
Related information

valve (Left)
Possible causes 2) Disconnect connectors BRC2 and ASR4.
and standard value 3) Connect T-adapter.
in normal state
Grounding fault or short
2 BRC2 (female) (8) and (female) (8), ASR4 (female) Min. 1 MΩ
circuit in wiring harness ASR4 (female) (1) (1) and chassis ground
(female) (18) and ASR4 (female) (2)
20-1080 HD465-7, HD605-7

➄
[DX18KY] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

SHORT CIRCUIT WITH POWER SOURCE (KY)
Action code Error code Controller code ASR proportional solenoid pressure reducing valve (Left): Short
Trouble
E01 DX18KY BK circuit with power source (KY)
• When the output to the ASR proportional solenoid pressure reducing valve circuit is turned OFF, a cur-
Contents of trouble
rent flows.
Related information

valve (Left)
Possible causes 3) Insert connect T-adapter.
and standard value 4) Connect connector
in normal state 5) Turn starting switch ON.
2 Wiring harness between Voltage between BRC2
(female) (18) and ASR (female) (2)
HD465-7, HD605-7 20-1081

➄
[DX18MA] ASR PROPORTIONAL SOLENOID PRESSURE REDUCING VALVE (LEFT):

MALFUNCTION (MA)
Trouble
• The ASR proportional solenoid pressure reducing valve (Left) does not operate (does not move) or the
Contents of trouble
Related information • The state of the ASR switch (Left) can be checked with the monitoring function (Code: 39606).

• Check the ASR proportional solenoid pressure reducing valve (Left)
valve (Left)
2
valve (Left) oil pressure 5) Turn starting switch ON.
switch
Possible causes
3
20-1082 HD465-7, HD605-7

➄
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEMS (H MODE)
H-1 Machine does not start ....................................................................................................................20-1102

H-2 Machine does not travel smoothly (machine jerks) .........................................................................20-1104
H-3 Lock-up clutch cannot be disengaged (engine stalls) .....................................................................20-1104
H-4 Excessive shock when starting or shifting.......................................................................................20-1105
H-5 Transmission does not shift up........................................................................................................20-1105
a. Does not shift up ........................................................................................................................20-1105
b. Does not shift up ........................................................................................................................20-1105
H-6 Machine lacks power or speed when traveling................................................................................20-1106
a. Abnormality at all speed ranges.................................................................................................20-1106
b. Torque converter lock-up does not engage................................................................................20-1107
c. Abnormality at specific speed ranges ........................................................................................20-1108
H-7 Time lag is excessive when starting or shifting gear .......................................................................20-1110
H-8 Torque converter oil temperature is high .........................................................................................20-1112
H-9 Torque converter oil pressure is low................................................................................................20-1113
H-10 Front brake is ineffective, or effective only on one side ..................................................................20-1114
H-11 Rear brake is ineffective, or effective only on one side ...................................................................20-1115
H-12 Steering wheel is heavy ..................................................................................................................20-1116
H-13 Steering wheel does not work .........................................................................................................20-1117
H-14 Steering wheel vibrates ...................................................................................................................20-1117
H-15 Hoist cylinder lacks lifting force (lifting speed) ...............................................................................20-1118
H-16 Hoist cylinder does not work ...........................................................................................................20-1119
H-17 Excessive hydraulic drift of dump body ...........................................................................................20-1120
HD465-7, HD605-7 20-1101

➁
TROUBLESHOOTING H-1
H-1 Machine does not start
Ask the operator the following questions

• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal noise?
Yes = Broken part
Checks before troubleshooting

• Is the oil level in the transmission case cor-
rect?
• Is the torque converter, transmission input
shaft broken? (Check with the transmission
input shaft speed sensor.)
• Is the drive shaft broken?
Drop in set pressure of main relief valve (torque converter valve)

• Is there any dragging of the brakes?
• Is any failure code related power trains dis-
played?
Defective transmission clutch seal ring, groove
Defective speed clutch (defective oil tightness)
Defective shaft seal ring in speed clutch circuit
Defective actuation of ECMV solenoid valve

Causes
Pump does not drive (defective PTO)

Air sucked in at suction side of pump
Defective operation of ECMV valve
Damage inside torque converter
Defective speed sensor function

Damage inside transmission
Seized transmission clutch
Clogged strainer
Defective pump
a b c d e f g h i j k l m n
Remedy
No. C " " " " " " " " "
" "
Problems
1 Abnormal noise comes from between pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 Machine does not start when torque converter oil temperature

rises
5 Low at every speed range
6 Set pressure of Becomes lower at certain speed range

transmission is low
7 Indicator is unstable and fluctuates
excessively
8 When pressure pickup plug is removed and engine is cranked,

no oil comes out
9 Modulation pressure is abnormal
10 Hydraulic pressure at pump outlet port is low
20-1102 HD465-7, HD605-7

(7)
TROUBLESHOOTING H-1
Clutch combination table

Clutch
No.
H L 4th 3rd 2nd 1st R
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1103

➁
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)
• There is hunting.
• Look-up lamp flashes.
Causes Remedy
• Drop in main relief pressure 

 A. See H-6
• Worn clutch seal ring 
H-3 Lock-up clutch cannot be disengaged (engine stalls)

• Is the oil level in the transmission case correct?
• Is any failure code related power trains displayed?
Defective actuation of lock-up ECMV solenoid valve
Defective actuation of lock-up ECMV valve

Causes
Seized lock-up clutch
a b c
Remedy
C
.
No. " " "
Problems
1 Lock-up pressure does not become "0"
2 Lock-up clutch is not disengaged even when lock-up

pressure is "0"
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid valve is normal
20-1104 HD465-7, HD605-7

(7)
H-4 Excessive shock when starting or shifting
Judgement standard
There is some shock, but it is difficult to judge if the shock is excessive or not, so judge that it is excessive in the
following cases.
• It is clear that the shock has suddenly become excessive.
• The shock is excessive compared with other machines of the same class.
Cause
• Defective operation because of dirt caught in the ECMV pressure control valve spool and pressure detector
valve spool, or defective operation of the ECMV proportional solenoid.
H-5 Transmission does not shift up
a. Does not shift up

# Shifts up on downhill slopes.
Causes Remedy
Slipping or damage of torque converter lock-up clutch ×
# The above is the most probable cause, but for details, see "Torque converter lock-up does not engage".
b. Does not shift up

Causes Remedy
Defective operation of ECMV for clutch which does not shift up C ×

Defective piston seal ring, defective groove for clutch which does not shift up ×
Drop in main relief pressure A C ×
Clutch combination table
Clutch
No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
HD465-7, HD605-7 20-1105

(7)
TROUBLESHOOTING H-6
H-6 Machine lacks power or speed when traveling
a. Abnormality at all speed ranges

• Is the oil level in the transmission case cor-
rect?
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
• Is there any external oil leakage from the
piping or valve joints?
Defective operation of torque converter relief valve, deteriorated spring

• Is there any dragging of the parking brake,
Drop in set pressure of main relief valve (torque converter valve)

service brake, or retarder?
• Is any failure code related power trains dis-
Cooler, piping beyond torque converter outlet port damaged

played?
Damage inside torque converter (turbine rivet broken)

Checking for abnormalities
• Engine high idring speed
• Torque converter stall speed
Torque converter lock-up does not engage

• Machine travel speed Causes
• Transmission clutch pressure
Defective torque converter freewheel

• Torque converter lock-up pressure
Drop in performance of engine

• Main relief pressure
Crogged strainer
Defective pump
a b c d e f g h i j k
Remedy A
C ✕ ✕ A ✕
No. ✕
✕ ✕ ✕
Problems See TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.
2 Torque converter stall speed is high
3 Torque converter stall speed is low

Low at every speed range
4
(Item 2 abnormal)
Set pressure of Indicator is unstable and fluctuates
5
transmission is low excessively
Low after entering torque converter See TORQUE CONVERTER LOCK-UP DOES
6
lock-up NOT ENGAGE.
Hydraulic pressure at torque converter inlet port is low
7
(Items 4 – 6 normal)
Hydraulic pressure at torque converter outlet port is low
8
(Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of
9
transmission case
10 Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops
20-1106 HD465-7, HD605-7

➁
TROUBLESHOOTING H-6
b. Torque converter lock-up does not engage

Yes = Internal seizure, damage
• When this happened, was there any abnormal noise?
Yes = Broken part

• Is there any external oil leakage ?
• Is electricity flowing to the lock-up solenoid?
(Use a checker)

• Main relief pressure
• Lock-up oil pressure
Defective operation of lock-up ECMV solenoid valve spool

• Main travel speed
Defective operation of lock-up ECMV valve spool

Drop in set pressure of main relief valve
Causes
Worn lock-up clutch piston seal ring
Cracked lock-up clutch case

Defective lock-up solenoid
Worn lock-up clutch disc
a b c d e f g
Remedy
No. " " "
" " " "
Problems
1 Main relief pressure is low
2 With Item 1 normal, lock-up pressure is low or "0"
3 Solenoid is normal in Item 2 (proper continuity, no short circuit)
4 Solenoid is defective in Item 2 (no continuity, there is short circuit)
5 With Items 1 – 4 normal, lock-up pressure is low
6 Oil pressure is normal in Item 5
7 Lock-up pressure is low and main pressure is also low
8 Lock-up takes time to engage
HD465-7, HD605-7 20-1107

(7)
TROUBLESHOOTING H-6
c. Abnormality at specific speed ranges

• Is the oil level in the transmission case correct? Clutch combination table
• Is there any dragging of the parking brake, ser-
vice brake, or retarder? Clutch
No.
• Is any failure code related power trains dis- H L 4th 3rd 2nd 1st R
played? (Rotat- (Rotat-
Speed ing) ing)
range
• Machine travel speed R
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
(1) F1 is normal, but F2 is defective
1
(2) Returns to normal when replaced with any ECMV except 2nd.
(1) F2 is normal, but F1 is defective or only F1 is defective

2
(2) Returns to normal when replaced with any ECMV except 1st.
(1) F1 and F2 are normal, but F3 is defective

3
(2) Returns to normal when replaced with any ECMV except H.
(1) F1, F2 and F3 are normal, but F4 is defective

4
(2) Returns to normal when replaced with any ECMV except 3rd.
(1) F1 – F5 are normal, but F6 is defective

5
(2) Returns to normal when replaced with any ECMV except 4th.
(1) F3, F5, and F7 are normal, but others are defective
6
(2) Returns to normal when replaced with any ECMV except L.
(1) Only R is defective

7
(2) Returns to normal when replaced with any ECMV except R.
# Remove all the mud and dirt from around the ECMV, and clean it before replacing.
# After replacing, tighten the ECMV mounting bolts to the specified tightening torque.
ECMV mounting bolt : 8.0 – 10.0 Nm {0.8 – 1.0 kgm}
20-1108 HD465-7, HD605-7

(7)
Causes
"
H clutch disc worn or seized, seal ring worn
"
L clutch disc worn or seized, seal ring worn
"
4th clutch disc worn or seized, seal ring worn
HD465-7, HD605-7
d
"
3rd clutch disc worn or seized, seal ring worn
TROUBLESHOOTING
"
2nd clutch disc worn or seized, seal ring worn
"
1st clutch disc worn or seized, seal ring worn
"
R clutch disc worn or seized, seal ring worn
"
Defective operation of H clutch ECMV
"
Defective operation of L clutch ECMV
"
Defective operation of 4th clutch ECMV
"
Defective operation of 3rd clutch ECMV
"
Defective operation of 2nd clutch ECMV
"
m
Defective operation of 1st clutch ECMV
"
Defective operation of R clutch ECMV
(7)
H-6
20-1109
TROUBLESHOOTING H-7
H-7 Time lag is excessive when starting or shifting gear

• Is there any external oil leakage from the piping or valve joints?
• Is operation of control valve normal?
Checking for abnormalities Clutch combination table

• See the STANDARD VALUE TABLE to check
Clutch
if the time lag is actually excessive. No.
(Rotat- (Rotat-
Speed ing) ing)
range
F1
F2
F3
F4
F5
F6
F7
Remedy
No.
Problems
1 Abnormal noise comes from pump
2 There is time lag when transmission is placed in any speed range
3 F1 is normal, but there is time lag when shifting to F2
4 F2 is normal, but there is time lag when shifting to F1
5 F1 and F2 are normal, but there is time lag when shifting to F3
6 F1, F2, and F3 are normal, but there is time lag when shifting to F4
7 F1 - F5 are normal, but there is time lag when shifting to F6
8 F3, F5, and F7 are normal, but there is time lag when in other speed ranges
9 There is time lag in R
10 Transmission modulating pressure is low when placed in any speed range
11 Torque converter oil temperature goes above operating range
20-1110 HD465-7, HD605-7

➁
Causes
C
Clogged strainer
b
"
Defective pump
HD465-7, HD605-7
d
Defective oil tightness in rotating clutch
TROUBLESHOOTING
"
Defective shaft seal ring in rotating clutch circuit
"
Drop in set pressure of main relief valve
"
H clutch disc worn or defective seal ring, worn groove
"
L clutch disc worn or defective seal ring, worn groove
"
4th clutch disc worn or defective seal ring, worn groove
"
3rd clutch disc worn or defective seal ring, worn groove
"
2nd clutch disc worn or defective seal ring, worn groove
"
1st clutch disc worn or defective seal ring, worn groove
"
m
R clutch disc worn or defective seal ring, worn groove
"
Defective operation of H clutch ECMV
"
Defective operation of L clutch ECMV
"
Defective operation of 4th clutch ECMV
"
Defective operation of 3rd clutch ECMV
"
Defective operation of 2nd clutch ECMV
"
Defective operation of 1st clutch ECMV
"
Defective operation of R clutch ECMV
(7)
20-1111
H-7
TROUBLESHOOTING H-8
H-8 Torque converter oil temperature is high

• Does oil temperature go up when torque converter is stalled and go down when torque converter is not
stalled?
Yes = Normal (If torque converter is stalled frequently, however, selection of speed range is
incorrect)

• Is oil level in transmission case correct?

• Use STANDARD VALUE TABLE to judge if torque converter oil temperature is actually high.
★ If oil temperature is normal but oil temperature gauge on machine goes above operating rangey
→ defective oil temperature gauge
Oil leakage inside torque converter (defective seal ring, loose bolt,
Defective operation of torque converter relief valve
Causes
crack in pump, turbine)

Clogged strainer
Defective pump
Clogged filter
Torque
Tank-punp converter
a b c d e f
Remedy
No. C × ×
Problems ✕ ✕ ✕
1 Pump makes abnormal noise when oil temperature is low
2 High idling and low idling speeds are low
3 Torque converter outlet port oil pressure is low
4 Torque converter inlet port oil pressure is low
5 Transmission modulating pressure is low
6 Excessive leakage inside torque converter
If troubleshooting shows
that all other items are
normal, this is the cause.
20-1112 HD465-7, HD605-7

➁
TROUBLESHOOTING H-9
H-9 Torque converter oil pressure is low

• Is there any external oil leakage from the piping or valve joints?

• Pump outlet port oil pressure
Clogged hydraulic pump suction strainer or suction of air into circuit
Drop in set pressure of torque converter relief valve
Excessive leakage inside torque converter

Causes
Defective hydraulic pump
a b c d
Remedy
No. C
✕ ✕ ✕
Problems
1 Abnormal noise comes from pump
2 Oil pressure is low between pump and relief valve
3 Torque converter inlet port pressure is low

Transmission and lock-up pressures are normal, but torque
4
converter inlet pressure is low
When set pressure of torque converter relief valve is adjusted,
5
inlet pressure becomes high
HD465-7, HD605-7 20-1113

➁
TROUBLESHOOTING H-10
H-10 Front brake is ineffective, or effective only on one side

• Is the brake pedal play correct?
• Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in front brake accumulator gas pressure (gas leakage, defective

• Is the tire inflation and tread condition nor-
mal?
• Is any failure code related to the brakes
displayed?
Air sucked in at suction side of brake operating pump

• Is the front brake cut-off switch turned on?
Defective brake operating pump drive system (PTO)
Defective front brake accumulator charge valve
Defective operation of front brake cut valve

Causes
Defective wheel brake piston seal

Defective brake operating pump
Defective brake valve (front)
Air in brake circuit

piston seal
a b c d e f g h i
Remedy
No. ✕ ✕
✕ ✕ ✕ ✕ ✕
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Extremely large operating effort is needed to obtain specified

braking effect
5 Hydraulic and steering do not work
6 Abnormal noise is heard from around PTO
7 Abnormal noise is heard from around transmission oil pan or

PPC pump
8 Accumulator charge pressure is low
9 Brake immediately loses power after engine is stopped
10 There is time lag before brake starts to take effect
11 Brake oil pressure is low
12 When air is bled from brake system, air comes out
13 When front brake cut-off switch is turned ON (When its lower

part is pressed), front brake is not released
20-1114 HD465-7, HD605-7

➁
H-11 Rear brake is ineffective, or effective only on one side

• Is the brake pedal play correct?
• Is there any leakage of oil from the brake
piping or deformation of the piping?
Drop in rear brake accumulator gas pressure (gas leakage, defective

• Is the tire inflation and tread condition nor-
Defective retarder solenoid valve (Proportional reducing valve)

mal?
• Is any failure code related to the brakes dis-
played?
Air sucked in at suction side of brake operating pump

Defective brake operating pump drive system (PTO)
Defective rear brake accumulator charge valve
Defective operation of wheel brake piston

Causes
Defective wheel brake piston seal

Defective brake operating pump
Breakage inside wheel brake

Defective brake valve (rear)
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Air in brake circuit
Improper axle oil

piston seal
a b c d e f g h i j k l m n O
Remedy
No. ✕ ✕ ✕
✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕ ✕
Problems
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
5 Extremely large operating effort is needed to obtain specified

braking effect
6 When brakes are applied, abnormal noise is heard from brake

portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard from around transmission oil pan or

PPC pump
10 When oil is drained from inside axle case, large amounts of

metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
HD465-7, HD605-7 20-1115

➁
H-12 Steering wheel is heavy

• Is the oil level in the hydraulic tank correct?
• Is there any external oil leakage between the pump and steering valve?
• Is the steering wheel play correct?
• Is any failure code related steerings displayed?

• Operating effort of steering wheel
• Time taken to turn the steering wheel from
lock to lock
• Relief pressure of steering circuit
Drop in relief valve set pressure or defective sealing
Defective operation of spool or stuck spool

Causes
Defective opening of check valve

Air sucked in at suction end
Defective steering cylinder

Defective steering pump
Defective steering valve

Crushed suction tube
Defective hoist pump

Clogged strainer
Demand
valve
a b c d e f g h i j
Remedy A
No. C ✕ ✕ ✕
✕ ✕
Problems ✕
1 Circuit pressure is too high at engine low idling or pressure

rises to relief pressure
2 Relief pressure in steering circuit is too low
3 Hoist force is also low
4 Item 3 is abnormal and noise of oil blowing is heard from relief

valve
5 Relief pressure is low at end of cylinder stroke

(Items 1 – 4 normal)
7 When steering wheel is turned to right (left), oil flows out

continuously when hose on opposite side is removed
8 Condition is normal at engine low idling
9 Pump discharge amount is too low
10 Item 3 is normal but speed is slow
11 Excessive play in steering wheel
20-1116 HD465-7, HD605-7

➁
H-13 Steering wheel does not work

• Is there any external oil leakage between the
pump and steering valve?
• Is the steering wheel play correct?
• Is any failure code related steerings dis-
played?


• Relief pressure
Causes

Air sucked in at suction end
Defective steering cylinder

Defective steering valve

Defective hoist pump

Clogged strainer Demand
valve
a b c d e f g h i j k
Remedy A
No. C ✕ ✕ ✕ ✕
Problems ✕
1 Hoist cylinder also does not work
2 When pressure pickup port plug is removed and engine is

cranked, no oil comes out
3 Circuit pressure is too high at engine low idling, or pressure

rises to relief pressure (Item 2 normal)
4 Hoist is normal
5 Relief pressure is low at end of cylinder stroke (Item 4 normal)
6 Item 5 is abnormal and noise of oil blowing is heard from relief

valve
8 Steering wheel works when engine is at low idling
9 When steering wheel is turned to right (left) and hose on oppo-

site side is removed, rod does not move but oil flows out
10 Pump discharge amount is too low
11 Excessive play in steering wheel
H-14 Steering wheel vibrates

• Is any failure code related steerings displayed?
Causes Remedy
Air in hydraulic oil C
Leakage of air inside steering cylinder ✕
HD465-7, HD605-7 20-1117

➁
H-15 Hoist cylinder lacks lifting force (lifting speed)

• Is the actuation of the control levers normal?
• Is the input signal value of the dump lever in the normal range?
• Is any failure code related dump bodys dis-
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
played?
• Is there any external oil leakage from the
pump
and cylinder?
Drop in safety valve set pressure or defective sealing


• Relief pressure
• Body lifting speed

Causes
Drop in performance of hydraulic pump
Drop in performance of steering pump

Defective hoist cylinder

Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C ✕ ✕ C ✕ ✕
✕ ✕ ✕
Problems
1 Steering wheel is also heavy
2 Steering wheel is normal
3 Item i is defective and hoist circuit relief pressure is low

Item 3 is abnormal and noise of oil blowing is heard from relief
4
valve
Hoist circuit pressure is too high at engine high idling
5
(Items 1 – 4 are normal)
6 Only hoist circuit relief pressure is low
7
valve
8 Dump body rises irregularly
9 Pump discharge amount is low
10 Measured dump EPC valve oil pressure is low
11 Excessive hydraulic drift of hoist cylinde
12 Items 1 – 9 are normal but dump body lifting speed is slow
20-1118 HD465-7, HD605-7

➁
H-16 Hoist cylinder does not work

Yes = Seizure, damage to equipment
• Had drop in lifting speed or other symptoms
appeared before?
Drop in dump EPC circuit oil pressure or defective operation of EPC valve
Yes = Worn parts, deteriorated spring, etc.

Drop in safety valve set pressure or defective sealing

• Is the input signal value of the dump lever in

the normal range?
• Is any failure code related dump bodys

displayed?

Causes

• Relief pressure
Crushed pump suction tube
Defective hydraulic pump
Defective hoist cylinder
Defective dump lever

Clogged strainer
Demand valve Hoist valve
Remedy A A A
No. C ✕ ✕ ✕ ✕ ✕
Problems ✕
✕ ✕ ✕
When pressure pickup port plug is removed and engine is
1
cranked, no oil comes out
2 Steering also does not work
3 Steering is normal, only hoist does not work
4 In Item 2, hoist circuit relief pressure is low

5
valve
6 Only hoist circuit relief pressure is low at engine high idling
7
valve
Hoist circuit pressure is too high at engine low idling or
8
pressure rises to relief pressure (Items 1 - 5 normal)
9 Works when engine is at low idling
10 Pump discharge amount is low

When hoist lever is operated to RAISE, and hose on opposite
11
side is removed, cylinder does not move, but oil comes out
12 Measured dump EPC valve oil pressure is low
HD465-7, HD605-7 20-1119

➁
H-17 Excessive hydraulic drift of dump body

• IIs any failure code related dump bodys displayed?

• Hydraulic drift of cylinder
Causes
Defective hoist cylinder piston ring
Defective sealing of valve spool
a b
Remedy
No. ✕ ✕
Problems
1 When engine is stopped with Oil continues to flow out

body fully raised and head pip-
2 ing is removed Oil does not continue to flow out
20-1120 HD465-7, HD605-7

➁
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Points to remember when troubleshooting.................................................................................................20-1152

Method of using troubleshooting charts .....................................................................................................20-1153
S- 1 Starting performance is poor (starting always takes time) .............................................................20-1156
S- 2 Engine does not start ....................................................................................................................20-1159
a) Engine does not turn ................................................................................................................20-1159
b) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............................20-1160
c) Exhaust smoke comes out but engine does not start (fuel is being injected) ..........................20-1162
S- 3 Engine does not pick up smoothly (follow-up is poor) ...................................................................20-1164
S- 4 Engine stops during operations .....................................................................................................20-1166
S- 5 Engine does not rotate smoothly (hunting) ....................................................................................20-1168
S- 6 Engine lacks output (or lacks power).............................................................................................20-1170
S- 7 Exhaust smoke is black (incomplete combustion) ........................................................................20-1172
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................20-1175
S- 9 Oil becomes contaminated quickly ...............................................................................................20-1176
S-10 Fuel consumption is excessive ......................................................................................................20-1177
S-11 Oil is in cooling water, or water spurts back, or water level goes down ........................................20-1178
S-12 Oil pressure caution lamp lights up (drop in oil pressure)..............................................................20-1179
S-13 Oil level rises .................................................................................................................................20-1180
S-14 Water temperature becomes too high (overheating) ....................................................................20-1181
S-15 Abnormal noise is made ................................................................................................................20-1182
S-16 Vibration is excessive ....................................................................................................................20-1183
HD465-7, HD605-7 20-1151

(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

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

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
20-1152 HD465-7, HD605-7

(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

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

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are
marked with , and of these, causes that have a
high probability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for
items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HD465-7, HD605-7 20-1153

(7)
• Example of troubleshooting when exhaust gas is black

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

General causes why exhaust smoke is black
• Insufficient intake of air
• Defective condition of fuel injection
• Excessive injection of fuel
20-1154 HD465-7, HD605-7

(7)
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
HD465-7, HD605-7 20-1155

(7)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor Causes
• Defective electrical system
Defective preheating circuit (when starting in low temperatures)

• Insufficient supply of fuel
• Improper selection of fuel
• Defective HPI sensor
• Defective HPI actuator
Defective contact of valve, valve seat
Clogged timing rail actuator screen

Loose piping, fuel filter, entry of air
Defective or deteriorated battery

Worn piston ring, cylinder liner
Defective alternator regulator

Clogged air cleaner element
Defective injector check ball

Clogged fuel filter, strainer
Cut, worn injector O-ring

Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period
Starting performance became worse gradually
Engine starts easily when warm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Starting motor cranks engine slowly
When engine is Little fuel comes out even when injection pump sleeve nut is loosened
cranked with
starting motor, Little fuel comes out even when fuel filter air bleed plug is loosened
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly

When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary
When pressure at outlet port of fuel pump is measured, it is found to be low
Inspect fuel pump directly
Troubleshooting
Inspect fuel shut-off valve directly

Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with Yes
engine at low idling? No
Inspect sensor directly (Output voltage and resistance)
Inspect actuator directly (Resistance and filter for clogging)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-1156 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-1
Causes 1.If the following error codes are displayed, carry out
the troubleshooting in "ENG mode". (If any of the fol-
lowing error codes is not displayed, they are not
probably the cause of the trouble. In this case,
inspect the other devices for the cause.)
Defective intake manifold temperature sensor
[C514LK]: Abnormality in fuel rail actuator

Defective atmospheric pressure sensor
[C112LK]: Abnormality in timing rail actuator

Defective fuel pump pressure sensor
Defective timing rail pressure sensor
Defective water temperature sensor
[C318LK]: Abnormality in fuel pump actuator

Defective fuel rail pressure sensor
Defective fuel pump actuator ( 1)

Defective timing rail actuator ( 1)
Defective boost pressure sensor
Defective fuel rail actuator ( 1)

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1157

(7)
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine does not turn
General causes why engine does not turn

• Internal parts of engine seized
a See Troubleshooting S-4. Causes
• Defective electrical system
• Problem in power train (troubleshooting for machine)
a See the manual for the machine.
Defective safety relay or safety switch

Defective battery terminal connection
Defective starting circuit wiring

Broken flywheel ring gear
Defective starting switch
Defective starting motor

Defective battery relay
Questions
Condition of horn when starting Horn does not sound

switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items
Speed of rotation is low

When starting switch is turned Makes grating noise
to START, starting pinion moves
out, but Soon disengages again
Makes rattling noise and does not turn
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
There is no 24V between battery relay terminal B and terminal E
OFF, connect cord,
and carry out When terminal B and terminal C of starting motor are connected, engine starts
troubleshooting at When terminal B and terminal C of safety relay are connected, engine starts
1.
ON
When terminal of safety switch and terminal B of starting motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
Remedy
1. Carry out troubleshooting of machine
HD465-7, HD605-7 20-1159

(7)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out (fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
• Defective HPI sensor Causes

Defective fuel shut-off valve wiring

Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
Questions
Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
When fuel filter is drained, fuel does not come out
Check items
There is leakage from fuel piping

Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with Fuel pump outlet port coupler is pushed, almost no fuel comes out
starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting
Inspect fuel pump drive shaft directly

Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
20-1160 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-2
1.If the following error codes are displayed, carry out

Causes probably the cause of the trouble. In this case,
Defective intake manifold temperature sensor
Defective water temperature sensor



Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1161

(7)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start (fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
• Insufficient supply of fuel Causes
Defective dynamic valve system (valve, rocker arm, etc.)

• Improper selection of fuel and oil
Defective preheating heater circuit

Clogged timing actuator screen

Defective fuel pump
Defective injector
Suddenly failed to start
Questions

Starts when engine is warm
When preheating, preheating indicator lamp does not light up
When fuel filter is drained, no fuel comes out
Check items

Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with starting
motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel

Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly

When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
20-1162 HD465-7, HD605-7

(7)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective water temperature sensor Causes
HD465-7, HD605-7
Replace Defective intake manifold temperature sensor
Replace Defective fuel rail actuator ( 1)
TROUBLESHOOTING
Replace Defective timing rail actuator ( 1)

Replace Defective fuel pump actuator ( 1)
Replace Clogged fuel rail actuator

(7)
20-1163
S-2
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly Causes
• Defective condition of fuel spray
• Improper fuel used
• Abnormality in fuel control system
Defective contact of valve and valve seat


• Normal output is not applied
Failure boost pressure sensor

o See Troubleshooting S-6

Improper valve clearance

Seized turbocharger
Defective fuel pump

Defective injector
Engine pick-up suddenly became worse
Questions

Rust and water are found when fuel is drained
When engine is cranked Fuel pump outlet port coupler is pushed, almost no fuel comes out
with starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Blue under light load

Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Noise of interference is heard from around turbocharger
High idling speed under no load is normal, but speed suddenly drops when load is applied

When turbocharger is rotated by hand, it is found to be heavy
Inspect valve clearance directly
Troubleshooting

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
20-1164 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-3
Air leakage from piping between turbocharger and cylinder head

Replace
Replace
Replace
Replace
Replace
HD465-7, HD605-7 20-1165

(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
• Seized parts inside engine
• There is overheating Causes
a See Troubleshooting S-14.
Broken dynamic valve system (valve, rocker arm, etc.)

• Problem in power train (troubleshooting for machine)
Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)

Failure in power train (troubleshooting for machine)


Broken, seized piston, connecting rod
Broken fuel pump drive shaft

Broken, seized gear train
Defective injector
Abnormal noise was heard and engine stopped suddenly
Engine overheated and stopped
Condition when engine stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel level caution lamp lights up
Metal particles are found when oil is drained
Does not turn at all
When it is attempted
Check items
Turns in opposite direction

to turn by hand using
barring tool Moves amount of gear backlash
Fuel pump shaft does not turn
Engine turns, but stops when load is applied to machine

Carry out troubleshooting of machine
Inspect piston, connecting rod directly

Inspect main bearing, connecting rod directly
Inspect gear train directly
Troubleshooting

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
Add
20-1166 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-4


Defective fuel shut-off valve

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
HD465-7, HD605-7 20-1167

(7)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
Causes
• Air in fuel system
• Defective governor mechanism
High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator

Defective actuation of fuel rail actuator
Defective injector check ball


Defective fuel pump
Defective injector
Questions
Occurs at a certain speed range

Occurs at low idling
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
Engine speed sometimes rises too far
Engine is difficult to stop

Troubleshooting

When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1168 HD465-7, HD605-7

(7)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective fuel pump actuator ( 1)
Causes
HD465-7, HD605-7
— Defective in throttle sensor
Replace Defective in speed sensor
TROUBLESHOOTING
Replace Clogged fuel rail actuator screen

Replace Clogged timing rail actuator screen
this case, inspect the other devices for the cause.)
played, it is not probably the cause of the trouble. In
1.If the following error code is displayed, carry out the
troubleshooting in "ENG mode". (If it is not dis-
(7)
20-1169
S-5
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

a Measure the engine speed and judge if the problem is in the engine or on the machine.
General causes why engine lacks output
• Insufficient intake of air Causes
(if non-specified fuel is used, output drops)
• There is overheating
a See Troubleshooting S-14.

Improper adjustment of valve clearance


Seized turbocharger, interference


Defective fuel pump

Defective injector
Suddenly
Power was lost
Questions
Gradually
Dust indicator lamp is red
Black
Check items

Engine pickup is poor and combustion is irregular
High idling speed of engine is low

Troubleshooting

Check part No. of controller calibration data
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
20-1170 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-6
High resistance or clogged fuel circuit

Defective controller calibration data

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
—
—
HD465-7, HD605-7 20-1171

(7)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• Defective condition of fuel injection Causes
Leakage of air between turbocharger and cylinder head


Improper adjustment of valve clearance
Failure timing rail pressure sensor

Seized turbocharger, interference

Crushed, clogged muffler

Defective fuel pump
Defective injector
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly

Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated ( 2)
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-1172 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-7

2.If an error code of the timing rail pressure sensor
system is displayed, carry out the troubleshooting in
"EA mode".
HD465-7, HD605-7 20-1173

(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

a To prevent the oil from leaking up or down in the turbocharger, do not run the engine at idling for more than
20 minutes continuously (both low and high idling).
General causes why oil consumption is excessive
Causes
• Abnormal combustion of oil
• External leakage of oil
• Wear of parts in lubrication system
Worn seal at turbine end

Worn seal at blower end
Worn, damaged valve (stem, guide, seal)
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system
Leakage from oil filter or oil cooler

Leakage from oil drain plug

Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping

Broken piston ring
Broken oil cooler

Turbocharger
Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake pipe is dirty with oil
Check items
Inside of exhaust pipe is dirty with oil

There is oil in engine cooling water
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
Troubleshooting
When intake manifold is removed, inside is found to be dirty with oil

Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
HD465-7, HD605-7 20-1175

(7)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Defective combustion
Causes
• Operation under excessive load
• Oil change interval is too long
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
Clogged breather, breather tube

Worn valve (stem, guide, seal)
Defective oil filter safety valve

Too much engine oil added
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)
Check items
Engine oil temperature rises quickly

Black
Excessive
Amount of blow-by gas
None
Inspect turbocharger lubrication drain tube directly
Troubleshooting S-7
Troubleshooting
Excessive play of turbocharger shaft

Inspect breather element directly
Carry out
Inspect oil cooler directly

Inspect oil filter directly
Inspect safety valve directly
Replace
Replace
Replace
Replace
Correct
eplace
Clean
Clean
Clean
Remedy
20-1176 HD465-7, HD605-7

(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel
• Defective condition of fuel injection
• Defective HPI sensor Causes
High resistance, clogged fuel return circuit

Failure timing rail pressure sensor
Leakage of fuel inside head cover

Failure fuel rail pressure sensor

Defective fuel pump
Defective injector
Questions
More than for other machines of same model

Condition of fuel consumption Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Check items
Black
Exhaust smoke color
White
Inspect inside of head cover directly

Troubleshooting

Abnormality in fuel rail pressure sensor system is indicated ( 1)
Abnormality in timing rail pressure sensor system is indicated ( 1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1. If an error code of the fuel rail pressure sensor system or timing rail pressure sensor
Correct
Clean
Clean
system is displayed, carry out the troubleshooting in "EA mode". Remedy
HD465-7, HD605-7 20-1177

(7)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
Broken power train oil cooler (troubleshooting for machine)

Damaged cylinder liner O-ring, holes caused by pitting
Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Broken water pump seal
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Check items
Engine oil level has risen, oil is cloudy white

Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Troubleshooting
Carry out pressure-tightness test of cylinder head

Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Replace
Replace
Replace
Replace
Replace
Replace
Remedy Replace
20-1178 HD465-7, HD605-7

(7)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure caution lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper selection of fuel (insufficient viscosity) Causes
• Deterioration of oil due to overheating
Clogged, broken oil pump suction pipe

Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping

Clogged oil pan suction strainer
Defective oil pump relief valve
Defective oil pressure sensor

Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler

Clogged oil filter
Water, fuel in oil

Questions
Non-specified oil is being used

Engine oil pressure caution lamp lights up
Lights up at low idling
Lights up at low, high idling
Condition when oil pressure lamp lights up
Lights up on slopes
Sometimes lights up
Oil level caution lamp lights up (machines equipped with caution lamp)
Check items
There is crushing, external leakage from hydraulic piping

Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found

Carry out Troubleshooting
Inspect suction strainer, pipe directly

Troubleshooting
Oil pump rotation is heavy, there is play

Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure lamp goes out
(machines equipped with oil level sensor)
S-13
When oil pressure is measured, it is found to be normal

Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
HD465-7, HD605-7 20-1179

(7)
S-13 Oil level rises

a If there is oil in the cooling water, carry out Troubleshooting S-11.
General causes why oil level rises
• Cooling water in oil (milky white)
• Fuel in oil (diluted, and smells of diesel fuel) Causes
• Entry of water or oil from other component
Clogged water pump drain hole (breather hole), defective seal
Defective auxiliary equipment (pump, compressor) seal

Defective cylinder head injector sleeve
Broken, broken rear oil seal face

Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal

Broken aftercooler core
Worn fuel pump seal

Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in cooling water
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles
appear, or water spurts back
Check items
Exhaust smoke is white

Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank

Troubleshooting
Inspect rear oil seal directly

Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1180 HD465-7, HD605-7

(7)
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Rise in oil temperature in power train Causes
(troubleshooting for machine)
Rise in power train oil temperature (troubleshooting for

Defective radiator cap (pressure valve)
Defective water temperature gauge

Defective operation of thermostat

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core

Lack of cooling water
Broken water pump
machine)
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level caution lamp lights up (machines equipped with caution lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on cooling water
Excessive air bubbles inside radiator, water spurts back
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Check items
Water is leaking because of cracks in hose or loose clamps

When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Cooling water flows out from overflow hose
Power train oil temperature enters red range faster than engine water temperature
When compression pressure is measured, it is found to be low Carry out troubleshooting of machine
Inspect oil cooler directly
Troubleshooting
Inspect radiator core directly

When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
Carry out function test on thermostat (cracking temperature)
When water temperature is measured, it is found to be normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
HD465-7, HD605-7 20-1181

(7)
S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external noise.
General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion noise Causes
• Air sucked in from intake system
Air leakage from auxiliary equipment (pump, compressor)

Broken dynamic valve system (valve, rocker arm, etc.)
Defect inside muffler (dividing board out of position)

Leakage of air between turbocharger and head
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference

Seized turbocharger, internal interference
Defective adjustment of valve clearance
Missing, seized gear bushing

Improper gear train backlash
Seized crankshaft bearing
Defective injector
Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
Check items
Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine

Troubleshooting
When muffler is removed, abnormal noise disappears

Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
20-1182 HD465-7, HD605-7

(7)
S-16 Vibration is excessive

a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment between engine and chassis
• Abnormal combustion Causes
Defective dynamic valve system (valve, rocker arm, etc. stuck)
Internal damage in clutch chamber or damper chamber

Loose engine mounting bolts, broken cushion
Worn front support spigot joint portion
Worn main bearing, connecting rod
(troubleshooting for machine)

Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
Questions
Suddenly increased
Condition of vibration
Gradually increased
Seal on injection pump has come off
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black

Inspect main bearing, connecting rod directly
Troubleshooting
Inspect cam bushing directly

Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
HD465-7, HD605-7 20-1183

(7)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................30- 3 FRONT WHEEL

PRECAUTIONS WHEN CARRYING Removal and Installation.......................... 30-81
OUT OPERATION .......................................30- 4 REAR WHEEL
SPECIAL TOOL LIST................................. 30-5-1 Removal ................................................... 30-82
FUEL INJECTION PUMP Installation ................................................ 30-83
Removal and Installation ..........................30- 6 FRONT BRAKE CALIPER PADS
RADIATOR Removal and Installation.......................... 30-84
Removal....................................................30- 7 FRONT BRAKE CALIPERS
Installation.................................................30- 8 Removal and installation .......................... 30-85
ENGINE AND TORQUE CONVERTER AND Disassembly and Assembly ..................... 30-86
TRANSMISSION OIL COOLER FRONT WHEEL HUB
Removal and Installation ..........................30- 9 Disassembly............................................. 30-88
ENGINE FRONT SEAL Assembly.................................................. 30-89
Removal and Installation ..........................30-10 FINAL DRIVE CARRIER
OUTPUT SHAFT Removal and installation .......................... 30-91
Removal and Installation ..........................30-11 Disassembly and Assembly ..................... 30-92
Disassembly .............................................30-12 FINAL DRIVE AND REAR BRAKE
Assembly ..................................................30-13 Removal ................................................... 30-93
ENGINE REAR SEAL Installation ................................................ 30-95
Removal and Installation ..........................30-15 SKETCH OF SPECIAL TOOL ..................... 30-96
CYLINDER HEAD FINAL DRIVE, REAR BRAKE AND
Removal....................................................30-17 PARKING BRAKE
Installation.................................................30-19 Removal and Installation ......................... 30-97
ENGINE Disassembly............................................. 30-98
Removal....................................................30-22 Assembly................................................ 30-103
Installation.................................................30-23 FRONT SUSPENSION CYLINDER
TORQUE CONVERTER AND TRANSMISSION Removal ................................................. 30-109
Removal....................................................30-25 Installation .............................................. 30-110
Installation.................................................30-26 Disassembly............................................30-111
TRANSMISSION AND TORQUE CONVERTER Assembly................................................ 30-112
Separation and Coupling ..........................30-28 REAR SUSPENSION CYLINDER
TORQUE CONVERTER Removal and Installation........................ 30-114
Disassembly .............................................30-29 Disassembly........................................... 30-115
Assembly ..................................................30-33 Assembly................................................ 30-116
TRANSMISSION RETARDER COOLING PUMP
Disassembly .............................................30-39 Removal and Installation........................ 30-118
Assembly ..................................................30-52 STEERING, HOIST, AND HOIST CONTROL
DIFFERENTIAL PUMP
Removal....................................................30-67 Removal and Installation........................ 30-119
Installation.................................................30-68
Disassembly .............................................30-69
Assembly ..................................................30-73
HD465-7, HD605-7 30-1

➃
TORQUE CONVERTER, TRANSMISSION
AND RETARDER COOLING, AND BRAKE
PUMP
Removal and Installation ........................30-120
STEERING VALVE
Disassembly ...........................................30-122
Assembly ................................................30-125
DEMAND VALVE
HOIST VALVE
STEERING CYLINDER
Disassembly ...........................................30-134
Assembly ................................................30-135
HOIST CYLINDER
Disassembly ...........................................30-137
Assembly ................................................30-138
DUMP BODY
Removal..................................................30-141
Installation...............................................30-142
OPERATOR'S SEAT
Disassembly ...........................................30-144
Assembly ................................................30-149
30-2 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY .....Title of operation
..............................................................Precautions related to safety when carrying out the opera-
tion
1. X X X X (1) ...........................................Step in operation
★...........................................................Technique or important point to remember when removing
XXXX (1).
2. (2): .................................... Indicates that a technique is listed for use during
installation
3. assembly (3)
..................................................Quantity of oil or water drained
INSTALLATION OF cccc ASSEMBLY ....Title of operation

• Carry out installation in the reverse order to removal.
....................................................Technique used during installation
★...........................................................Technique or important point to remember when installing
(2).
• Adding water, oil ...............................Step in operation
★...........................................................Point to remember when adding water or oil
...................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
HD465-7, HD605-7 30-3

➂
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATIONL
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
1. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
2. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HD465-7, HD605-7 30-5

➂
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79 T- - can not be supplied (they are items to be locally manufactured).
★ Necessity: ■ : .......Cannot be substituted, should always be installed (used)
● : .......Extremely useful if available, can be substituted with commercially available part.
New/remodel:N : .......Tools with new part numbers, newly developed for this model.
R : .......Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank....Tools already available for other models, used without any modification
★ Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Nece N ew / Ske-
Component Symbol Part No. Part Name -ssity Q ’ty del tch
rem o Nature of work, remarks
795-799-5410 Adapter ■ 1
A Removal, installation of injec-
tor assembly
795-799-5420 Remover ■ 1
795-621-1140 Push tool ■ 1
A2 795-902-1460 Bolt ■ 3 Installation of engine front

seal
01582-02218 Nut ■ 3
Disassembly, assembly of
engine assembly 795-621-1130 Push tool ■ 1
A3 Installation of engine rear seal
01050-32280 Bolt ■ 5
792-420-1110 Centering tool ■ 1
• 792-420-1120 • Flange 2 Centring engine assembly and

C4 torque converter, transmission
• 790-413-1120 • Color 1 assembly
• 01010-51230 • Bolt 8
790-501-5000 Unit repair stand ■ 1

1 790-901-2110 Bracket ■ 1 trque converter assembly
Disassembly, assembly of C 790-901-3011 Plate ■ 1
torque convertor assembly
2 790-101-1871 Nut wrench ■ 1 Removal, installation of PTO
nut
3 792-103-5110 Wrench ■ 1 Removal, installation of pump
nut
Disassembly, assembly of • 792-420-1120 • Flange 2 Centring engine assembly and

torque convertor C4 torque converter, transmission
transmission assembly • 790-413-1120 • Color 1 assembly
• 01010-51230 • Bolt 8
Disassembly, assembly of D1 799-301-1600 Oil leak tester ■ 1 Checking actuation of piston
transmission assembly
Disassembly, assembly of dif-
1 790-901-5110 Bracket ■ 1 ferential assembly
Disassembly, assembly of H
diffelential assembly
790-901-3420 Plate ■ 1
2 790-425-1660 Wrench ■ 1 Adjust side bearing preload
30-5-1 HD465-7, HD605-7

➃
Nece N ew / Ske-
Component Sym bol Part No. Part Name -ssity Q’ty del tch
3 790-102-1130 Power wrench ■ 1 Removal, installation of bear-

Disassembly, assembly of ing cap bolt
H
diffelential assembly Removal, installation of pin-
4 797-101-1171 Power wrench ■ 1
ion bearing lock nut
792T-422-1610 Spacer ■ 4 N
1 01010-61620 Bolt ■ 4
01643-31645 Washer ■ 4
Disassembly, assembly of 2 795-102-2102 Spring washer ■ 1 Removal, installation of spring

final drive and rear brake, J
parking brake assembly 792-520-2110 Installer ■ 1 Removal, installation of floa-
3 tin seal
792-520-1600 Push tool ■ 1 (for small diameter)
791-585-1510 Installer ■ 1 Removal, installation of floa-

4 tin seal
791-530-1700 Push tool ■ 1 (for large diameter)
792-103-4102 Push tool ■ 1
792-625-1300 Push tool ■ 1 Press fitting of bushing

1 (for front)
790-101-5421 Grip ■ 1 (for rear)
suspension cylinder Q 01010-81240 Bolt ■ 1
assembly
792-610-1000 Suspension tool ■ 1
2 • 792-610-1100 • Pump assembly 1 Adjusting of suspension cylin-

der
• 792-610-1200 • Charging tool 1
1 790-452-1200 Pilot ring tool ■ 1 Centering valve body and

Disassembly, assembly of upper case
T
steerin valve assembly
2 790-452-1100 Tool installer set ■ 1 Installation of spacer
790-502-1003 Repair stand ■ 1

Disassembly and assembly
1 steering cylinder
790-101-1102 Hydraulic pump ■ 1
2 790-102-3802 Wrench ■ 1 Removal of cylinder head
3 790-302-1270 Socket ■ 1 Removal of piston nut
790-201-1702 Push tool KIT ■ 1
• 790-101-1771 • Push tool KIT ■ 1

steering cylinder assembly U 4 Press fitting of bushing
• 790-101-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
790-201-1500 Push tool KIT ■ 1
• 790-101-1580 • Push tool KIT ■ 1

5 Press fitting of dust seal
• 790-101-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
HD465-7, HD605-7 30-5-2

➃
Nece N ew / Ske-
Component Symbol Part No. Part Name -ssity Q ’ty del tch
6 790-720-1000 Expander ■ 1
steering cylinder assembly U 7 796-720-1650 Ring ■ 1 Removal of steerig cylinder
8 07281-01029 Clamp ■ 1
790-502-1003 Repair stand ■ 1

1 hoist cylinder
2 790-102-3802 Wrench ■ 1 Removal, installation of cylin-

der dead
3 790-720-1000 Expander ■ 1
4 796-720-1680 Ring ■ 1 Removal of piston ring
5 07281-01580 Clamp ■ 1
792-201-7310 Push tool ■ 1

Press fitting of bushing
790-101-5421 Grip ■ 1
(for cylinder )
01010-81240 Bolt ■ 1
6 790-201-1702 Push tool KIT ■ 1

Disassembly, assembly of H
hoist cylinder assembly
• 790-201-1851 • Push tool ■ 1
Press fitting of bushing
(for cylinder )
• 790-101-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
792-201-7410 Plate ■ 1
Press fitting of dust seal
790-101-5021 Grip ■ 1
(for cylinder )
01010-80816 Bolt ■ 1
7 790-201-1500 Push tool KIT ■ 1
• 790-201-1660 • Push tool ■ 1

Press fitting of dust seal
(for cylinder )
• 790-201-5021 • Grip ■ 1
• 01010-50816 • Bolt ■ 1
Removal of dump body V1 790-441-1320 Hook ■ 1 Lifting of dump body
assembly
799-703-1200 Service KIT tool ■ 1
799-703-1100 Vacuum pump ■ 1

Collection re-use of new X 799-703-1110 Vacuum pump ■ 1
freon gas (220V) Collection charging with freon
Vacuum pump gas
799-703-1120 ■ 1
(240V)
799-703-1400 Gas leak tester ■ 1
30-5-3 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND INSTALLA-

TION OF FUEL INJECTION
PUMP ASSEMBLY
REMOVAL
Stop the truck on level ground and set the park-

ing brake switch to the PARK position, then lock
the wheels with blocks.
Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Close the fuel supply valve.
2. Remove the clamp and move hose (1).
3. Disconnect wiring connector (2).
4. Disconnect fuel hose (3) and fuel tubes (4) and

(5).
5. Remove mounting bolts (6) and fuel pump

assembly (7).
INSTALLATION
• Carry out installation in the reverse order to
removal.
★ Bleed air from the fuel circuit. For details, see

TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
30-6 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLA- 6. Disconnect wiring connector (5) and hose (6)
from the left side of the radiator and move hose
TION OF RADIATOR ASSEM- (7).
BLY
REMOVAL

1. Remove the engine underguard.
2. Drain the cooling water.

7. Disconnect hose (8) from the left bottom of the
Radiator: 69
radiator.
3. Bleed air conditioner refrigerant gas.
4. Remove radiator mask (1) and guard (2).

Mask : 30 kg
Guard : 100 kg
8. Remove tube (9).
9. Disconnect hose (10).
10. Remove hose (11) form the clamp and move it.
5. Disconnect hoses (3) and (4).
HD465-7, HD605-7 30-7

➂
DISASSEMBLY AND ASSEMBLY RADIATOR
11. Disconnect wiring connector (12) of the coolant 15. Remove air conditioner condenser (18), fuel
level sensor above the radiator. cooler (19), steering oil cooler (20), and air after-
cooler (21) from the radiator assembly.
12. Disconnect hoses (13) and (14) above the radia-

tor and remove pipe (15).
INSTALLATION
13. Remove guard (16).
removal.
• Charge the air conditioner circuit with refrig-

erant gas (R134a).
,
Hose clamp:
13.7 ± 0.5 Nm {140 ± 5 kgcm}
★ When using 2 hose clamps continuously, set

their bolts at an angle of 180° to each other.
14. Lift off radiator assembly (17).
• Refilling with water
Radiator assembly: 310 kg Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
Radiator: 69
30-8 HD465-7, HD605-7

➂
ENGINE AND TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY AND TRANSMISSION OIL COOLER

TION OF ENGINE AND
TORQUE CONVERTER AND
TRANSMISSION OIL COOLER
ASSEMBLY
REMOVAL

1. Remove the engine underguard.
2. Drain the engine oil and hydraulic oil.
Engine oil pan: 57
Hydraulic tank: 122
3. Disconnect hose (1) from the underside of the

cooling fan.
INSTALLATION
removal.
Mounting bolt: Adhesive (LT-2)

Mounting bolt:
4. Disconnect hoses (2) and (3). 245 – 309 Nm {25 – 31.5 kgm}
[Target: 279 Nm {28.5 kgm}]
5. Remove tubes (4) and (5).
• Refilling with oil
6. Supporting the engine and torque converter and Add oil through the oil filler to the specified level.
transmission oil cooler assembly (6) with jacks, Run the engine to circulate the oil through the
system. Then, check the oil level again.
etc., remove them.
Engine oil pan: 57 (EO30-CD)
Engine and torque converter and trans-
mission oil cooler assembly: 140 kg
Hydraulic tank: 122 (EO10-CD)
HD465-7, HD605-7 30-9

➂
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLA- INSTALLATION

TION OF ENGINE FRONT 1. Using tool A2, press fit engine front seal (3) and
SEAL dust seal (2) together to the front cover.
★ Press fitting dimension a of dust seal: 4 mm
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-621-1140 Push tool ■ 1
A2 795-902-1460 Bolt ■ 3
01582-02218 Nut ■ 3
REMOVAL
1. Remove the radiator assembly. For details, see
REMOVAL, INSTALLATION OF RADIATOR 2. Install crank pulley (1).
ASSEMBLY. Mounting bolt:
1st time : 73.5 – 19.6 Nm {7.5 ± 2 kgm}
2. Remove the fan belt. 2nd time : 245.0 – 19.6 Nm {25 ± 2 kgm}
3rd time : 637.0 – 19.6 Nm {65 ± 2 kgm}
3. Remove crank pulley (1).
Crank pulley: 55 kg 3. Carry out the rest of installation work in the
reverse order to removal.
4. Remove dust seal (2) and engine front seal (3).
30-10 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT

INSTALLATION
TION OF OUTPUT SHAFT
ASSEMBLY • Carry out installation in the reverse order to
removal.
★ For application of ENS grease to each part, see
REMOVAL
DISASSEMBLY AND ASSEMBLY.
the wheels with blocks. Mounting bolt: Adhesive (LT-2)
Mounting bolt:
Raise the dump body and lock it with the safety
98 – 123 Nm {10 – 12.5 kgm}
pin.
1. Remove drive shaft assembly (1).

Mounting bolt:
Drive shaft assembly: 30 kg 98 – 123 Nm {10 – 12.5 kgm}
2. Remove coupling (2).
Mounting bolt:
3. Remove cover (3).
98 – 123 Nm {10 – 12.5 kgm}

Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4. Remove snap ring (4).
5. Remove the bearing and cover (5) together.
★ Use the guide bolt and forcing screws to

remove the bearing and cover.
Cover assembly: 35 kg
6. Lift off output shaft assembly (6).

Output shaft assembly: 90 kg
HD465-7, HD605-7 30-11

➂

OF OUTPUT SHAFT ASSEMBLY
DISASSEMBLY
1. Oil cage assembly
Remove oil seal (1) from cover (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Disassembly of damper assembly (5)

1) Before disassembling, make marks of flange
(6), body assembly (7), and body outer (9)
for balancing them after reassembly.
2) Remove body assembly (7) and rubber
pieces (8) from body outer (9).
★ There are 2 rubber pieces (8), large one
and small one. Check their locations.
3) Remove bearing (10) from the flywheel.
30-12 HD465-7, HD605-7

➂
ASSEMBLY 3. Install damper assembly (5) to the flywheel.

Spline of body assembly shaft:
ENS grease
4. Press fit bearing (3) to cover (4).

Bearing: ENS grease
5. Install cover assembly to the flywheel.

Cover assembly: 55 kg
Mating faces of cover assembly and fly-
wheel: Gasket sealant (LG-6)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6. Fit oil seal (1) to cover (2).

Insertion part of cover and outside of oil
seal: LOCTITE 648 (287-01-12830)
★ Degrease and dry the above parts before
applying gasket sealant.
Mating faces of covers (2) and (4):
Gasket sealant (LG-6)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Using the push tool, press fit bearing (10) to the

flywheel.
Inside of bearing: ENS grease
2. Assembly of damper assembly

1) Apply gasket sealant to body outer (9) and
the mating face of flange (6), then install
them.
Mating face of flange:
2) Install body assembly (7).
3) Install body outer (9), body assembly (7),
and rubber pieces (8).
★ When installing large and small rubber
pieces (8), check their locations.
★ Before installing these parts, apply grease to
them.
Body outer, body assembly, and rub-
ber pieces: Grease (G2-LI)
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
4) Install flange (6).
Mating face of flange:
Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
★ When installing the body outer, body inner,
and flange, match them marks to each other.
HD465-7, HD605-7 30-13

➂
7. Install the cage assembly to the cover assembly.
• Procedure for filling ENS grease

1) Part No. of ENS grease: 427-12-11871
2) Parts to be filled with ENS grease, quantity of
ENS grease to be supplied (Total: Approx.
500 g), and parts to be coated with ENS
grease are shown below.
30-14 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

TION OF ENGINE REAR SEAL 1. Using tool A3, press fit engine rear seal (2) until
it comes to the end of the housing.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-621-1130 Push tool ■ 1
A3
01050-32280 Bolt ■ 5
REMOVAL
1. Remove the output shaft assembly. For details,
see REMOVAL, INSTALLATION OF OUTPUT
SHAFT. 2. Install flywheel (1).
★ Secure the flywheel and housing with a stop-
2. Install guide bolt [1] and lift off flywheel (1). per, etc.
Since the faucet joint part of the flywheel is
shallow, the flywheel may fall suddenly. ★ Check each mounting bolt head for punch
Take care. marks. If there are 5 punch marks, replace
Flywheel: 45 kg the bolt.
★ Tighten the mounting bolts to the specified
torque in the following order.
Mounting bolt: Engine oil (EO30-CD)
Mounting bolt:
1st time : 198 ± 19.6 Nm {20 ± 2 kgm}
2nd time : 460.6 ± 19.6 Nm {47 ± 2 kgm}
3rd time : 90° +30°
0
★ When reusing a bolt, make a punch mark on

its head after tightening it.
3. Remove engine rear seal (2).
HD465-7, HD605-7 30-15

➂
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
★ Using dial gauge [2], check the flywheel for

radial runout and facial runout.
• Radial runout: Max. 0.15 mm
• Facial runout: Max. 0.20 mm
3. Carry out the rest of installation work in the

reverse order to removal.
30-16 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLA- 9. Loosen the hose clamp and remove air intake
connector (9).
TION OF CYLINDER HEAD
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-799-5410 Adapter ■ 1
A
795-799-5420 Remover ■ 1
REMOVAL
Stop the truck on level ground and set the park- 10. Remove air intake tube (10).
the wheels with blocks. 11. Remove covers (11) and (12).
12. Disconnect lubrication tubes (13) and (14).
pin.
Disconnect the cable from the negative (–) ter- 13. Disconnect exhaust tube (15).
1. Drain the cooling water.
Radiator: 69
2. Open the engine top cover and remove the bat-

tery case in the rear and engine cover.
3. Remove fuel filter bracket assembly (1).
4. Disconnect fuel tubes (2) and (3).
5. Remove corrosion resistor and bracket assembly

(4).
6. Disconnect each wiring connector and ground 14. Remove turbocharger and exhaust manifold
wire and move wiring harness (4). assembly (16).
7. Remove air intake connectors (6) and (7). Turbocharger and exhaust manifold
assembly: 60 kg
8. Remove air intake manifold (8).
Reference: The same parts are used in the
front and rear sections.
HD465-7, HD605-7 30-17

➂
15. Remove spill tube (30). 20. Remove the mounting bolts and rocker arm
housing (37).
16. Remove cylinder head cover (32).
21. Remove cylinder head mounting bolts (38).

17. Remove rocker arm assembly (33). Using the sling bolts, remove cylinder head
★ Loosen the locknut, then loosen adjustment assembly (39).
screw 2 – 3 turns. Cylinder head assembly: 60 kg
18. Remove cross heads (34) and push rods (35).
19. Using tool A, remove injector assembly (36).
30-18 HD465-7, HD605-7

➂
INSTALLATION
• Carry out installation in the reverse order to Mounting bolt of cylinder head cover:
removal. 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
Fuel tube sleeve nut (2): ★ Clean the mounting bolt holes before install-
ing the bolts.
43 – 47 Nm {4.4 – 4.8 kgm}
★ Check that the ball of the adjustment screw
Fuel tube sleeve nut (3): is fitted to the socket of the push rod.
24 – 27 Nm {2.4 – 2.8 kgm}
Rocker arm mounting bolt:
Engine oil (EO30-CD)
★ Tighten the mounting bolts of the air intake Rocker arm mounting bolt:
manifold in the following order. 235.2 – 254.8 Nm {24 – 26 kgm}
Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
★ Adjust each cross head according to the fol-

lowing procedure.
1) Loosen the locknut and return the adjust-
ment screw until it does not touch the
valve stem.
2) Hold the contact face of the cross head
against the rocker arm and keep the
cross head in contact with the valve stem
on the push rod side.
3) Tighten the adjustment screw gradually.
After it touches the valve stem, tighten it
20° – 30° further.
★ Tighten the mounting bolts of the turbo- 4) Tighten the locknut.
charger and exhaust manifold in the follow-
ing order. Locknut:
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
Mounting bolt of turbocharger and
exhaust manifold assembly:
1st time : 39.2 – 58.8 Nm {4 – 6 kgm}
2nd time :
112.8 – 122.5 Nm {11.5 – 12.5 kgm}
HD465-7, HD605-7 30-19

➂
1) Using tool A, insert injector (60) in the cylin-

der head.
O-ring: Engine oil (EO30-CD)
★ When inserting the injector, check that the
gasket at its end will not fall.
★ Direct the draft hole of the injector toward the
diagonal point of the holder and set the
holder to the installation position, too.
★ Insert the injector straight in the cylinder
head hole. Using the cylinder side of tool A,
press the injector top and set the seal of its
end to the cylinder head.
Rocker arm housing:

★ Apply the gasket sealant in a line 2 – 3 mm in
diameter along the housing groove as shown
below.
Mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
2) Tighten the holder mounting bolts.

★ Measure stem length a of each mounting
bolt. If it is 80 mm or longer, do not use
the bolt but use new one.
Threads and seat of mounting
bolt: Engine oil (EO30-CD)
Mounting bolt:
1st time:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2nd time:
Retighten 90° +30°0
30-20 HD465-7, HD605-7

➂
★ After tightening the bolts, make punch mark

★ Check that there is not foreign matter on the a on the main bolt (Do not make the punch
fitting face of the cylinder head and in the cyl- mark if the bolts are new).
inder.
★ When fitting the gasket, check that the grom-
met is not removed.
★ Check each mounting bolt head for punch
marks. If there are 3 punch marks, replace
the bolt.
★ Tighten the cylinder head mounting bolts in
the following order.
Mounting bolt:
Molybdenum disulfide grease (LM-P)
Cylinder head mounting bolts
( – ):
1st time : 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time : 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time : Make marks on bolts, and • Refilling with water
cylinder head with paint, Add water through the water filler to the specified
then retighten the bolts 90° level. Run the engine to circulate the water
– 120°. through the system. Then, check the water level
Mounting bolts (( – )) again.
93.2 – 103 Nm {9.5 – 10.5 kgm}
Radiator: 69
HD465-7, HD605-7 30-21

➂
DISASSEMBLY AND ASSEMBLY ENGINE

5. Disconnect exhaust tube (5).
TION OF ENGINE ASSEMBLY 6. Disconnect wiring connector E13A (6) and E13B
(7).
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-420-1120 • Flange 2
C4
790-413-1120 • Collar 1
01010-51230 • Bolt 8
REMOVAL
ing brake switch to the PARK position, then lock 7. Remove engine oil cooler tubes (8) and (9).
pin.
1. Remove battery box (1), engine top cover (2)
(2A), air cleaner (3), and air intake tube.
8. Disconnect wiring connectors SIG (10), POW

(11), and ENG (12) from the left rear part of the
engine and remove bracket (13).
2. Remove the radiator assembly. For details, see

REMOVAL, INSTALLATION OF RADIATOR
ASSEMBLY.
3. Remove the radiator cross bar.
4. Remove washer tank (4).
30-22 HD465-7, HD605-7

➂
10. Remove oil filter bracket assembly (17).
12. Disconnect air conditioner pipe (20).
13. Remove plate (21) and drive shaft (22).

Drive shaft: 30 kg
INSTALLATION
removal.
14. Sling the engine assembly temporarily. ★ When tightening the bolts, check that the key
way of the spider cap is fitted to the key way
15. Remove engine mounting bolts (23) and (24) of the mating yoke.
and pull out engine assembly (25) forward to Mounting bolt: Adhesive (LT-2)
remove it. Mounting bolt:
★ When removing the engine assembly, check 98 – 123 Nm {10 – 12.5 kgm}
that the all wires and pipes are disconnected
and take care that the engine assembly will
not interfere with the chassis. ★ Center the engine assembly and torque con-
Engine assembly: 2,750 kg verter and transmission assembly according
HD465-7, HD605-7 30-23

➂
1. Install flange (C4-1) and collar (C4-2) of tool

C4 between coupling (20) on the engine side
and coupling (21) on the torque converter
side.
2. Center the engine assembly and torque con-
verter and transmission assembly by moving
the engine assembly so that collar (C4-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
Reference: The allowable vertical and lateral
deviation between both flanges
is 3 mm maximum.
Engine mount mounting bolt (Both front

and rear):
343 – 426.3 Nm {35.0 – 43.5 kgm}
★ If the engine mount bracket was removed
from the chassis, tighten its mounting bolts to
the following torque.
Mounting bolt of front engine mount
bracket:
343 – 426.3 Nm {35.0 – 43.5 kgm}
Mounting bolt of rear engine mount
bracket:
450 – 608 Nm {50 – 62 kgm}
• Refilling with water

Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
Radiator: 69
30-24 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION
REMOVAL AND INSTALLA- 6. Disconnect hose (4) and tube (5).
TION OF TORQUE CON-

VERTER AND TRANSMISSION
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-420-1120 • Flange 2
C4
790-413-1120 • Collar 1 7. Remove drive shaft (6).
01010-51230 • Bolt 8
Drive shaft: 30 kg
REMOVAl 8. Disconnect hoses (7), (8), (9), (10), and (11).

pin.
1. Remove the transmission underguard.
2. Drain the transmission oil and hydraulic oil.
Transmission case: 190
Hydraulic tank: 122
3. Disconnect wiring connectors (1) (TM2 and TM3).
4. Remove drive shaft (2).

Drive shaft: 65 kg
HD465-7, HD605-7 30-25

➂
9. Disconnect hoses (12), (13), and (14) and tubes Torque converter and transmission
(15) and (16) from the left underside of the trans-
assembly: 1,600 kg
mission.
10. Sling the torque converter and transmission

assembly temporarily.
INSTALLATION
11. Remove mounting bolts (17) and (18) of the front removal.
and rear mounts, then remove torque converter
and transmission assembly (19). ,
★ When removing the torque converter and ★ When tightening the bolts, check that the key
transmission assembly, check that the all way of the spider cap is fitted to the key way
wires and pipes are disconnected and take of the mating yoke.
care that the assembly will not interfere with
the chassis.
★ Check the thickness and quantity of the
shims set in the rear mount.
• Standard thickness of shims: 2 mm Mounting bolt:
• Thickness of each shim: 0.5 mm (1 type) 157 – 198 Nm {16.0 – 20.1 kgm}

Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-26 HD465-7, HD605-7

➂
★ Center the engine assembly and torque con-

verter and transmission assembly according
1. Install flange (C4-1) and collar (C4-2) of tool

C4 between coupling (20) on the engine side
and coupling (21) on the torque converter
side.
2. Center the engine assembly and torque con-
verter and transmission assembly by moving
the engine assembly so that collar (C4-2) will
move smoothly between both flanges while
coupling (21) on the torque converter side
makes a full turn.
Reference: The allowable vertical and lateral
deviation between both flanges
is 3 mm maximum.
★ If the transmission mount bracket was

removed from the chassis, tighten its mount-
ing bolts to the following torque.
Mounting bolt:
450 – 608 Nm {50 – 62 kgm}

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
Transmission case: 190 (EO30-CD)
HD465-7, HD605-7 30-27

➂
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND TORQUE CONVERTER
SEPARATION AND COUPLING 5. Lift off torque converter assembly (9).

OF TRANSMISSION ASSEM- Torque converter assembly: 410 kg
BLY AND TORQUE CON-
6. Remove seal rings (10) and (11).
VERTER ASSEMBLY
SEPARATION
1. Remove pump assemblies (1), (2), and (3) and
their pipes.
Retarder cooling pump assembly (1):
30 kg
Steering hoist and hoist control pump
assembly (2): 35 kg
Torque converter, transmission, retarder
cooling, and brake pump assembly (3):
25 kg
2. Remove plate (4) and trunnion (5).
3. Remove cover (6) and disconnect torque con-

verter oil temperature sensor connector (7) and
torque converter intermediate oil pressure sen-
sor connector (8).
COUPLING
• Carry out coupling in the reverse order to sepa-
ration.
Torque converter assembly mounting bolt:

245 – 308.7 Nm {25 – 31.5 kgm}
Outside of seal ring: Grease (G2-LI)
4. Sling the torque converter and transmission

assembly, then place it with the torque converter
side up.
30-28 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY AND ASSEM-

BLY OF TORQUE CON-
VERTER ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-901-2110 Bracket ■ 1
C 790-901-3011 Plate ■ 1
2 790-101-1871 Nut wrench ■ 1 2) Using 2 forcing screws [1], lift off PTO case
3 792-103-5110 Wrench ■ 1 assembly (10).
★ Before removing the PTO case assem-
bly, make match marks on it.
DISASSEMBLY
1. Set the torque converter assembly to tool C1.
2. Remove control valve assembly (1).
3. Remove torque converter oil temperature sensor

(2) and torque converter intermediate oil pres-
sure sensor (3).
4. Remove elbows (4) and (5) and tube (6).
6. Disassembly of PTO case assembly

1) Using tool C2, remove nuts (9).
2) Remove snap ring (12) and plate (13).
5. PTO case assembly

1) Remove holder (7) and coupling (8).
★ Before removing the holder and coupling,
loosen 3 nuts (9) with tool C2 (Use the
coupling as a stopper).
HD465-7, HD605-7 30-29

➂
3) Press the shaft to remove PTO gear and 9) Remove bushing (25) and outer race (26)
bearing assembly (14). from the PTO case.
★ If the PTO gear and bearing assembly
comes off, bearing (15) comes off, too.
4) Remove inner race spacer (16) and bearing
(17) from the PTO gear.
5) Remove outer races (18) and (19) and outer
race spacer (20) from the PTO case.
★ Since parts (15) – (20) form an assembly,
do not replace any of them with one of
another assembly. (The combination
symbol is stamped on each part.)
7. Turbine and clutch assembly

1) Remove mounting bolts (27) on the pump
side.
2) Remove turbine and clutch assembly (28).
6) Remove snap ring (21).

7) Using forcing screws [2], remove cage (22).
8. Disassembly of turbine and clutch assembly

1) Input shaft
i) Using forcing screws [3], remove input
shaft (29).
ii) Remove bearing (30) from the input
shaft.
8) Remove oil seal (23) and dust seal (24) from

the cage.
30-30 HD465-7, HD605-7

➂
2) Turn over the drive case and remove the 6) Using push tool [4], remove shaft (38) from
mounting bolts and turbine (31). clutch housing assembly (33), then remove
piston (39).
3) Remove drive case (32) from clutch housing

assembly (33). 7) Remove seal rings (40) from piston (39).
4) Remove 2 discs (34) and plate (35).
8) Using push tool [5], remove bearing (41)

5) Turn over the clutch housing and remove from the clutch housing.
snap ring (36) and plate (37). 9) Remove pin (42) and seal ring (43).
HD465-7, HD605-7 30-31

➂
9. Stator assembly
Pull up and remove stator assembly (44).
3) Remove the pump, stator shaft, and rear

10. Disassembly of stator assembly housing assembly from tool C1.
1) Remove stator (45).
4) Remove the mounting bolts and push out
and remove stator shaft (54).
★ At this time, inner race (55) comes off.
2) Remove bushings (47) and (48) and free

wheel (49) from outer race (46).
★ Take care to lose balls (50).
5) Remove seal ring (56), inner race (57), and
sleeve (58) from stator shaft (54).
11. Disassembly of pump, stator shaft, and rear

housing assembly
1) Remove snap ring (51) and inner race (52).
2) Using tool C3, remove nuts (53).
30-32 HD465-7, HD605-7

➂
6) Remove retainer (60) and guide (61) from ASSEMBLY

pump (59).
7) Remove bearing (62) from guide (61). 1. Assembly of pump, stator shaft and rear
housing assembly
1) Install bearing (62) to guide (61) and install
them to pump (59).
★ Bearing (62) is an assembly. Check that
the serial No. and match symbol (A or B)
on its end face are the same as those on
the mating inner race.
2) Install retainer (60) to pump (59).
Retainer mounting bolt:
Adhesive (LT-2)
58.8 – 73.5 Nm {6 – 7.5 kgm}
3) Press fit inner race (57) to stator shaft (54).

★ Inner race (57) is an assembly. Check
that the serial No. and match symbol (A
or B) on its end face are the same as
those on the mating bearing.
4) Fit sleeve (58) and seal ring (57).
★ Fit sleeve (58) by expansion fit.
HD465-7, HD605-7 30-33

➂
5) Install stator shaft assembly (54) to rear

housing (63).
Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
2. Assembly of stator assembly

1) Install free wheel (49) to outer race (46).
★ Install the free wheel with its arrow mark
end on the input side. Check the revolv-
ing direction of the outer race, seeing it
6) Install the stator shaft and rear housing
from the input side.
assembly to tool C1.
Clockwise: Free rotation
7) Install pump assembly (64) and inner race
Counterclockwise: Locked
(55) to stator shaft (54).
Sliding surface:
★ Inner race (55) is an assembly. Check
Engine oil (EO10-CD or EO30-CD)
that the serial No. and match symbol (A
or B) on its end face are the same as
2) Install balls (50) to outer race (46), then
those on the mating bearing.
install bushings (48) and (47) by expansion
fit.
Sliding surface:
8) Using tool C3, tighten nuts (53).

★ Drop about 6 CC of engine oil (EO10-CD
or EO30-CD) over the bearing and rotate
the bearing 10 turns.
Threads of nut: Adhesive (LT-2)
Nut: 441.3 – 490.3 Nm {45 – 50 kgm}
9) Install inner race (52) and snap ring (51).
★ Install the inner race with the wider end
face up.
30-34 HD465-7, HD605-7

➂
3) Install stator (45). 3) Using push tool [6], install bearing (41) to the
Mounting bolt: Adhesive (LT-2) clutch housing.
★ Press fit the bearing until it is stopped by
Mounting bolt:
the clutch housing.
58.8 – 73.5 Nm {6 – 7.5 kgm}
★ Drop about 6 cc of engine oil (EO10-CD
3. Stator assembly
Install stator assembly (44).
4) Install seal ring (40) to piston (39).
★ For the installing direction, see the fol-
lowing figure.
4. Assembly of turbine and clutch assembly

1) Install seal ring (43) to the clutch housing.
★ For the installing direction, see the fol-
lowing figure.
5) Install piston (39) to clutch housing assembly
2) Install pin (42) by expansion fit.
(33).
6) Using push tool [7], press fit shaft (38) to
clutch housing assembly (33).
★ Press fit the shaft until it is stopped by
the bearing.
HD465-7, HD605-7 30-35

➂
7) Install plate (37) to the shaft, then install

snap ring (36).
11) Input shaft

8) Install 2 discs (34) and plate (35).
i) Using push tool [8], install bearing (30).
Sliding surface of disc:
★ Drop about 6 cc of engine oil (EO10-CD
9) Install drive case (32) to clutch housing
assembly (33).
ii) Install input shaft assembly (29) to clutch
★ Watch through holes A (at 6 places on
housing assembly (33).
the periphery) and check that plate (35)
is meshed with the gear of drive case
(32). Mounting bolt:
Mounting bolt: Adhesive (LT-2) 269.7 – 308.9 Nm {27.5 – 31.5 kgm}
Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
5. Turbine and clutch assembly

1) Install turbine and clutch assembly (28).
10) Install turbine (31). 2) Tighten mounting bolts (27) (30 pieces).
Mounting bolt: Adhesive (LT-2) Mounting bolt: Adhesive (LT-2)
Mounting bolt: Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm} 49.0 – 58.8 Nm {5 – 6 kgm}
30-36 HD465-7, HD605-7

➂
6. Assembly of PTO case assembly 3) Fit the O-ring to cage (22) and install them to
1) Press fit outer race (26) and bushing (25) to the PTO case.
the PTO case. 4) Install snap ring (21).
★ After press fitting bushing (25), bend the ★ Install the snap ring so that its closed gap
PTO case end (by 4 points equally will be on the left side (in the direction of
spaced on the periphery) with a punch, 9 o'clock) when it is on the truck and
etc. until it is over the bushing. seen from the engine side.
2) Using push tool [9], install dust seal (24) and 5) Install outer race spacer (20) and outer races
oil seal (23) to cage (22). (18) and (19) to the PTO case.
i) Thinly apply gasket sealant (LG-5) to the 6) Install bearing (17) and inner race spacer
seal fitting surface inside the cage.ii) (16) to the PTO gear.
ii) Install the seals so that the distances 7) Install PTO gear and bearing assembly (14)
from the cage top to their tops will be as to the PTO case, then install bearing (15) to
follows. the shaft.
• Distance a: 23.6 ± 0.2 mm ★ Since parts (20) – (15) form an assembly,
• Distance b: 8.75 ± 0.25 mm do not replace any of them with one of
★ After installing, wipe off the projected another assembly. (The combination
gasket sealant thoroughly. symbol is stamped on each part.)
iii) Fill the space between the oil seal and ★ Apply grease (G2-LI) to the inside spline
dust seal and the space between the lips of the PTO gear shaft.
of the oil seal with silicone grease
(ThreeBond 1855)
★ Supply grease of quantity equivalent
to 40 – 60% of the space between
the lips so that it will not be projected.
HD465-7, HD605-7 30-37

➂
8) Install plate (13) and snap ring (12).

9) Using tool C2, tighten nuts (9) temporarily.
★ Install the nuts with the chamfered side
down.
★ Tighten the nuts permanently after install-
ing the PTO case assembly (since they
will be used to stop the coupling).
Threads of nut: Adhesive (LT-2)
8. Install elbows (5) and tube (6).

★ When installing elbows (5), check that there
are stamps of <2> on their outside.
Elbow: 34.3 – 63.8 Nm {3.5 – 6.5 kgm}
9. Install elbows (4).

Threads of elbow:
7. PTO case assembly Gasket sealant (LG-5)
1) Sling PTO case assembly (10) and fit the O- Elbow: 16.7 – 29.4 Nm {1.7 – 3.0 kgm}
ring. Using guide bolt [10], install the PTO
case assembly. 10. Install torque converter intermediate pressure
★ When installing the PTO case assembly, sensor (3).
match the match marks. Threads of sensor:
Mounting bolt: Gasket sealant (LG-5)
98.1 -– 122.6 Nm {10 – 12.5 kgm} Sensor: 9.8 – 19.6 Nm {1 – 2 kgm}
11. Install torque converter oil temperature sensor

(2).
Threads of sensor:
Sensor: 29.4 – 49.0 Nm {3.0 – 5.0 kgm}
12. Install control valve assembly (1).

Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 Kgm}
2) Install coupling (8) and holder (7).

Mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
3) Using tool C2, tighten the nuts (9) to the fol-
lowing torque which were tightened tempo-
rarily in steps 6-9).
★ Use the coupling as a stopper.
Nut:
392.4 – 441.5 Nm {40 – 45 kgm}
30-38 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY AND ASSEM- 4) Remove cover (7) and lubricating oil temper-
ature sensor (8).
BLY OF TRANSMISSION 5) Remove block (9).
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
D1 799-301-1600 Oil leak tester kit ■ 1
DISASSEMBLY
1. Transmission mount, cover, wiring harness,
and sensors
2. Control valve assembly
1) Remove both transmission mounts (1).
1) Separate the connector of each control valve
2) Remove covers (2) and (3).
and remove wiring harness (10).
2) Install a sling bolt to position A and remove
control valve assembly (11) and valve seat
together.
★ After removing the control valve, cover
the oil holes on the mating face of the
transmission case with tapes, etc. to pre-
vent foreign matter from entering the
transmission case.
3) Remove each control valve (12) and filter
assembly (13) from the valve seat.
3) Remove input shaft speed sensor (4), inter-

mediate shaft speed sensor (5), and output
shaft speed sensor (6).
3. Sleeve
Using a forcing screw, remove 5 sleeves (14).
HD465-7, HD605-7 30-39

➂
4. Oil pan 5. Check of operation of pistons

1) Sling transmission assembly (15) and remove Using tool D1, blow air into the clutch ports and
oil pan (16). check the operation of the pistons of No. 1, 2,
and 3 clutches. (Since you cannot check the
operation of the pistons of No. 2 and 3 clutches
directly, check it by movement of the discs or
plates.)
★ The locations of the clutch ports are shown
below.
• No. 1 clutch port: A
• No. 2 clutch port: B
• No. 3 clutch port: C
★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
• Standard stroke of clutch No. 1 piston:
4.2 mm
6. No. 1 clutch plates

2) Remove cover (17) from the oil pan, then 1) Using sling bolts, remove No. 1 clutch plates
remove spring (18) and magnet assembly (24).
(19). ★ There are 2 bolts installed from the trans-
mission case side.
3) Remove blocks (20) and (21) from the oil

pan, then remove relief valves (22) and (23). 2) Remove bearing (25) from No. 1 clutch plates.
30-40 HD465-7, HD605-7

➂
7. No. 1 clutch spring and guide 10. Input shaft and No. 1 ring gear assembly
Remove spring (26) and guide (27). 1) Sling the input shaft and remove the input
shaft and No. 1 ring gear assembly (33).
8. Discs, plates, and springs
Remove discs (28), plates (29), and spring (30).
2) Pull up remove No. 1 ring gear (34).

3) Remove seal rings (206) and (207) from the
9. No. 1 clutch drum and piston input shaft.
1) Using hanging bolts, remove clutch No. drum
(31) and piston (32) together, then separate
them from each other.
4) Remove inner race (35) from No. 1 ring gear

(34).
2) Remove seal rings (100) and (101) from pis-

ton (32).
HD465-7, HD605-7 30-41

➂
5) Remove snap ring (36) and press down and 11. No. 2 clutch assembly
remove gear (37). Lift of No. 2 clutch assembly (42).
6) Remove inner race (38) from gear (37). 12. Disassembly of No. 2 clutch assembly
1) Turn over No. 2 clutch assembly and remove
housing (43).
7) Remove snap ring (39), then remove input

shaft (41) from bearing (40).
2) Remove mounting bolts, cover (44), and pis-
ton (45).
30-42 HD465-7, HD605-7

➂
3) Remove seal ring (46) from piston (45).
8) Remove plates (59) from carrier (60).

4) Housing assembly
i) Remove seal rings (47) and (48).
ii) Remove snap ring (49), bushing (50),
and ball (205).
★ Take care not to lose ball (205).
iii) Remove inner race (51) and bearing
(52).
9) Carrier assembly
i) Remove shaft (61).
ii) Remove planetary gears (63), thrust
washer (64), and bearing (65).
5) Remove snap ring (53) and ring gear (54).
6) Remove discs (55), plates (56), and spring

(57).
7) Using sling bolts, remove drum (58).
HD465-7, HD605-7 30-43

➂
iii) Remove seal ring (66), inner race (67), and 14. Check of operation of piston
bearing (68) from carrier (60). Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
Standard strokes of pistons
Piston No. Stroke (mm)
4 4.8
5 5.8
6 5.0
7 5.0
13. Transmission case

1) Remove cage assembly mounting bolts (69)
and lift off transmission case (70) vertically.
15. No. 3 clutch housing assembly

Remove the housing mounting bolts and No. 3
clutch housing assembly (75).
★ For disassembly, see Step 12, DISASSEM-
BLY OF NO. 2 CLUTCH ASSEMBLY, 1) - 4).
(No. 3 clutch assembly has the same struc-
2) Remove the following parts from the trans- ture as No. 2 clutch assembly.)
mission case.
i) Remove the assembly of cage (71) and
bearings (72), then remove the bearings
from the cage.
ii) Remove collars (73) and bearings (74)
from the case.
iii) Remove seal ring (204) from the collar.
30-44 HD465-7, HD605-7

➂
16. No. 3 clutch drum, discs, and plates 18. Tie bolts
1) Using hanging bolts, remove No. 3 clutch drum Remove tie bolts (83).
(76), discs, plates, and spring together.
2) Remove discs (77), plates (78), and spring 19. No. 4 clutch plates and sun gear
(79). 1) Remove plates (84).
2) Remove snap ring (85) and sun gear (86).
17. No. 3 clutch ring gear

1) Remove No. 3 clutch ring gear (80).
2) Remove inner race (81) and seal ring (82) 3) Remove seal ring (200) from No. 4 sun gear
from the ring gear. (86).
HD465-7, HD605-7 30-45

➂
20. No. 4 clutch discs, plates, and springs 2) Remove seal rings (93) and (94) from No. 4
Remove discs (87), plates (88) and (101), and housing (91) and piston (92).
springs (89) and (90).
★ Distinguish plates (88) and (101) from each
other.
★ Since springs (90) of a clutch line have a part
No. different from those of another clutch
line, store them for each clutch line.
22. No. 5 clutch discs, plates, and springs

Remove discs (95), plates (96), and springs (97)
and (98).
★ Since springs (97) of a clutch line have a part
No. different from those of another clutch
line, store them for each clutch line.
21. No. 4 housing, piston, and ring gear

1) Using hanging bolts, remove No. 4 housing
(91), piston (92), and ring gear (93) together.
★ If the dowel pin is hard to remove and it
may cuff the housing, take care
extremely.
30-46 HD465-7, HD605-7

➂
23. No. 5 housing, piston, ring gear, and guide 24. No. 6 clutch discs, plates, and springs
pins Remove discs (108), 4 plates (109) and (110),
1) Using sling bolts, remove No. 5 housing (99), and springs (111) and (112).
piston (102), and ring gear (103) together. ★ Since springs (111) of a clutch line have a
★ If the dowel pin is hard to remove and it part No. different from those of another
may cuff the housing, take care clutch line, store them for each clutch line.
extremely. ★ Distinguish plates (109) and (110) from each
2) Remove guide pins (202). other.
3) Remove seal rings (106) and (107) from No.

5 housing (99) and piston (102).
25. No. 4 and No. 5 carriers assembly

Using hanging bolts, remove No. 4 and No. 5
4) Remove sleeve (203) for tie bolt (83) from carriers assembly (201).
No. 5 housing and check the direction of the
sleeve (slit A).
HD465-7, HD605-7 30-47

➂
26. Disassembly of No. 4 and No. 5 carriers assem- 5) Drive out shaft (123) toward No. 4 carrier and
bly remove ball (124).
1) Remove No. 5 sun gear (113). ★ Take care not to lose ball (124).
6) Drive out shaft (123) further and remove it.
7) Remove No. 4 planetary gears (300), bear-
ing (125), thrust washer (126), No. 5 plane-
tary gear (119), bearing (120), collar (121),
and thrust washer (122).
8) Remove snap ring (127) and ring gear (129).
2) Turn over the carrier assembly and remove

bearing (115) and seal ring (116).
3) Drive out shaft (117) toward the ball and

remove ball (118).
★ Take care not to lose the ball.
4) Drive out shaft (117) from the ball side and
remove No. 5 planetary gears (119), bearing 27. No. 6 and No. 7 housings, pistons, and springs
(120), collar (121), and thrust washer (122). 1) Using sling bolts, remove No. 6 and No. 7
★ At this time, 4 of 8 No. 5 planetary gears housings (131) and pistons (132) and (133).
come off. ★ If the dowel pin is hard to remove and it
may cuff the housing, take care extremely.
30-48 HD465-7, HD605-7

➂
2) Remove seal rings (134), (135), and (136) 29. No. 6 and No. 7 carriers assembly
from No. 6 and No. 7 housings and pistons Using sling bolts, sling the shaft and remove No.
(132) and (133). 6 and No. 7 carriers assembly (142).
28. No. 7 clutch discs, plates, and springs 30. Disassembly of No. 6 and No. 7 carriers assem-
Remove discs (138), plates (139), and springs bly
(140) and (141). 1) Remove collar (143).
★ Since springs (141) of a clutch line have a 2) Remove inner race (144) and snap ring (145)
part No. different from those of another from collar (143).
clutch line, store them for each clutch line.
3) Tighten forcing screws [1] to remove plates

(146).
4) Remove seal ring (147) and bearing (148)
from the plates.
HD465-7, HD605-7 30-49

➂
5) Remove intermediate shaft (149) and No. 6

sun gear (150) together.
6) Remove snap ring (151) and inner race (152)
from intermediate shaft (149).
31. Guide pins and No. 7 clutch ring gear

1) Remove guide pins (168).
2) Remove No. 7 clutch ring gear (169).
7) Pull out shaft (153) and remove No. 6 plane-
tary gear (154), bearing (155), thrust washer
(156), and ball (157).
32. Cage assembly

1) Using forcing screws [3], remove cover (172)
from cage assembly (171).
2) Remove seal ring (173) from the cover.
8) After removing No. 6 planetary gear, drive 3) Remove bearing (174) from the cage.
out shaft (158), collar (159), inner race (160),
and ball (161), using drive shafts [2] (14 mm
or less in diameter and about 200 mm in
length).
★ Hit both shafts evenly to drive out the
above parts gradually.
9) Remove seal ring (170) from collar (159).
10) Remove planetary gear No. 7 (162), bearing
(163), and thrust washer (164).
11) Remove snap ring (165), collar (166), and
ball (167).
30-50 HD465-7, HD605-7

➂
33. Output shaft and cage assembly

1) Remove mounting bolts (301) and output 3) Support cage (178) and press the output
shaft and cage assembly (175). shaft (179) with a press to drive it out of the
★ Since the whole transmission is being bearing.
disassembled now, the output shaft and
cage assembly are removed at this time.
You can remove only the output shaft
assembly for repair of a leaking oil seal,
etc., however, if you remove the speed-
ometer gear (optional) in advance.
4) Remove bearing (180) from output shaft

(179).
2) Remove worm (176) and collar (177) from

the output shaft.
★ The collar consists of 2 semicircular
pieces.
5) Remove oil seal (181) and bearing (182)

from cage (178).
HD465-7, HD605-7 30-51

➂
ASSEMBLY 1. Output shaft and cage assembly

1) Install bearing (182) and oil seal (181) to
★ Clean the all parts and check them for dirt or cage (178).
damage before installing. Oil seal lip:
★ Coat the sliding surfaces of each part with Silicone grease (ThreeBond 1855)
engine oil before installing. Press fitting surface on cage side:
★ Soak the discs in clean engine oil (EO-10CD) for Gasket sealant (LG-5)
at least 2 minutes. ★ After press fitting, wipe off the excessive gas-
★ Install each piston seal ring (a) of the clutch ket sealant.
assembly with its pressure receiving side (side
b) directed toward housing (c).
★ Apply grease (G2-LI) to the periphery of the all
seal rings.
★ When fitting a bearing by expansion fit, drop
engine oil (EO10-CD or EO30-CD) over it and
rotate it 10 turns before chilling it in dry ice, etc.
2) Press fit bearing (180) to output shaft (179).
★ Securely fit springs (A) of No. 4 – No. 7clutches

to the seats of the piston and housing.
3) Set output shaft (179) on the press stand and

press the inner race side of the bearing to
install cage (178).
30-52 HD465-7, HD605-7

➂
4) Install collar (177) and worm (176) to the out- 3. Guide pins and No. 7 clutch ring gear
put shaft. 1) Install guide pins (168) to the cage.
★ The collar consists of 2 semicircular 2) Install No. 7 clutch ring gear (169).
pieces.

5) Fit the O-ring to the cage and install output Install discs (138), plates (139), and springs
shaft and cage assembly (175). (140) and (141).
★ Install the 4 discs and 3 plates.
★ Securely fit springs (141) to the seats of the
housing.
2. Cage assembly
1) Using the push tool, press fit bearing (174) to
cage (171).
2) Install cover (172) to cage (171).
Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
3) Install seal ring (173) to cover (172).
Periphery of seal ring:
Grease (G2-LI)
HD465-7, HD605-7 30-53

➂
5. No. 7 clutch piston 7. Assembly of No. 6 and No. 7 carriers assem-

Install seal ring (134) to piston (133), then match- bly
ing it to the springs. 1) Install bearing (163) to No. 7 planetary gear
★ Install the seal ring as shown below. (162). Fit thrust washers (164) to both sides
Periphery of seal ring: Grease (G2-LI) of them and set them to the carrier.
2) Press fit shaft (158) and set ball (161) to
6. No. 6 and No. 7 housings and No. 6 piston secure the shaft.
1) Install seal rings (134), (135), and (136) to ★ When press fitting the shaft, align it with
housing (131) and piston (132). the bearing and avoid hitting it strongly
★ Install the seal rings as shown below. so that the bearing cage will not be
Periphery of seal ring: Grease (G2-LI) deformed.
3) Install seal ring (170) to collar (159) and
press fit inner race (160).
Grease (G2-LI)
4) Install ball (167) and collar (166) to the car-

rier and secure them with snap ring (165).
5) Check that No. 7 planetary gear rotates
smoothly.
6) Install bearing (155) to No. 6 planetary gear

(154). Fit thrust washers (156) to both sides
of them and set them to the carrier.
7) Drive shaft (153) and set ball (157) to secure
the shaft.
2) Using sling bolts, sling No. 6 and No. 7 hous- ★ When driving the shaft, align it with the
ings (131), matching them to piston (133). bearing and avoid hitting it strongly so
★ If the dowel pin is hard, drive it with a that the bearing cage will not be
plastic hammer. deformed.
8) Check that No. 6 planetary gear rotates
smoothly.
30-54 HD465-7, HD605-7

➂
9) Press fit inner race (152) to intermediate 15) Install snap ring (145) to collar (143).
shaft (149). ★ Check that the snap ring is fitted to the
10) Install snap ring (151). collar groove.
★ Check that the snap ring is fitted to the 16) Press fit inner race (116) to collar (115) and
groove. install them to the intermediate shaft.
11) Install No. 6 and No. 7 carrier intermediate
shaft (149) and sun gear (150).

Using sling bolts, sling the shaft. Install No. 6
12) Press fit bearing (148) to plate (146). and No. 7 carriers assembly (142), matching the
★ Securely press fit the bearing to the cor- gear to the bearing.
rect stopper position.
13) Install seal ring (147).
Grease (G2-LI)
14) Install plate (146) to No. 6 and No. 7 carriers.
Mounting bolts: Adhesive (LT-2)
Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
HD465-7, HD605-7 30-55

➂
9. Assembly of No. 4 and No. 5 carriers assembly

1) Install bearing (300) to No. 4 planetary gear
2) Set collar (121) between 2 bearings (120)
and install them to No. 5 planetary gear
3) Chill shaft (123) in dry ice, then install it to
the carrier.
★ Check that the shaft, bearing, thrust
washers, and carrier are aligned and
take care that the bearing and thrust
washers will not be damaged.
★ Match the ball fitting hole of the shaft to
the hole of the carrier. 7) Set collar (121) between 2 bearings (120)
4) Fit ball (124) and install shaft (123) securely. and install them to No. 5 planetary gear
5) Check that the gear rotates smoothly. (119). Fit thrust washers (122) to both sides
6) Install ring gear (129) to the carrier and of them and set them to the carrier.
secure it with snap ring (127). 8) Drive shaft (117), matching the bearing to the
★ Mesh the external teeth on the carrier thrust washer.
side with the internal teeth on the ring 9) Drive out shaft (117) until the ball hole is
gear side, then align the carrier with the seen perfectly, then fit ball (118) and drive
ring gear so that the snap ring will be the shaft into the carrier.
★ When driving the shaft, align it with the
inside the 45° chamfering diameter of the
bearing and avoid hitting it strongly so
ring gear. that the bearing cage will not be
★ Check that the external teeth are deformed.
meshed with the internal teeth and the ★ Check that the gear rotates smoothly.
whole snap ring is inside the chamfering
diameter of the ring gear, then press in
the ring gear until it is locked.
★ Check that the clearance between the
bottom of the external teeth of the carrier
and the inside diameter of the fitted snap
ring is 2.0 – 3.2 mm through the circum-
ference.
★ Hold the ring gear and move it up and
down. Check that carrier does not come
off at this time.
10) Install bearing (115) and seal ring (116) to the

carrier assembly.
Grease (G2-LI)
30-56 HD465-7, HD605-7

➂

Using hanging bolts, sling the shaft. Install No. 4 2) Install gear (86).
and No. 5 carriers assembly (201), matching the 3) Install snap ring (85).
gear to the bearing.
★ You can install the "No. 4, No. 5 carriers, No.
6, and No. 7 assembly", too, as you
removed. If this assembly is slung and
moved, however, the bearing in the interme-
diate position may come off. Accordingly,
divide this assembly.

Install plate (110), discs (108), plates (109), and
★ Install the 4 discs, 4 plates (109), and 1 plate
(110).
★ Install one of plates (109) on the top.
11. No. 5 clutch sun gear ★ Check that springs (111) are fitted to the
Install sun gear (113). seats of the piston and housing.
★ Take care not to have your fingers caught in ★ Securely install 6 springs (112) to each disc.
the gears.
12. No. 4 clutch sun gear

1) Install seal ring (200) to gear (86).
Grease (G2-LI)
HD465-7, HD605-7 30-57

➂
14. No. 5 housing, piston, ring gear, and guide

pins
1) Install tie bolt sleeves (203) to No. 5 housing
(99).
★ When installing the sleeve, set slit A at
the position checked when removed.
★ When tie bolts (83) are installed, they
become hard because of the cushion
sleeves. At this time, do not drive them
forcibly with a hammer. (For prevention
of breakage)
15. No. 5 clutch, discs, plate, and springs

Install discs (95), plate (96), and springs (97) and
(98).
★ Install the 5 discs and 4 plate.
★ Securely install 6 springs (98) to each disc.
2) Install seal rings (106) and (107) to housing

(99) and piston (102), then install the piston
to the housing.
★ Install the seal ring as shown in the fol-
lowing figure.
Grease (G2-LI)
3) Set No. 5 clutch ring gear (103).

★ Set the gear with the chamfered side up.
4) Using hanging bolts, install No. 5 housing
(99), matching it to the spring.
★ If the dowel pin is hard, drive it with a
plastic hammer.
5) Install guide pins (202).
30-58 HD465-7, HD605-7

➂
16. No. 4 housing, piston, and ring gear

1) Install seal rings (93) and (94) to housing
(91) and piston (92), then install the piston to
the housing.
★ Install the seal rings as shown below.
Grease (G2-LI)
2) Using sling bolts, install No. 4 housing,

matching it to the spring.
★ Check that the springs are fitted to the
seats of the piston and plate.
★ If the dowel pin is hard, drive it with a
plastic hammer.
3) Install ring gear (93).
★ Set the gear with the chamfered side up.
18. No. 4 clutch plate

Install plate (84).
★ Check that the springs are fitted to the seats
of the piston and plate.
19. Tie bolts

Install tie bolts (83).
★ Press in each bolt to the end of the cup hole.
Do not use a hammer at this time.
★ Do not use an impact wrench until the bolt
catches the threads.
Tie bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
17. No. 4 clutch, discs, plate, and springs
Install plate (101), discs (87), plates (88), and
★ Install the 4 discs, 3 plates (88), and 1 plate
(101).
★ Securely install 6 springs (89) to each disc.
HD465-7, HD605-7 30-59

➂
20. No. 3 clutch ring gear

1) Install inner race (81) and seal ring (82) to
the ring gear.
Grease (G2-LI)
22. Check of operation of piston

Using tool D1, check the operation of pistons of
No. 4, 5, 6, and 7 clutches.
2) Install No. 3 clutch ring gear (80). ★ Air pressure: 0.29 – 0.59 MPa {3 – 6 kg/cm2}
Mounting bolt: Adhesive (LT-2) Standard stroke of piston
Mounting bolt:
156.9 – 196 Nm {16 – 20 kgm} Piston No. Stroke (mm)
4 4.8
5 5.8
6 5.0
7 5.0
★ If the pistons do not move smoothly, apply

engine oil to them.
21. No. 3 clutch housing assembly

★ For disassembly, see Step 24, DISASSEM-
BLY OF No. 2 CLUTCH ASSEMBLY, 5) – 8).
(No. 3 clutch assembly has the same struc-
ture as No. 2 clutch assembly.)
★ The plates, discs, and springs are 1 each
less than those of No. 2 clutch assembly.
★ Using hanging bolts, sling and install housing
assembly (75), matching the internal teeth of
23. Transmission case
the disc to the external teeth of the ring gear.
1) Install the following parts to the transmission
Mounting bolt: Adhesive (LT-2) case.
Mounting bolt: i) Install seal ring (204) to the outer groove
98 – 122.5 Nm {10 – 12.5 kgm} of collars (73), then install them, match-
ing to the dowel pin of the transmission
case.
Grease (G2-LI)
ii) Install cage (71).
iii) Install bearings (72) and (74) to both
sides.
★ Press fit the bearings until they are
stopped by collars (73).
30-60 HD465-7, HD605-7

➂
★ When driving the shaft, align it with

th e b ear in g a nd av oid hi tti ng it
strongly so that the bearing cage will
not be deformed.
iv) Fit ball (64) and install shaft (61) securely.
★ If the shaft moves out, caulk the car-
rier side with a punch.
★ Check that the gear rotates smoothly.
2) Install the O-ring to the transmission case.

3) Sling and install transmission case (70) and
tighten cage assembly mounting bolts (69).
2) Install plate (59) to carrier (60).

Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
24. Assembly of No. 2 clutch assembly

1) Carrier assembly
i) Install inner race (67), bearing (68), and
seal ring (66) to carrier (60).
Grease (G2-LI)
3) Turn over the carrier assembly. Using sling

bolts, install drum (58), matching it to the
gear of the carrier.
ii) Install bearing (65) to gear (63). Fit thrust

washers (64) to both sides of them and
set them to the carrier.
iii) Matching the thrust washer to the bear-
ing, drive shaft (61).
HD465-7, HD605-7 30-61

➂
4) Install the ring gear (54), matching it to the 8) Install piston (45) to the housing, then install
carrier, and secure it with snap ring (53). cover (44).
5) Discs, plates, and springs Mounting bolt: Adhesive (LT-2)
Install discs (55), plates (56), and springs
Mounting bolt:
(57) between the drum and ring gear.
★ Install the 5 discs, 4 plates, and 5 58.8 – 73.5 Nm {6 – 7.5 kgm}
springs.
9) Install housing (43) to the drum.

6) Housing assembly
i) Install inner race (51) and bearing (52) to Mounting bolt: Adhesive (LT-2)
the housing. Mounting bolt:
ii) Install ball (205) and bushing (50), then 98 – 122.5 Nm {10 – 12.5 kgm}
secure them with snap ring (49).
iii) Install seal rings (47) and (48).
Grease (G2-LI)
25. No. 2 clutch assembly

Using sling bolts, sling and install No. 2 clutch
assembly (42), matching the external teeth of the
piston to the internal teeth of the drum.
7) Install seal ring (46) to piston (45).
★ Install the seal ring as shown below.
Grease (G2-LI)
30-62 HD465-7, HD605-7

➂
26. Input shaft and No. 1 ring gear assembly 4) Install inner race (35) to No. 1 ring gear (34).
1) Press fit bearing (40) to input shaft (41) and
install snap ring (39).
5) Install ring gear (34) and seal rings (206) and

(207) to the input shaft.
2) Install inner race (38) to gear (37). Periphery of seal ring:
Grease (G2-LI)
3) Install gear (37) to the outer race side of the

bearing, then install snap ring (36). 6) Sling the input shaft and install the input
shaft and No. 1 ring gear assembly (33),
matching the gear to the bearing.
HD465-7, HD605-7 30-63

➂
27. No. 1 clutch, drum, and piston 29. No. 1 clutch plate
1) Install seal rings (100) and (101) to piston 1) Install bearing (25) to No. 1 clutch plate.
(32), then install them to the drum (31).
Grease (G2-LI)
2) Using sling bolts, install No. 1 clutch drum
(31) and piston (32) together.
2) Using sling bolts, install plate (24), matching

it to the spring and guide.
Mounting bolt:
156.9 -– 196 Nm {16 – 20 kgm}
30. Check of operation of piston

Using tool D1, blow air into the clutch ports and
check the operation of the pistons of No. 1, 2, and
3 clutches. (Since you cannot check the opera-
28. No. 1 clutch discs, plates, and springs tion of the pistons of No. 2 and 3 clutches directly,
Install discs (28), plates (29), springs (26) and check it by movement of the discs or plates.)
(30), and guide (27). ★ The locations of the clutch ports are shown
★ Install the 3 discs and 2 plates. below.
• No. 1 clutch port: A
• No. 2 clutch port: B
• No. 3 clutch port: C
• Standard stroke of clutch No. 1 piston
4.2 mm
30-64 HD465-7, HD605-7

➂
31. Oil pan 32. Sleeve

1) Install relief valves (22) and (23) to the oil Fit the O-rings to sleeves (14) and install them to
pan, then install blocks (20) and (21). the transmission.
2) Install magnet assembly (19) and spring (18)

to the oil pan, then fit the O-ring and install 33. Control valve assembly
cover (17). 1) Install each control valve (12) to the valve
seat.
Control valve:
8.0 – 10.0 Nm {0.8 – 1.0 kgm}
2) Install filter assembly (13).
★ If the filter case and filter bracket plug
were removed, tighten them to the fol-
lowing torque.
Filter case:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
Plug:
15.7 – 19.2 Nm {1.6 – 2.0 kgm}
3) Install sling bolts to A, then install the valve
seats and control valve assembly (11)
together.
3) Fit the plate gasket to oil pan (16) horizon- Mounting bolt:
tally, then sling and install transmission Gasket sealant (LG-5)
assembly (15). 4) Install wiring harness (10) and connect the
Both sides of plate gasket: connectors to each control valve.
HD465-7, HD605-7 30-65

➂
34. Sensors, wiring harness, covers, and trans-

mission mounts
1) Install block (9).
2) Install lubricating oil temperature sensor (8)
and cover (7).
3) Install output shaft speed sensor (6), inter-

mediate shaft speed sensor (5), and input
shaft speed sensor (4).
★ For installation procedure, see TESTING
AND ADJUSTING, Adjusting transmis-
sion speed sensors.
4) Install covers (2) and (3).

5) Install both transmission mounts (1).
30-66 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL AND INSTALLA- 5. Remove guard (3) and drive shaft (4).
TION OF DIFFERENTIAL 6. Disconnect hoses (5), (6), and (7) and remove
ASSEMBLY slack adjuster (8).
REMOVAL
Apply the parking brake and put blocks under

the wheels.
1. Remove the dump body assembly. For details,

see REMOVAL AND INSTALLATION OF DUMP
BODY ASSEMBLY".
2. Drain oil from the differential case and final drive

case.
Differential case: 95
Final drive case (Each side): 21 7. Using forcing screws [2] and guide bolt [3], pull
3. Using guide bolts [1], remove cover (1). (The out differential assembly (9) forward.
rear wheel assembly is removed in the following Differential assembly: 850 kg
photo. It does not need to be removed, how-
ever.)
4. Pull out drive shaft (2).

★ Install a hanging bolt to the shaft end to pull
out the shaft.
Drive shaft: 110 kg
HD465-7, HD605-7 30-67

➂
INSTALLATION
removal.
Drain plug
(Center of cover on final drive case side):
127.4 – 176.4 Nm {13.0 – 17.9 kgm}
(Periphery of cover on final drive case side):
24.5 – 34.3 Nm {2.5 – 3.4 kgm}
★ Before tightening the bolts, check that the

key way of the spider cap is fitted to the key
way of the mating yoke.
Mounting bolt:
157 – 196 Nm {16.0 – 19.9 kgm}
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
Refilling with oil

Differential case: 95 (EO30-CD)
Final drive case (Each side):

21 (EO30-CD)
30-68 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEM- 4. Bevel pinion and cage assembly

1) Lift off bevel pinion and cage assembly (5).
BLY OF DIFFERENTIAL ★ Before removing the bevel pinion and
ASSEMBLY cage assembly, make match marks on
the cage and differential case.
Special tools ★ Check the thickness, quantity, and loca-
tion of shim (6).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-901-5110 Bracket ■ 1
790-901-3420 Plate ■ 1
H
2 790-425-1660 Wrench ■ 1
3 790-102-1130 Power wrench assembly ■ 1
4 797-101-1171 Wrench ■ 1
DISASSEMBLY
1. Tool of differential assembly
Set the differential assembly to tool H1. 2) Using press [2], press down bevel pinion
assembly (7) and remove it and bearing (8)
2. Coupling together from cage assembly (9).
Remove holder (1) and coupling (2). ★ Set a block, etc. under the bevel pinion
assembly to prevent the assembly from
falling to the floor.
3. Cage
1) Using forcing screws [1], remove cage (3).
★ Before removing the cage, make match
marks on it and differential case.
2) Remove oil seal (4) from cage (3).
HD465-7, HD605-7 30-69

➂
3) Disassembly of bevel pinion assembly

Remove spacer (11) and bearing (12) from
bevel pinion assembly (10).
4) Disassembly of cage assembly

Remove outer races (14) and (15) from cage
(13).
4) Sling differential gear assembly (20) tempo-

rarily.
5) Using tool H3, remove 4 bearing cap bolts
(21).
6) Remove bearing caps (22) and (23) and
adjustment nuts (18) and (19).
5. Removal of differential gear assembly

1) Turn over tool H1.
2) Remove locks (16) and (17).
3) Using tool H2, loosen adjustment nuts (18)
and (19) until you can turn them with the
hand.
30-70 HD465-7, HD605-7

➂
7) Remove outer races (24) and (25) from both 3) Remove bearing (29) from case (27).
bearings and lift off differential gear assem-
bly (20).
4) Remove side gear (30).
6. Disassembly of differential gear assembly

1) Lift off case and bearing assembly (26).
★ Before removing the assembly, make
match marks on the top and bottom of
the case.
5) Remove cross shaft and pinion gear assem-

bly (31).
2) Remove washer (28) from inside of case

(27).
HD465-7, HD605-7 30-71

➂
6) Remove pinion gear assembly (33) from 10) Remove washer (38).
cross shaft (32).
11) Turn over the case and bevel gear assembly.

7) Using tool H4, remove nut (34).
8) Remove sleeve (35) and the bearing. 12) Remove bevel gear (39) from case (40).
★ The bearing is an assembly of large ★ Before removing the bevel gear, make
bearing A, small bearing B, outer race match marks on it and the case.
spacer C, and inner race spacer D. 13) Remove bearing (41).
9) Remove side gear (37).
30-72 HD465-7, HD605-7

➂
ASSEMBLY ★ After installing the washer, check that

distance a between the washer surface
★ Clean the all parts and check them for dirt or and the end of dowel pin E is 0.35 – 0.75
damage. mm. (If the dowel pin has been
★ Coat the sliding surfaces with engine oil (EO30- removed, drive it to the above dimen-
CD) before installing. sion.)
1. Assembly of differential gear assembly

1) Install bearing (41) to case (40) by shrink fit.
★ Shrink fit temperature of bearing: Keep at
120°C for 30 min.
★ After installing the bearing, drop engine
oil (EO30-CD) over it.
2) Install bevel gear (39) to case (40).
★ When installing, match the match marks.
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
5) Install side gear (37).
3) Turn over the case and bevel gear assembly.

4) Install washer (38).
★ Install the washer with the grooved side
up.
HD465-7, HD605-7 30-73

➂
6) Install the bearing to the pinion gear. 10) Install cross shaft and pinion gear assembly
★ Drop engine oil (EO30-CD) over the slid- (31).
ing parts.
★ The bearing is an assembly of large
bearing A, small bearing B, outer race
spacer C, and inner race spacer D.
★ Do not change the combination of the
above parts. (The same combination
mark is stamped on each part.)
7) Install sleeve (35) as shown in the following
figure.
8) Using tool H4, tighten nut (34).
Nut:
490 – 408 Nm {50.0 – 61.9 kgm}
★ After tightening the nut, rotate the bear-
ing 5 turns or more to check that it
rotates lightly. 11) Install side gear (30).
9) Install pinion gear assembly (33) to cross 12) Install bearing (29) to case (27) by shrink fit.
shaft (32). ★ Shrink fit temperature of bearing: Keep at
120°C for 30 min.
★ After installing the bearing, drop engine
oil (EO30-CD) over it.
30-74 HD465-7, HD605-7

➂
13) Turn over case (27) and install washer (28). 2. Installation of differential gear assembly
★ Install the washer with the grooved side 1) Sling differential gear assembly (20) to the
up. installation position of the differential case.
★ Keep the differential gear assembly
above the differential case.
2) Install outer races (24) and (25) to both bear-
ings.
★ Drop sufficient amount of engine oil
(EO30-CD) over the bearings.
3) Install adjustment nuts (18) and (19) to the
differential case temporarily.
★ After installing the washer, check that

distance a between the washer surface
and the end of dowel pin E is 0.35 - 0.75
mm. (If the dowel pin has been
removed, drive it to the above dimen-
sion.)
4) Install bearing caps (22) and (23).

5) Using tool H3, tighten 4 bearing cap bolts
(21).
★ Before tightening the bearing cap bolts,
rotate the bevel gear 20 - 30 turns to fit
the bearing.
Mounting bolt:
2,450 – 3,040 Nm {249.9 – 309.9 kgm}
★ Before installing the locks for fixing the
adjustment nuts, finish the following
"Adjusting preload on bearing", "Adjust-
14) Sling and install case and bearing assembly ing backlash", "Testing tooth contact",
(26). and "Adjusting tooth contact".
HD465-7, HD605-7 30-75

➂
4. Bevel pinion and cage assembly

1) Assembly of cage assembly
Install outer races (14) and (15) to cage (13).
★ Press fit the outer races until they are
stopped by the cage.
3. Adjusting preload on bearing

Press push-pull scale [3] against the periphery of
bevel gear (39) and measure the starting tangen-
tial force in the tangential direction.
• Standard starting tangential force: 2) Assembly of bevel pinion assembly
39.2 – 62.8 N {4.0 – 6.4 kg} i) Install bearing (12) to bevel pinion (10)
[Target: 51.0 N {5.2 kg}] by shrink fit or press fit it to the end with
★ If the starting tangential force is below the the push tool.
standard value, tighten the adjustment nuts ★ Shrink fit temperature of bearing: Keep at
on both sides with tool H2. If the former 120°C for 30 min.
exceeds the standard value, loosen the ★ After installing the bearing, drop engine
adjustment nuts on both sides. oil (EO30-CD) over it.
★ When adjusting, rotate the bevel gear so that ii) Install spacer (11).
the bearings will be fitted sufficiently. Reference: This spacer is a part of cage
assembly (13) shown above.
30-76 HD465-7, HD605-7

➂
3) Place cage assembly (9) on bevel pinion 5. Cage

assembly (7). 1) Install oil seal (4) to cage (3).
4) Install bearing (8). ★ Press fit the oil seal until it is stopped by
5) Using push tool [4] and revolving cage the cage.
assembly (9), press fit bearing (8) to the end. Outer ring of oil seal:
★ Drop engine oil (EO30-CD) over bearing SEALEND 242 or equivalent
(8). Lip of oil seal: Grease (G2-LI)
★ Do not use a press to press fit the bear- 2) Fit the O-ring and cage (3).
ing. ★ When installing, match the match marks.
6) Hold bevel pinion assembly (7) and revolve Mounting bolt:
cage assembly (9) with the push-pull scale 455 – 565 Nm {46.4 – 57.6 kgm}
and measure the starting tangential force in
the tangential direction.
• Standard starting tangential force:
Max. 24.5 N {2.5 kg}
★ If the starting tangential force exceeds
the standard value, replace bearings (8)
and (12) or cage assembly (9) and mea-
sure again. Check that the starting tan-
gential force is in the standard range.
3) Set dial gauge [5] on the top of bevel pinion

assembly (7). Move the bevel pinion assem-
bly in the thrusting direction and measure the
end play.
• Standard end play: 0 – 0.15 mm
★ If the end play exceeds the standard
value, replace bearings (8) and (12) or
cage assembly (9) and measure again.
Check that the end play is in the stan-
7) Install shim (6) of the thickness and quantity dard range.
checked when disassembled. Fit the O-ring
and sling and install bevel pinion cage
assembly (5).
• Thicknesses of shims:
0.2 mm, 0.3 mm, 1.0 mm
HD465-7, HD605-7 30-77

➂
6. Coupling 3) If the backlash is out of the standard range,

1) Install coupling (2), O-ring, and holder (1). adjust it by moving the bevel gear.
★ Rotate the bevel gear to rotate the bevel ★ Move the bevel gear with tool H2 and
pinion 20 – 30 turns and tighten the adjustment nuts (18) and (19).
mounting bolts gradually. ★ If either adjustment nut is tightened
Mounting bolt: Adhesive (LT-2) (loosened), loosen (tighten) the other
adjustment nut by the same angle so that
Mounting bolt:
the preload applied to bearings (29) and
1,520 – 1,910 Nm {155.0 – 194.7 kgm}
(41) (in Step 3) will not change.
2) Rotate the coupling 20 – 30 turns, and then
check that the holder mounting bolts are
tightened to the specified torque.
7. Adjusting backlash
1) Apply the probe of dial gauge [5] to a tooth
tip of the bevel gear at right angles.
2) Fix the bevel pinion and move the bevel gear
forward and backward (in the revolving direc-
tions) and read the dial gauge.
• Standard backlash: 0.41 – 0.56 mm
★ Measure the backlash at 3 – 4 places
and check that the difference between
the measured values is 0.1 mm or less.
30-78 HD465-7, HD605-7

➂
• When the backlash is below standard 9. Adjusting tooth contact

value If the tooth contact pattern is not proper, adjust
Loosen adjustment nut (19) on the bevel the tooth contact according to the procedure
gear side and tighten adjustment nut (18) on shown in the following page.
the right side by the same angle (to move the ★ Adjust the toot contact by increasing or
bevel gear in the direction of A). decreasing shim (6) (to move the bevel pin-
• When the backlash is above standard ion) and revolving the adjustment nuts (to
value move the bevel gear: See Adjusting back-
Loosen adjustment nut (18) on the right side lash).
and tighten adjustment nut (19) on the bevel ★ After adjusting the tooth contact, check the
gear side by the same angle (to move the backlash again.
bevel gear in the direction of B).
8. Testing tooth contact

Apply red lead thinly to the surfaces of 7 – 8
teeth of the bevel gear and turn the bevel gear in
the forward and reverse directions, then check
the tooth contact pattern on the bevel gear.
★ The center of the tooth contact must be as
follows.
• Middle of tooth height
• Point on tooth at distance of x from small
end C
(x = 46 ± 6 mm)
★ Width y of the tooth contact must be 41 – 82
mm.
★ Check that there is not a strong contact at tip
A, bottom B, small end C, or large end D.
HD465-7, HD605-7 30-79

➂
Tooth contact Cause Adjusting method
Bevel pinion is too far 1. Reduce shim (6) to move bevel

from bevel gear. pinion close to bevel gear.
2. Move bevel gear away from
bevel pinion.
Bevel pinion is too 1. Increase shim (6) to move bevel

close to bevel gear. pinion away from bevel gear.
2. Move bevel gear close to bevel
pinion.
Bevel gear is too close 1. Reduce shim (6) to move bevel

to bevel pinion. pinion close to bevel gear.
2. Move bevel gear away from
bevel pinion.
Bevel gear is too far 1. Increase shim (6) to move bevel

from bevel pinion. pinion away from bevel gear.
2. Move bevel gear close to bevel
pinion.
10. Locks
Install locks (17) and (16) of the adjustment nuts.
30-80 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FRONT WHEEL
REMOVAL AND INSTALLA- 4. Remove wheel assembly (3) with a forklift, etc.
TION OF FRONT WHEEL Wheel assembly: 1,000 kg

ASSEMBLY Rest the removed wheel assembly against
a safe place and put blocks under it to pre-
REMOVAL vent it from falling down.
★ Take care not to break the air valves.
the rear wheels with blocks.
1. Set a hydraulic jack (50 t) under arm (1) and

raise the front wheel assembly.
INSTALLATION
removal.
2. Support the frame on a stand, etc.
★ Tighten the hub nuts evenly in the diagonal

order.
★ Tighten the hub nuts permanently after low-
ering the truck body.
Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
★ After installing the wheel assembly, drive the
truck about 5 - 6 km, then check that the hub
nuts are tightened to the specified torque.
3. Remove hub nuts (2).
HD465-7, HD605-7 30-81

➂
DISASSEMBLY AND ASSEMBLY REAR WHEEL

TION OF REAR WHEEL
ASSEMBLY
REMOVAL

the front wheels with blocks.
1. Set a hydraulic jack (50 t) under either rear axle

and raise the rear wheel assembly.
5. Remove inner hub nuts (4).
2. Loosen the locknut of the air valve and remove

lock plate (1).
3. Remove outer hub nuts (2). 6. Remove wheel assembly (5) with a forklift, etc.
Wheel assembly: 850 kg
Rest the removed wheel assembly against
vent it from falling down.
4. Remove wheel assembly (3) with a forklift, etc.

Wheel assembly: 850 kg
Rest the removed wheel assembly against
vent it from falling down.
30-82 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY REAR WHEEL
INSTALLATION
removal.
,
★ Tighten the hub nuts evenly in the diagonal
order.
★ Tighten the hub nuts permanently after low-
ering the truck body.
Hub nut:
1,519 – 1,617 Nm {154.9 – 164.8 kgm}
★ After installing the wheel assembly, drive the
truck about 5 - 6 km, then check that the hub
nuts are tightened to the specified torque.
HD465-7, HD605-7 30-83

➂
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPER PADS
REMOVAL AND INSTALLATION

INSTALLATION OF FRONT • Carry out installation in the reverse order to
BRAKE CALIPER PADS removal.
REMOVAL
★ Push in the torque pin and fix it with the bolt
1. Remove the front wheel assembly. For details, securely.
see REMOVAL, INSTALLATION OF FRONT ★ Adjust the clearance between the pin and
WHEEL ASSEMBLY. disc to 1.5 – 3 mm.
Pin fixing bolt:
2. Pull out torque pin (1). 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
★ Pin fixing bolt (2) and pull out pin (1) to a ★ For precautions for installing the pin fixing
degree that you can remove the pads. bolt, see DISASSEMBLY, ASSEMBLY OF
FRONT BRAKE CALIPERS ASSEMBLY.
★ Bleed air from the front brake circuit. For
details, see TESTING AND ADJUSTING,
Bleeding air from brake circuit.
3. Remove pads (3).

1) Install a vinyl hose to bleeder screw (4) so
that the brake oil will be drained.
2) Loosen the bleeder screw and return pistons
(5) with a bar to the bottoms of the cylinders.
30-84 HD465-7, HD605-7

➃
DISASSEMBLY AND ASSEMBLY FRONT BRAKE CALIPERS

TION OF FRONT BRAKE CALI- • Carry out installation in the reverse order to
PERS ASSEMBLY removal.
REMOVAL
1. Remove the front wheel assembly. For details, Mounting bolt:
see REMOVAL, INSTALLATION OF FRONT 785 – 980 Nm {80.1 – 100 kgm}
WHEEL ASSEMBLY.
★ Bleed air from the front brake circuit. For
2. Disconnect hose (1). details, see TESTING AND ADJUSTING,
Bleeding air from brake circuit.
3. Sling the calipers assembly temporarily and
remove bolts (2).
4. Remove calipers assembly (3).

★ Sling the calipers assembly, adjusting it with
a lever block, etc.
Calipers assembly: 75 kg
HD465-7, HD605-7 30-85

➂

ASSEMBLY OF FRONT
BRAKE CALIPERS
ASSEMBLY
DISASSEMBLY
1. Pin fixing bolts (1) and (2) and remove torque
pins (3), (4), and (5) and pads (6).
2. Remove plate (7), plug (8), backup ring (9), and

seal (10).
3. Remove dust seal (11) and piston (12).
4. Remove seal (13) and backup ring (14).

★ Disassemble the other pistons similarly.
1. Fit backup ring (14), seal (13), and dust seal (11)
to the grooves of torque plate (15).
2. Install piston (12).

★ Fit the dust seal lip to the groove of the pis-
ton.
3. Install seal (10), backup ring (9), plug (8), and

plate (7).
4. Install pads (6) and torque pins (5), (4), and (3)
and tighten pin fixing bolts (2) and (1).
Bolt: 51.5 ± 2.5 Nm {5.25 ± 0.25 kgm}
★ Unlike a usual bolt, each of the above bolts
has pointed end (part "a"). The pointed end
bites in the surface of torque pin (5) (deforms
the pin plastically) (Bitten part: "b", Trace of
biting: "c) to fix the pin. (The bolt must be
tightened further after resistance is felt.)
Accordingly, if the bolt is not tightened to the
specified torque, it cannot bite in and fix the
pin sufficiently.
★ Move the pin in the axial direction, tightening
the pin fixing bolts, check that the bolts are
fitted in the grooves of the torque pin.
30-86 HD465-7, HD605-7

➃
★ Be sure to install torque pin (4), (5) which is

shorter than torque pin (5) to the plate side.
★ Assemble the other pistons similarly.
★ Adjust clearance "d" between disc plate (7)
and torque pin (3) to 1.5 – 3.0 mm.
5. Install the front brake calipers assembly. For

details, see REMOVAL, INSTALLATION OF
FRONT BRAKE CALIPERS.
★ Install the front brake calipers assembly so
that clearance "d" between disc plate (16)
and torque pin (3) will be 1.5 to 3.0 mm.
HD465-7, HD605-7 30-87

➃
DISASSEMBLY AND ASSEMBLY FRONT WHEEL HUB

BLY OF FRONT WHEEL HUB
ASSEMBLY
DISASSEMBLY
1. Front brake calipers assembly
Remove the front brake calipers assembly. For
2. Cover
Remove cover (1).
3. Wheel hub assembly

1) Support wheel hub assembly (2) with a fork- 5) Disassemble wheel hub assembly according
lift. to the following procedure.
2) Remove retainer (3). i) Remove the mounting bolts and brake
★ Check the quantity of the shims and disc (5).
store them. ii) Remove oil seal (6).
iii) Remove outer race (7).
iv) Remove outer race (8).
4. Bearing and retainer

1) Remove bearing (10).
2) Remove retainer (11).
3) Slant wheel hub assembly (2) lightly from the

rear and press it and bearing (4) out
together.
4) Remove bearing (4) and wheel hub assem-
bly (2).
Wheel hub assembly: 330 kg
30-88 HD465-7, HD605-7

➂
ASSEMBLY
1. Retainer and bearing
1) Install retainer (11).
2) Install bearing (10).
iv) Set brake disc (5) and tighten the mount-

ing bolts.
2) Support and install wheel hub assembly (2)
2. Wheel hub assembly with a forklift.
1) Assemble the wheel hub assembly accord-
ing to the following procedure.
i) Using the push tool, press fit outer race
(8).
ii) Using the push tool, press fit outer race
(7).
iii) Using the push tool, press fit oil seal (6).
★ Degrease the sealing side of wheel hub
A and periphery of the seal.
★ Degrease part B.
Periphery of seal:
Adhesive: (Loctite No. 648)
Space c of seal lip:
Fill with grease (See Table 1).
Fill the shaded parts in the following
Table 1 figure with sufficient amount of
No. Manufacturer Brand of grease grease. (Grease: 9 for each wheel
hub assembly)
1 NIHON KOYU HIREX HD-2
★ Take care not to damage the oil seal on
2 SHELL OIL Super Duty Grease 2 the inside of the hub.
3 ESSO OIL RONEX MP ★ Select the grease from Table 1.
4 BP Energrease LS-EP2
Table 1
No. Manufacturer Brand of grease
1 NIHON KOYU HIREX HD-2
2 SHELL OIL Super Duty Grease 2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
HD465-7, HD605-7 30-89

➂
★ Fill the hatched space between the roll-

ers of the bearing until it is projected from
the opposite side of the retainer.
5) Install the shims and retainer (3). Revolving

the hub 20 – 30 turns, tighten the bolts
evenly to the specified torque..
Mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
★ After tightening the bolts, rotate the hub
and check that it rotates normally.
4) Adjust the preload on the bearing according

i) Install retainer (3) without inserting any
shim with 3 mounting bolts. Revolving 3. Cover
the hub 20 – 30 turns, tighten the bolts Fit the O-ring and install cover (1).
evenly to the specified torque. Fill the inside of cover (hatched part)
Mounting bolt (For adjustment): with grease.
103 – 113 Nm {10.5 – 11.5 kgm} ★ Use grease of the brand used for the wheel
ii) Measure distance c between the retainer hub in 2-2).
and axle end with depth micrometer [1].
★ Measure at 2 places and obtain the
average.
iii) Remove retainer (3) and measure its
thickness T. Add 0.3 mm to the differ-
ence between above distance c and
thickness d (c – T), then use the result as
the shim thickness.
★ Measure at 2 places and obtain the
average.
★ Combine the shims so that their
quantity will be minimum.
★ When removing the retainer, take
care that the bearing will not come
off. 4. Front brake calipers assembly
Install the front brake calipers assembly. For
30-90 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
REMOVAL AND INSTALLA- 5. Using guide bolts [2] and forcing screws [3], pull
out and remove carrier assembly (6).
TION OF FINAL DRIVE CAR- ★ When the carrier assembly comes off the
RIER ASSEMBLY guide bolts, it is unbalanced suddenly.
Accordingly, insert a bar in the center shaft
REMOVAL hole to balance the carrier assembly.
• The rear wheel assembly is removed in the fol- Carrier assembly: 220 kg
lowing photo. It does not need to be removed,
however.
1. Remove the drain plug of the cover and drain oil

from the final drive case.
Final drive case: 32 (Each side)
2. Using guide bolts [1], remove cover (1).
INSTALLATION
removal.
Drain plug
(Center of cover on final drive case side):
3. Pull out drive shaft (2). 127.4 – 176.4 Nm {13.0 – 17.9 kgm}
★ Install a sling bolt to the shaft end to pull out (Periphery of cover on final drive case side):
the shaft. 24.5 – 34.3 Nm {2.5 – 3.4 kgm}
Drive shaft: 110 kg
4. Remove snap ring (3), sun gear (4), and spacer

Carrier assembly mounting bolt:
(5).
455 – 565 Nm {46.4 – 57.6 kgm}
Final drive case (Each side):

32 (EO30-CD)
HD465-7, HD605-7 30-91

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE CARRIER
DISASSEMBLY AND ASSEM- ASSEMBLY

BLY OF FINAL DRIVE CAR- 1. Install bearing (4) to planetary gear (3).
RIER ASSEMBLY
2. Set planetary gear (3) to the case.
★ Securely match the planetary gear to the
DISASSEMBLY
hose on the case side.
1. Drive out shaft (1) by hitting it outward.
★ Take care not to lose ball (2). 3. Matching the ball hole of shaft (1) to the cut for
the ball on the case side, press fit the shaft until
2. Remove planetary gear (3) and bearing (4). the ball hole comes in contact with the case end.
4. Install ball (2) and press fit shaft (1) to the end.
30-92 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE AND REAR BRAKE
REMOVAL AND INSTALLA- ★ Fix outer gear (5) and wheel hub (6) at fol-
lowing points a, b, c and d (4 points in total).
TION OF FINAL DRIVE AND
REAR BRAKE ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792T-422-1610 Spacer ■ 4 N
J 1 01011-61620 Bolt ■ 4
01643-31645 Washer ■ 4
REMOVAL
6. Remove retainer (7) and shim (8).
1. Remove the dump body assembly. For details, ★ Before removing the retainer completely,
see REMOVAL, INSTALLATION OF DUMP pass a guide bolt through the retainer, and
BODY ASSEMBLY". then pull out the retainer and ring gear
assembly together slowly and sling them.
2. Remove the (outer and inner) rear wheel assem- ★ Check the thickness and quantity of the
blies on the side of the final drive and rear brake shims.
assembly to be removed. For details, see
REMOVAL, INSTALLATION OF REAR WHEEL
ASSEMBLY.
3. Remove the final drive carrier assembly. For

FINAL DRIVE CARRIER ASSEMBLY.
4. Release the parking brake. For details, see

TESTING AND ADJUSTING, emergency method
of releasing parking brake.
5. Using tool J1, fix outer gear (5) and wheel hub
(6).
★ Be sure to install tool J1 to protect the float-
ing seal before removing the retainer. 7. Remove ring gear assembly (9).
Ring gear assembly: 100 kg
HD465-7, HD605-7 30-93

➂
8. When disassembling the ring gear assembly, ★ Since bearing (16) comes off, take care not
remove bolt (10) and take the assembly apart to drop it.
into holder (11), inner hub (12), and ring gear
(13).
★ For disassembly and assembly, see DISAS-

S E M B LY A N D A S S E M B LY O F F I N A L
9. Sling final drive and rear brake assembly (14) DRIVE, REAR BRAKE, AND PARKING
temporarily. BRAKE ASSEMBLY.
10. Remove 31 bolts (15) and pull out final drive and
rear brake assembly (14) sideway to remove it.
Final drive and rear brake assembly:
800 kg
30-94 HD465-7, HD605-7

➂
INSTALLATION
removal.
After installing, be sure to remove tool J1 and

parking brake releasing bolt.
• Adjusting preload on bearing

1) Install retainer (7) without inserting any shim
and tighten 3 mounting bolts to the following
torque.
★ Rotating the hub 20 – 30 turns, tighten
the bolts evenly to the specified torque.
181 – 191 Nm {18.5 – 19.4 kgm}
[Target: 186 Nm {18.9 kgm}
2) Measure distance a between the end of tube
(17) and end of retainer (7) with depth
micrometer [2].
★ Measure at 2 places and obtain the aver-
age.
3) Remove retainer (7) and measure its thick-
ness b.
★ Measure at 2 places and obtain the aver-
age.
4) Calculate shim thickness c by the following
expression.
c (mm) = a – b + 0.3
5) Install the shim of the calculated thickness
and retainer (7) with the all mounting bolts (6
bolts).
★ Rotating the hub 20 – 30 turns, tighten
the bolts evenly to the specified torque.
Mounting bolt:
785 – 980 Nm {80.1 – 99.9 kg}
6) Rotate the wheel hub again and check that it
revolves normally.
HD465-7, HD605-7 30-95

➂
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOL
SKETCH OF SPECIAL TOOL

Spacer J1
30-96 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FINAL DRIVE, REAR BRAKE, AND PARKING BRAKE

TION OF FINAL DRIVE, REAR
BRAKE, AND PARKING
BRAKE ASSEMBLY
REMOVAL
1. Perform Steps 1 - 7 of REMOVAL, INSTALLA-
TION OF FINAL DRIVE AND REAR BRAKE
ASSEMBLY.
★ If the final drive, rear brake, and parking
brake assembly does not need to be disas-
sembled after removed, the parking brake
does not need to be released.
★ Since bearing (16) comes off, take care not
2. Disconnect hoses (1) and (2) and remove pipes to drop it.
(3) and (4).
3. Sling final drive, rear brake, and parking brake

assembly (5) temporarily. INSTALLATION
4. Remove 30 nuts (6) and pull out final drive, rear • Carry out installation in the reverse order to
brake, and parking brake assembly (5) sideway removal.
to remove it.
Final drive, rear brake, and parking
brake assembly: 1,100 kg Mounting nut of final drive, rear brake,
and parking brake assembly:
455 – 565 Nm {46.4 – 57.6 kgm}
• Adjusting preload on bearing

See REMOVAL, INSTALLATION OF FINAL
DRIVE AND REAR BRAKE ASSEMBLY.
HD465-7, HD605-7 30-97

➂
DISASSEMBLY AND ASSEM- 3. Parking brake assembly

1) Check that the parking brake is released.
BLY OF FINAL DRIVE, REAR (See TESTING AND ADJUSTING, Emer-
BRAKE, AND PARKING gency method of releasing parking brake.)
BRAKE ASSEMBLY 2) Remove parking brake assembly (1).
★ Make match marks on parking brake
assembly (1) and outer gear (5) for refer-
Special tools
ence for installation.
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792T-422-1610 Spacer ■ 4 N
1 01011-61620 Bolt ■ 4
01643-31645 Washer ■ 4
2 795-102-2102 Spring washer ■ 1
J
792-520-2110 Installer ■ 1
3
792-530-1600 Push tool ■ 1
791-585-1510 Installer ■ 1
4
791-530-1700 Push tool ■ 1
• For the sketch of tool J1, see REMOVAL,

4. Disassembly of parking brake assembly
INSTALLATION OF FINAL DRIVE AND REAR
BRAKE ASSEMBLY. Since the installing load on the internal
spring is large, disassemble the assembly
DISASSEMBLY carefully according to the following proce-
dure.
Remove the internal parts (piston, damper, 1) Gradually loosen and remove parking brake
disc, plate, floating seal, etc.) carefully so that releasing bolts A (10 pieces).
they will not be damaged by impacts, fall, etc. ★ Loosen all releasing bolts A evenly so
that the internal brake piston will not
1. Place the final drive, rear brake, and parking slant.
brake assembly with the parking brake side up. Reference: Total installing load on spring:
Using blocks, etc., place the assembly sta- Approx. 199 kN {20.3 ton}
bly.
2. Remove tool J1 which is fixing outer gear (5) and

wheel hub (6).
30-98 HD465-7, HD605-7

➂
2) Turn over the parking brake assembly. 6) Remove seal rings (8) and (9) from cylinder
3) Gradually loosen and remove 13 cylinder (7).
mounting bolts (4).
7) Remove 30 springs (10) from cylinder (2).

4) Remove cylinder (7). ★ There are 22 double springs and 8 single
★ Make match marks on cylinder (7) and springs.
piston assembly (3) for reference for ★ Make distinction marks at locations of the
installation. single springs (8 places) with paint for
reference for installation.
5) Remove piston assembly (3).

★ Make match marks on piston assembly 8) Turn over the piston assembly disassembled
(3) and cylinder (2) for reference for in Step 5).
installation. 9) Using tool J2, compress the springs and
remove pin (11), washer (12), spring (13),
and guide (14).
HD465-7, HD605-7 30-99

➂
5. Dampers, discs, plates, and spacer

1) Remove plates (19).
10) Remove parking brake piston (15).

★ Make match marks on parking brake pis- 2) Remove damper (20), 12 discs (21), 11
ton (15) and brake piston (16) for refer- plates (22), and damper (23).
ence for installation.
11) Remove seal rings (17) and (18) from brake

piston (16).
30-100 HD465-7, HD605-7

➂
3) Install bolts [3] to the sling taps and remove 7. Inner gear
spacer (24). 1) Remove inner gear (27).
6. Outer gear 2) Remove floating seal (28) on the outside of

1) Remove outer gear (5). the inner gear, retainer (29), and floating seal
★ Take care not to drop the floating seal (30) on the inside of the inner gear.
from the bottom.

2) Remove oil seal (25) and floating seal (26) 1) Remove retainer and floating seal assembly
from outer gear (5). (31).
★ Retainer and floating seal assembly (31)
is free when the inner gear (in the previ-
ous section) is removed.
HD465-7, HD605-7 30-101

➂
2) Remove floating seal (33) from retainer (32).
3) Remove bearing (34).
4) Remove outer races (35) and (36).
30-102 HD465-7, HD605-7

➂
ASSEMBLY
★ Clean the all parts and check them for dirt or
damage.
★ Coat the sliding surfaces with engine oil before
installing.
★ Remove the white powder from the O-ring sur-
face of the floating seal with engine oil, etc.
Even a slight flaw of the floating seal made by

an impact, fall, etc. can cause oil leakage.
Accordingly, install the floating seal carefully.

1) Install outer races (35) and (36).
4) Set retainer and floating seal assembly (31)
to the center.
★ Set the assembly with the floating seal
side up.
2. Inner gear
1) Using tool J3, install floating seal (30) to the
inside of inner gear (27).
3) Using tool J3, install floating seal (33) to

retainer (32).
★ Thinly apply grease (G2-LI) to the top of
the floating seal.
2) Install retainer (29) to inner gear (27).

3) Using tool J4, install floating seal (28).
★ Thinly apply grease (G2-LI) to the top of
the floating seal.
HD465-7, HD605-7 30-103

➂
3. Outer gear
1) Using tool J4, install floating seal (26).
★ After installing, measure distance a

between the end of retainer (29) and end ★ After installing, measure distance b
of seal (28) at 4 points on the periphery. between the end of outer gear (5) and
Check that the difference between the end of seal (26) at 4 points on the periph-
values at the 4 points does not exceed 1 ery. Check that the difference between
mm. the values at the 4 points does not
exceed 1 mm.
4) Install inner gear (27).

★ When installing the inner gear, match it to 2) Install oil seal (25).
the retainer and floating seal assembly ★ Apply grease to part P shown below.
installed in Step 1-4). Part P: Grease (G2-LI)
★ Take care not to damage the floating
seal.
Inner gear mounting bolt:
455 – 565 Nm {46.4 – 57.6 kgm}
30-104 HD465-7, HD605-7

➂
3) Install outer gear (5).

★ Take care not to drop the floating seal
from the bottom.
★ Take care that the oil seal at the bottom
will not be rolled up.
3) Install discs (21) and plates (22) alternately

in order.
★ Install the 12 discs and 11 plates.
4) Install damper (20).
4. Dampers, discs, plates, and spacer
1) Install bolts [3] to the sling taps, and then
install spacer (24).
★ Install damper (20) with seat b (projected

part: 4.5 mm thick) up.
If the damper is installed reversely, the
★ Install spacer (24) with the chamfered
disc will be worn abnormally. Accord-
side down.
ingly, be sure to install it in the correct
2) Install damper (23).
direction.
★ Install damper (23) with seat a (projected
part: 1 mm thick) down.
If the damper is installed reversely, the
disc will be worn abnormally. Accord-
ingly, be sure to install it in the correct
direction.
HD465-7, HD605-7 30-105

➂
5) Install plates (19). 3) Pass guide (14) through spring (13) and install
them to the parking brake piston.
4) Using tool J2, compress spring (13) and install
washer (12) from the underside of the brake
piston. Pass pin (11) through guide (14) to
fix the guide.
5. Assembly of parking brake assembly

Since the installing load on the internal
spring is large, assemble the assembly
carefully according to the following proce-
dure.
1) Install seal rings (17) and (18) to brake piston
(16).
Grease (G2-LI)
2) Install parking brake piston (15) to brake pis-

ton (16).
★ Match the match marks made when the
piston was removed.
30-106 HD465-7, HD605-7

➂
5) Install 30 springs (10) to cylinder (2). ★ When installing the piston assembly,
★ For the locations of the 8 single springs, match it to dowel pin C.
see the distinction marks made when
they were removed.
8) Install guide bolt [2] and cylinder (7).

6) Install seal rings (8) and (9) to cylinder (7). cylinder was removed.
Periphery of seal ring: ★ Match the faucet joint portion of cylinder
Grease (G2-LI) (7) to that of cylinder (2) by hitting cylin-
der (7) evenly with a plastic hammer, etc.
7) Install piston assembly (3) to cylinder (2).

★ Match the match marks made when the 9) Tighten 13 cylinder mounting bolts (4) gradu-
piston assembly was removed. ally and evenly to the specified torque.
Mounting bolt:
153 – 190 Nm {15.6 – 19.3 kgm}
HD465-7, HD605-7 30-107

➂
10) Apply hydraulic pressure to parking brake 7. Using tool J1, fix outer gear (5) and wheel hub
releasing port P (20 x 1.5) and check that the (6).
piston is pulled up and the parking brake
works.
• Parking brake releasing pressure:
8.7 MPa {85 kg/cm2}
★ Fix outer gear (5) and wheel hub (6) at fol-

lowing points a, b, c, and d (4 places in
total).
11) Tighten parking brake releasing bolts A (10

pieces) gradually and evenly.
6. Install parking brake assembly (1) to outer gear

(5).
parking brake assembly was removed.
30-108 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER

TION OF FRONT SUSPENSION
CYLINDER ASSEMBLY
REMOVAL
1. Remove the front wheel assembly. For details,
see REMOVAL, INSTALLATION OF FRONT
WHEEL ASSEMBLY.
2. Remove the front brake calipers assembly. For

FRONT BRAKE CALIPERS ASSEMBLY.
3. Remove the wheel hub assembly. For details,

see REMOVAL, INSTALLATION OF FRONT 9. Remove 4 bolts (8).
WHEEL HUB ASSEMBLY. 1) Revolve the knuckle arm toward the truck
body about 40 degrees and remove the bolt
4. Release nitrogen gas. For details, see TESTING marked with ●.
AND ADJUSTING, Testing and adjusting front 2) Return the knuckle arm to its original position
suspension cylinder. and jack up the king pin and remove the
bolts marked with .
10. Using a forklift, etc., sling the front suspension

6. Disconnect tubes (2) and (3). cylinder assembly and pull out pin (9) on the rod
side.
7. Pull out pin (4) and disconnect tie rod (5).
11. Disconnect and remove front suspension cylin-
8. Pull out pin (6) and remove steering cylinder (7). der assembly (10) from the knuckle arm.
Front suspension cylinder assembly:
500 kg
HD465-7, HD605-7 30-109

➂
INSTALLATION
removal.
Never align the pin with the pin hole by

starting the engine and operating the steer-
ing wheel. It is very dangerous.
When aligning the pin and pin hole, discon-
nect the hoses on the head side and bottom
side of the steering cylinder so that you can
adjust the length of the steering cylinder
rod. Use a lever block or a bar to align
them.
★ Refill the front suspension cylinder with nitro-

gen gas and adjust it. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
front suspension cylinder.
30-110 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEM- 2. Remove air intake valve (1) and oil level valve
(2).
BLY OF FRONT SUSPENSION
CYLINDER ASSEMBLY 3. Removal of cylinder rod assembly.
1) Remove flange mounting bolts (3) and air
Special tools bleeding valve (4).
2) Sling cylinder rod assembly (5), plate (6),
New/Remodel
retainer (7), and flange (8) together.
Symbol
Necessity
Part No. Part name
Sketch
4. Disassembly of flange
Q'ty
1) Remove plate (6), retainer (7), and flange (8)
792-103-4102 Push tool ■ 1 from rod assembly (5).
1 790-101-5421 Grip ■ 1 2) Remove dust seal (9) and bushing (10) from
01010-81240 Bolt ■ 1 retainer (7).
Q 3) Remove U-packing (11) and bushing (12)
from flange (8).
2 792-610-1100 • Pump assembly 1
792-610-1200 • Charging tool 1 5. Remove wear ring (13) from cylinder rod (5).
DISASSEMBLY
• Using a block, erect the cylinder assembly.
1. Cover
Remove the dust cover.
HD465-7, HD605-7 30-111

➂
ASSEMBLY 2) Press fit bushing (10) to retainer (7) and

(See the figure for disassembly, too.) install dust seal (9).
★ When press fitting the bushing, take care
1. Installation of wear ring not to deform it.
Install wear ring (13) to cylinder rod (5). Periphery of seal:
Outside of wear ring: Adhesive (LT-2)
3. Assembly of cylinder rod assembly
2. Assembly of flange 1) Install flange (8), retainer (7), and plate (6) to
1) Using tool Q1, press fit bushing (12) to flange the cylinder rod.
(8) and install U-packing (11). Mating faces of flange and retainer:
Inside of bushing: Gasket sealant (LG-6)
★ When installing the U-packing, check ★ Apply the gasket sealant evenly to
that there are 4 projections on the top of hatched part B and apply it thinly to U-
the inside lip. packing C so that it will not be projected.
★ Apply rust-preventive oil to part A indi- 2) Using a block, erect the cylinder.
cated with 2-dot chain lines on the ★ Fill the cylinder with engine oil.
periphery of the U-packing (NISSEKI
Cylinder: Approx.
P1300 or equivalent).
16.5 (EO10-CD)
3) Sling cylinder rod assembly (5) and install it

to the cylinder.
★ If the rod assembly is inserted too deep,
the oil spouts out. Stop it to a position
where the oil does not spout out.
★ After installing the front suspension assem-
bly to the truck body, adjust the oil and
gas, using tool Q2. For details, see
TESTING AND ADJUSTING FRONT
SUSPENSION CYLINDER.
4) Install flange (8), retainer (7), and plate (6) to

the cylinder with bolts (3).
Mounting bolt:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
30-112 HD465-7, HD605-7

➂
5) Install air bleeding valve (4).

Valve: 39.2 – 49.0 Nm {4 – 5 kgm}
4. Install oil level valve (2) and air intake valve (1).
Oil level valve and air intake valve:
39.2 – 49.0 Nm {4 – 5 kgm}
5. Cover
Install the dust cover.
★ The dust cover consists of 2 pieces. Reduce
the clearance between them to 0.5 mm or
less.
HD465-7, HD605-7 30-113

➂
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER

TION OF REAR SUSPENSION • Carry out installation in the reverse order to
removal.
CYLINDER ASSEMBLY
REMOVAL ,
Stop the truck on level ground and set the park- When aligning the pin holes, never insert
ing brake switch to the PARK position, then lock your fingers in them.
★ Refill the rear suspension cylinder with nitro-
Disconnect the cable from the negative (–) ter- gen gas and adjust it. For details, see TEST-
minal of the battery. ING AND ADJUSTING, Testing and adjusting
rear suspension cylinder.
1. Release nitrogen gas. For details, see TESTING
AND ADJUSTING, Testing and adjusting rear
suspension cylinder.
2. Remove protector (1).
3. Using a forklift, etc., sling the rear suspension

cylinder assembly and pull out pin (2) on the bot-
tom side.
4. Pull out pin (3) on the rod side and remove rear
suspension cylinder assembly (4).
Rear suspension cylinder assembly:
180 kg
30-114 HD465-7, HD605-7

➂

BLY OF REAR SUSPENSION
CYLINDER ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
792-625-1300 Push tool ■ 1
1 790-101-5421 Grip ■ 1
01010-81240 Bolt ■ 1
Q
2 792-610-1100 • Pump assembly 1 5. Flange and retainer
1) Remove retainer (6) and flange (8) from cyl-
792-610-1200 • Charging tool 1
inder rod assembly (7).
2) Remove U-packing (10), backup ring, and O-
DISASSEMBLY ring (11) from flange (8).
3) Remove bushing (12) from flange (8).
1. Guard
4) Remove seal (13) and bushing (14) from
Sling the cylinder assembly and loosen clamp
retainer (6).
(1), and then unbutton and remove guard (2).
2. Drain oil from the cylinder.
3. Air intake valve and oil level valve

Remove cover (3), air intake valve (4), and oil
level valve (5).
6. Wear ring
Remove wear ring (15) from rod (16).
4. Cylinder rod assembly

1) Erect the cylinder assembly upside down.
2) Remove the mounting bolt of retainer (6).
3) Slowly sling and remove cylinder rod assem-
bly (7), retainer (6), and flange (8) as 1 unit
from cylinder (9) with a crane.
HD465-7, HD605-7 30-115

➂
ASSEMBLY 3. Retainer
1) Using tool Q1, install bushing (14) to retainer
1. Wear ring (6).
Install wear ring (15) to rod (16). 2) Install seal (13) to retainer (6).
Periphery of seal: Adhesive (LT-2)
2. Flange
1) Using tool Q1, install bushing (12) to flange
4. Cylinder rod assembly
(8).
1) Using a block, erect cylinder (9).
2) Install U-packing (10) to flange (8).
2) Sling cylinder rod assembly (7) and install it
★ Apply rust-preventive oil to part A indi-
to cylinder (9).
cated with 2-dot chain lines on the
3) Install flange (8) and retainer (6) to cylinder
periphery of the U-packing (NISSEKI
rod assembly (7).
P1300 or equivalent).
3) Install backup ring and O-ring (11) to flange Mating faces of flange and retainer:
(8). Gasket sealant (LG-6)
★ Apply the gasket sealant evenly to
hatched part B and apply it thinly to U-
packing C so that it will not be projected.
30-116 HD465-7, HD605-7

➂
4) Install retainer (6) and flange (8) together to 6. Guard

cylinder (9) with the mounting bolts. 1) Install guard (2) and secure it with clamp (1).
Mounting bolt: Clamp: 6.8 ± 0.49 Nm {69 ± 5 kgcm}
98 – 123 Nm {10.0 – 12.5 kgm}
5. Air intake valve and oil level valve

1) Set the cylinder assembly upside down.
2) Sling the cylinder so that dimension D on its
bottom side will be 140 ± 3 mm.
3) Supply oil through the oil level port with the

oil level pump and spout oil from the air
intake port until bubbles do not come out any
more.
4) After supplying oil, install oil level (5) and air
intake valve (4).
Air intake valve and oil level:
39.2 – 49.0 Nm {4 – 5 kgm}
5) Install cover (3).
HD465-7, HD605-7 30-117

➂
DISASSEMBLY AND ASSEMBLY RETARDER COOLING PUMP

TION OF RETARDER COOL-
ING PUMP ASSEMBLY
REMOVAL
pin.
1. Disconnect tubes (1) and (2) and hose (3).

★ Prepare a pan to receive oil from the joints.
2. Remove retarder cooling pump assembly (4).

Retarder cooling pump assembly: 30 kg
INSTALLATION
removal.

30-118 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY STEERING, HOIST, AND HOIST CONTROL PUMP

TION OF STEERING, HOIST, • Carry out installation in the reverse order to
AND HOIST CONTROL PUMP removal.
ASSEMBLY • Refilling with oil
REMOVAL Run the engine to circulate the oil through the
Stop the truck on level ground and set the park- system. Then, check the oil level again.
ing brake switch to the PARK position, then lock Transmission case: 190 (EO30-CD)
pin.
1. Disconnect tubes (1) and (2) and hoses (3), (4),

and (5).
2. Remove steering, hoist and hoist control pump

assembly (6).
Steering, hoist and hoist control pump
assembly: 35 kg
HD465-7, HD605-7 30-119

➂
TORQUE CONVERTER, TRANSMISSION AND
DISASSEMBLY AND ASSEMBLY RETARDER COOLING, AND BRAKE PUMP

TION OF TORQUE CON-
VERTER, TRANSMISSION
AND RETARDER COOLING,
AND BRAKE PUMP ASSEM-
BLY
REMOVAL
pin.
1. Disconnect tubes (1), (2), and (3) and block (4).

2. Remove torque converter, transmission and

retarder cooling, and brake pump assembly (5).
Torque converter, transmission and retarder
cooling, and brake pump assembly: 25 kg
INSTALLATION
removal.

30-120 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY STEERING VALVE

TION OF STEERING VALVE • Carry out installation in the reverse order to
ASSEMBLY removal.
REMOVAL
★ Since the yoke fixing bolt has fine threads,
Stop the truck on level ground and set the park- do not apply excessive force to it to damage
ing brake switch to the PARK position, then lock the threads.
loosen the hydraulic oil filler cap slowly to
release the internal pressure of the hydraulic
tank.
1. Remove yoke fixing bolt (1).

★ Fix yoke (2) to the upper part with ropes, etc.
so that it will not come off the spline of the
column shaft.
2. Remove cover (3).
3. Disconnect hoses (4), (5), (6), (7), and (8).
4. Remove steering valve assembly (9).

★ Using ropes, etc., lift off the steering valve
assembly.
HD465-7, HD605-7 30-121

➂
DISASSEMBLY AMD ASSEM- DISASSEMBLY

BLY OF STEERING VALVE 1. Remove 7 mounting bolts (1). Insert a screw-
ASSEMBLY driver between end cover assembly (2) and case
(3) to remove end cover assembly (2).
★ Securing of clean working condition ★ After removing the end cover assembly,
check the edges of the end cover hole for
1. Cleanliness is essential to maintenance of the breakage.
power steering system. The hydraulic circuit
must be isolated from impurities.
2. When disassembling any part of the unit, pre-

pare a clean worktable.
3. Before disconnecting a pipe, wipe off the exter-

nal dirt from it.
4. Before placing the unit on the worktable, be sure

to wipe off the external dirt from it.
5. After disassembling the unit, clean the parts in

kerosene-based solvent free of impurities and
dry them by blowing dry compressed air free of 2. Remove commutator (5) and washer (6).
impurities against them. ★ Do not remove pin (4).
★ If any solvent other than the above is used, it
can deteriorate the rubber seals. Never wipe
the parts with cloths or blow steam against
the unit.
★ Since the solvent is combustible material,
handle it carefully and keep it off fire.
PREPARATION
1. Stop up the 5 ports of the valve body with plugs

and clean the outside of the valve, and then
remove the plugs.
2. Install tube nut [1] to one of the ports.
3. Install the valve body to vise [2] with the end

cover up.
★ Do not hold the valve body directly with the
vise. If it is held so, the unit may be broken.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name

Sketch
Q'ty
1 790-452-1200 Pilot ring tool ■ 1

T
2 790-452-1100 Tool installer set ■ 1
30-122 HD465-7, HD605-7

➂
3. Using 2 mounting bolts (1), remove commutator 9. Install valve body (11) to the vise with input shaft
ring (7) and manifold (8). (18) up and make match marks A on upper case
(19) and valve body (11).
4. Using 2 mounting bolts (1), remove rotor assem-
bly (9) and wear plate (10) similarly to the com- 10. Remove 4 mounting bolts (20) and raise input
mutator ring and manifold. shaft (18) to remove input shaft, upper case, and
valve spool assembly (23).
★ The valve spool is fitted to the body with very
narrow clearance between them. Accord-
ingly, if it is pressed sideway, it cannot be
pulled out completely. When removing it
from the housing, never apply an excessive
force to it.
5. Insert a screwdriver between case (3) and valve

body (11) to remove case (3).
6. Remove drive link (12).
7. Remove ball (13).
8. Remove rod (14), roller (15), rod (16), and spring

(17).
HD465-7, HD605-7 30-123

➂
11. Remove upper case assembly (22) from input 14. Using pin [3] (ø 3.0 mm, = Min. 16 mm),
shaft and valve spool assembly (23), and then remove needle roller (36) from input shaft (18).
remove shim (24) and spacer (25). ★ Perform this work on a wood block so that
★ Check the thickness and quantity of the the input shaft will not be damaged.
shims.
15. Direct valve spool (37) down and remove torsion

12. Remove seal (26) and snap ring (27), and then bar (38) and spacer (39) from the input shaft and
remove spacer (28), ring (29A), seal (29), and valve spool assembly.
seal ring (30) from upper case (19). ★ Do not remove needle roller (40) from the
★ Usually, seal (29) and seal ring (30) are in 1 torsion bar.
unit.
13. Remove snap ring (31), thrust washer (32),

thrust bearing (33), thrust washer (34), and wave
washer (35) from input shaft (18).
30-124 HD465-7, HD605-7

➂
16. Direct valve spool (37) down and revolve input ASSEMBLY
shaft (18) until drive link (41) comes off.
★ Before assembling, clean the parts in based-
17. Direct valve spool (37) down and rotate input based solvent free of impurities and dry them by
shaft (18) clockwise until ball (42) comes off. blowing dry compressed against them. Never
★ Since ball (42) may come off by itself, take wipe them with cloths.
care not to lose it. ★ Check the edges of the lapped surface for paint.
★ Do not apply oil to the parts to be installed,
unless otherwise specified.
★ Replace the all seals with new ones.
1. Set thrust washer (34), thrust bearing (35), and

thrust washer (32) in order to input shaft (18),
and then install snap ring (31).
★ Thrust washer (32) is larger than thrust
washer (34).
★ Remove ball retaining spring (43) only when

replacing it. When removing it, hold its flat
end with priers and raise it until it is removed
from valve spool (37). Take care not to dam-
age the periphery of the valve spool and con-
trol edge.
2. Install wave washer (35) to thrust bearing (33)

and thrust washer (34).
3. Install ball (42) to inside of valve spool (37).
HD465-7, HD605-7 30-125

➂
4. Insert input shaft (18) in valve spool (37), rotating 6. Check the splines of drive link (41) and input
it counterclockwise so that the ball will be fitted to shaft (18), and then install drive link (41), match-
its groove. ing the spline of valve spool (37).
★ Keep the spool horizontally during this work.
★ If the splines of the drive link and input shaft

5. Set the intermediate part of torsion bar (38) are not meshed with each other, rotate the
between thrust washer (34) and valve spool (37). input shaft a little to mesh them, and then
★ If the torsion bar is set as above, the valve insert the drive link.
spool and input shaft is positioned. ★ Set the torsion bar securely.
★ Rotate the input shaft in the spool projecting
direction (clockwise) until it stops. If the drive
link is installed correctly, a clearance of 8 – 9
mm is made between the thrust washer and
valve spool.
30-126 HD465-7, HD605-7

➂
7. Measure diameter of needle roller (40) of tor- 11. Install spacer (25) to the input shaft and valve
sion bar (38) at several points. Check that the spool.
difference between measured diameters does ★ When installing the spacer, direct lip surface
not exceed 0.025 mm. "B" in it toward washer (35).
8. Set spacer (39) to torsion bar (38) and insert 12. Install input shaft and valve spool assembly (23)
them in valve spool and input shaft assembly to valve body (11).
(23). ★ The valve spool is fitted to the body with very
narrow clearance between them. Accord-
ingly, if it is pressed sideway when installed,
it may not operate normally.
13. Set shim (24) on thrust washer (32). Apply

grease to new seal (19B) and fix it to the groove
of upper case (19). Install upper case (19),
matching match marks A, and tighten mounting
bolts (20) lightly.
9. Using pin [3] (Outside diameter: 3 mm), align the

pin holes of torsion bar (38) and input shaft (18).
10. Using pin [3], drive needle roller (36) in input

shaft to a depth of 0.8 mm.
★ Check that needle roller (36) is not projected
from the inspection sheet.
HD465-7, HD605-7 30-127

➂
14. Set tool T1 so that the valve body will be aligned 17. Pull down and fix input shaft (18) and mesh drive
with the upper case. link (12) with the spline of the valve spool, and
then rotate the spool so that its end will be flush
with the valve body.
18. Remove drive link (12) again and adjust its posi-
tion so that needle roller (40) of the torsion bar
will be in its groove. Then, insert drive link (12)
in spool (37).
15. Tighten 4 upper case mounting bolts and remove

tool T1.
Mounting bolt:
24.40 – 29.80 Nm {2.49 – 3.04 kgm}
★ Install the valve body to a vise with the input
shaft down.
16. Measure groove width of drive link (12) at sev- 19. Using depth gauge [4], measure fitting height h
eral points over the length and check that the dif- of the valve spool above the valve body.
ference between the obtained values does not
exceed 0.025 mm.
★ If fitting height h is below 0.063 mm, do not

adjust the shim.
If fitting height h is larger than 0.063 mm,
adjust the shim by repeating Steps 12 – 19
so that h will be below 0.063 mm.
30-128 HD465-7, HD605-7

➂
20. Install ball (13). 23. Lubricate a new seal and the seal groove with
grease and install ring (11A) and seal (11B) to
21. Set rod (16) to spring (17) and install them to valve body (11) in order.
valve body (11). Then, install roller (15) and rod
(14).
24. Using guide pin [6], install wear plate (10), rotor
assembly (9), manifold (8), and commutator ring
22. Before installing the rotor, check it according to (7).
the following procedure.
1) Set end cover assembly (2) with the pin side
up and set rotor assembly (9) with the rotor
spline side down, and then check that the
rotor rotates freely in the stator.
2) Measure thickness of rotor A and that of sta-

tor B at several points and check that the
each difference between them is below 0.18
mm.
3) Using filler gauge [5], the clearance between
stator B and rotor A is below 0.18 mm.
HD465-7, HD605-7 30-129

➂
25. Lubricate the inside of both ends of case (3) and ★ Set the oval hole of the commutator and one
the seal installed to valve body (11) with grease. of the bolt holes of the end cover assembly in
line.
26. Install case (3) to valve body (11).
★ Install end cover (2) to the end of the case
and tighten the mounting bolts (1) evenly so
that the case will be inserted straight.
27. Remove end cover (2) and lubricate a new seal

and the seal groove with grease, and then install
ring (2A) and seal (2B) to the end cover in order.
29. Rotate the input shaft so that the end of drive link
(12) will be inserted in the oval hole of the com-
mutator.
★ Lubricate the seal in the end cover with
grease.
30. Set end cover assembly (2) on cover (3) and

tighten the 5 mounting bolts evenly.
28. Apply grease to end cover assembly (2) and fit Mounting bolt:
washer (6) and commutator (5) so that they will 61.0 – 74.5 Nm {6.22 – 7.66 kgm}
not fall even if they are set down. ★ Tighten the mounting bolts in the diagonal
★ Install the commutator so that its hollow C order so that the sleeve and end cover will
will be on the end cover assembly side. not slant while they are being installed.
31. Remove guide pin [6] and tighten the remaining

2 bolts evenly.
Mounting bolt:
61.0 – 74.5 Nm {6.22 – 7.66 kgm}
30-130 HD465-7, HD605-7

➂
32. Direct the input side up and wind tapes onto the 33. Apply grease to the inside and outside of seal
serrated part. (29) and seal ring 30 and install them with the lip
★ Seal (26), spacer (28), ring (29A), seal (29), side in the valve.
and seal ring (30) are the parts of a kit.
★ Seal (29) and seal ring (30) have been 34. Install ring (29A).
installed as 1 unit.
35. Using tool T2, install spacer (28) from the small
diameter end.
36. Install snap ring (27) with its rounded side in the
valve.
37. Install seal (26) to the upper case.

★ When installing seal (26), apply grease to its
inside and outside.
HD465-7, HD605-7 30-131

➂
DISASSEMBLY AND ASSEMBLY DEMAND VALVE

TION OF DEMAND VALVE
ASSEMBLY
REMOVAL
pin.
1. Drain hydraulic oil.

Hydraulic tank: 122
2. Disconnect tubes (1), (2), (3), and (4).
3. Remove demand valve assembly (5).

Demand valve assembly: 30 kg
INSTALLATION
removal.
• Refilling with oil (Hydraulic tank)

• Bleed air. For details, see TESTING AND

ADJUSTING, Bleeding air from hydraulic cylinder
(for steering).
30-132 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY HOIST VALVE

TION OF HOIST VALVE
ASSEMBLY
REMOVAL
pin.
1. Drain hydraulic oil.

Hydraulic tank: 122
2. Disconnect the tube and hose from the under-

side of hoist valve assembly (1).
3. Disconnect tubes (2), (3), and (4) and hose (5).
4. Hoist valve assembly (1).

Hoist valve assembly: 35 kg
INSTALLATION
removal.
• Refilling with oil (Hydraulic tank)

HD465-7, HD605-7 30-133

➂
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

BLY OF STEERING CYLIN-
DER ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-502-1003 Repair stand ■ 1
1
2 790-102-3802 Wrench assembly ■ 1
3 790-302-1270 Socket ■ 1
790-201-1702 Push tool kit ■ 1 4. Remove cylinder (4) from tool U1.
790-101-1771 • Push tool ■ 1
4 5. Disassembly of piston rod assembly
790-101-5021 • Grip ■ 1
1) Set tool U1 to piston rod assembly (3).
U 01010-50816 • Bolt ■ 1 2) Using tool U3, remove nut (5).
790-201-1500 Push tool kit ■ 1 ★ Width across flats of nut: 50 mm
790-101-1580 • Push tool ■ 1
5
790-101-5021 • Grip ■ 1
01010-50816 • Bolt ■ 1
6 790-720-1000 Expander ■ 1
7 796-720-1650 Ring ■ 1
8 07281-01029 Clamp ■ 1
DISASSEMBLY
1. Set cylinder assembly (1) to tool U1.
2. Raise the lock of the cylinder head nut. Using

tool U2, remove cylinder head assembly (2).
3) Remove piston assembly (6) and cylinder
head assembly (7) from rod (8).
3. Pull cylinder head and piston rod assembly (3)

out of cylinder (4).
★ Prepare a container to receive oil which flows
out when the piston rod assembly is pulled
out of the cylinder.
30-134 HD465-7, HD605-7

➂
6. Disassembly of piston assembly ASSEMBLY

1) Remove wear ring (9) from piston (10).
2) Remove piston ring (11) from piston (10). ★ Apply engine oil to the sliding surfaces of each
part. When assembling, take care not damage
the packing, dust seal, and O-ring.
1. Assembly of cylinder head assembly

1) Using tool U4, press fit bushing (15) to cylin-
der head (16).
★ When press fitting the bushing, take
extreme care not to deform it.
2) Install rod packing (14).
★ Install the rod packing as shown in the
following figure.
3) Install backup ring (18) and O-ring (17) in
order.
★ Do not install the backup ring forcibly.
Warm it in water at 50 – 60°C before
7. Disassembly of cylinder head assembly installing it.
1) Remove snap ring (12) and dust seal (13). 4) Using tool U5, install dust seal (13) to cylin-
2) Remove rod packing (14). der head (16), and then install snap ring (12).
3) Remove bushing (15) from cylinder head
(16).
4) Remove O-ring (17) and backup ring (18).
2. Assembly of piston assembly

1) Using tool U6, expand piston ring (11).
★ Set the piston ring to the tool and rotate
the handle 8 – 10 turns to expand the
piston ring.
2) Remove the piston ring from the tool and
install it to piston (10).
HD465-7, HD605-7 30-135

➃
3) Set tool U7. Using tool U8, shrink the piston 3) Remove piston rod assembly (3) from tool
ring. U1.
4) Install wear ring (9). 4. Set the cylinder to tool U1.
5. Install cylinder head and piston rod assembly (3)

to cylinder (4).
3. Assembly of piston rod assembly

1) Install cylinder head assembly (7) and piston
assembly (6) to piston rod (8).
6. Using tool U2, tighten cylinder head assembly
(2).
Cylinder head nut:
637.5 ± 63.7 Nm {65 ± 6.5 kgm}
2) Using tool U3, tighten nut (5).

Nut: Adhesive (Loctite No. 262)
Nut:
1,078.8 ± 107.9 Nm {110 ± 11.0 kgm}
★ Width across flats of nut: 50 mm
30-136 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER

BLY OF HOIST CYLINDER
ASSEMBLY
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-502-1003 Repair stand ■ 1
1
2 790-102-3802 Wrench assembly ■ 1
3 790-720-1000 Expander ■ 1 3. Remove cylinder and rod assembly (3) from

cylinder (2).
4 796-720-1680 Ring (For cylinder ) ■ 1
Clamp
5 07281-01580 ■ 1
(For cylinder )
Push tool
792-201-7310 ■ 1
(For cylinder )
790-101-5421 Grip (For cylinder ) ■ 1
01010-81240 Bolt (For cylinder ) ■ 1

Push tool
6 790-201-1702 ■ 1
(For cylinder )
U
• Push tool
790-201-1851 ■ 1
(For cylinder )
• Grip
790-101-5021 ■ 1
(For cylinder )
• Bolt
01010-50816 ■ 1
(For cylinder )
792-201-7410 Plate (For cylinder ) ■ 1
4. Remove piston nut (4) and lift down rod (6) from
790-101-5021 Grip (For cylinder ) ■ 1
cylinder (5).
01010-80816 Bolt (For cylinder ) ■ 1
Push tool kit 5. Pull cylinder assembly (1) out of rod (6).
7 790-201-1500 ■ 1
(For cylinder )
• Plate
790-201-1660 ■ 1
(For cylinder )
• Grip
790-201-5021 ■ 1
(For cylinder )
• Bolt
01010-50816 ■ 1
(For cylinder )
DISASSEMBLY
• When disassembling, take care not to damage
the rod packing, dust seal, piston ring, wear ring,
etc.
1. Set the cylinder assembly to tool U1.
2. Using tool U2, remove cylinder head assembly

(1) from cylinde (2).
HD465-7, HD605-7 30-137

➂
6. Disassembly of cylinder head assembly ASSEMBLY

1) Remove snap ring (7) and dust seal (8) from
cylinder head assembly (1). ★ Check each part for dirt, flaw, etc. and apply
2) Remove rod packing (9) and bushing (10). engine oil to the sliding surfaces before assem-
3) Remove backup ring (11) and O-ring (12). bling.
1. Using tool U6, press fit bushing (21) to cylinder

(5).
7. Disassembly of piston assembly and cylin-

der
1) Remove wear ring (13).
2) Remove snap ring (14) and pull out piston 2. Install rod packing (20) to cylinder (5).
assembly (15). ★ Install the rod packing as shown in the fol-
3) Remove piston ring (16) and wear ring (17) lowing figure.
from piston assembly (15).
4) Remove snap ring (18) from cylinder (5), 3. Using too U7, install dust seal (19).
and then remove dust seal (19).
5) Remove rod packing (20) and bushing (21).
4. Install snap ring (18).
30-138 HD465-7, HD605-7

➂
5. Assembly of piston assembly 7. Install wear ring (13) to cylinder (5).

1) Using tool U3, expand piston ring (16) and
install it to piston (15).
★ Set the piston ring to tool U3 and rotate
the handle 8 – 10 turns to expand the
piston ring.
2) Set tool U4. Using tool U5, shrink piston ring
(16).
8. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (10).
3) Install wear ring (17).
9. Install rod packing (9) to cylinder head (1).

★ Install the rod packing as shown in the fol-
lowing figure.
6. Install piston assembly (15) to cylinder (5),

and then install snap ring (14).
HD465-7, HD605-7 30-139

➂
10. Using tool U7, install dust seal (8).
11. Install snap ring (7), O-ring (12), and backup ring 15. Install cylinder and rod assembly (3) to cylin-
(11). der (2).
12. Install head assembly (1) to rod (6). 16. Using tool U2, tighten cylinder head assembly
(1).
13. Sling rod (6) and install it to cylinder (5).
Cylinder head assembly:
★ Align the bolt holes of the piston assembly
1,569.1 ± 156.9 Nm {160 ± 16 kgm}
and rod.
14. Tighten piston mounting nut (4).

★ Degrease the fitting parts of the bolt and nut
sufficiently.
★ Width across flats of bolt: 24 mm
Threads of piston rod:
Adhesive (Loctite No. 262)
Mounting nut:
274 ± 27.4 Nm {28 ± 2.8 kgm}
30-140 HD465-7, HD605-7

➂
DISASSEMBLY AND ASSEMBLY DUMP BODY
REMOVAL AND INSTALLA- 5. Lift off dump body assembly (5).

TION OF DUMP BODY Dump body assembly
HD465-7: 10,750 kg
Special tools HD605-7: 13.450 kg
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
V1 790-441-1320 Hook ■ 4
REMOVAL
ing brake switch to the PARK position, then put
blocks under the wheels.
1. Using tool V1, sling the dump body assembly

temporarily by 4 points.
•
2. Remove hoist cylinder bottom pin (1) and fix it
with a lever block, etc. so that hoist cylinder (2)
will not fall down.
3. Disconnect body positioner rod (3) from the

body.
4. Remove body hinge pins (4) on both sides.

★ Check the thickness, quantity, and location of
the shims.
HD465-7, HD605-7 30-141

➂
INSTALLATION
removal.
When aligning the pin holes, never insert

your fingers in them.
Bottom pin:
157 – 196 Nm {16 – 30 kgm}
★ Adjust the body positioner sensor. For

details, see TESTING AND ADJUSTING,
Adjusting body positioner sensor. 1. Adjust the shim of the dump body bottom mount.
1) Insert spacer 29 mm thick [1] at the end of
dump body (5) (1 each on both sides).
★ Install the shims as removed. 2) Measure clearance x between the center of
installing part of bottom mount (6) and top of
When aligning the pin holes, never insert
rear frame (7).
your fingers in them.
★ Measure the clearance at parts A, B, and
Hinge pin: C, 6 parts in total on both sides.
245 – 309 Nm {25 – 31.5 kgm} 3) Calculate the respective shim thicknesses
for 6 parts of A, B, and C on both sides.
• Shim thickness = (x – 26) mm
After installing the dump body assembly, devia- 4) Set shims (8) calculated in 3) above to the
tion z of the dump body assembly from the cab bottom mount (6).
assembly is in the following range. • Standard shim thickness: 3 mm
• Standard range of dimension z: 58 ± 12 mm • Thicknesses of shims: 1 mm, 3.2 mm
5) Remove spacer [1] and lower the dump body
and check that the all 6 parts of A, B, and C
of the bottom mount are in contact with the
top of the rear frame.
★ If dimension z is out of the standard range,

adjust it with shims (11) of body hinge pins
on both sides.
• Thicknesses of shims: 1 mm, 6 mm
30-142 HD465-7, HD605-7

➂
2. After adjusting the shims on the bottom mount,

adjust the shims on the left front mount.
1) Lower the dump body and measure thick-
ness Y of pad (9).
• Standard thickness Y : 50 mm
2) If the pad thickness exceeds 50 mm or there
is a clearance between the dump body and
pad, add shim (10) to adjust the pad thick-
ness properly.
HD465-7, HD605-7 30-143

➂
DISASSEMBLY AND ASSEMBLY OPERATOR'S SEAT
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT

ASSEMBLY
! The procedure for disassembling and assembling the operator's seat assembly (air suspension (ISRING
HAUSEN)) is shown below.
A: Headrest E : Left-hand armrest

B: Seatback F : Suspension cover
C: Seat cushion G : Rails
D: Right-hand armrest
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the positions of
the 2 clips (2) of headrest stay (1) on both
sides.
30-144 HD465-7, HD605-7

(7)
2) Apply force b to part a of each clip (2) in the 2. Seatback

direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear left
Release headrest stay (1) from part d of the of seatback (4).
clip and pull out up headrest (3). ★ Before disconnecting the air hoses, check
their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
★ Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HD465-7, HD605-7 30-145

➃
4) Apply force E to the right side of seatback (4) 2) Push cushion stopper wire (9) down with
in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and remove
right side up. it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion • The procedure for disassembling right-hand arm-
1) Push cushion adjuster lever (7) inward and rest (10) is shown below. (Disassemble left-
slide seat cushion (8) to the front end. hand armrest (11) similarly.)
30-146 HD465-7, HD605-7

➃
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. ★ There are 2 position adjustment washers
★ Use a flat-head screwdriver, etc. to (16) installed to each bolt between the
remove the cap. armrest and seatback. Take care not
2) Loosen armrest hinge mounting bolt (13). lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of right- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear with
screwdriver [1], etc.
★ Take care not to damage the plastic plate
by prying it off forcibly with a screwdriver,
etc.
4) Turn right-hand armrest (10) up by 180

degrees.
★ If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mounting
bolt (15B)
HD465-7, HD605-7 30-147

➃
3) Remove 4 suspension cover fixing rings (19). 6) Remove 6 plastic suspension cover clips
(small) (25) and 2 plastic suspension cover
clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
★ If you remove the suspension cover with-
out performing the work in steps 5) and
6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear

fixing plate (21), 2 cushion rails (22), and 4
bushings (23).
6. Rails
1) Turn over the seat assembly to set rails (28)
on the upside.
5) Remove 3 metallic suspension cover clips

(24).
30-148 HD465-7, HD605-7

➃
2) Slide rails (28) to the rear end. ASSEMBLY

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of 1. Rails
each rail. 1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part of 2) Set rails (28) to the front end and install 1
each rail, and then remove rails (28). lock washer (30) and 1 hexagon socket head
bolt (29) to each rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
★ Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
3) Set rails (28) to the rear end and install 1 lock
washer (30) and 1 hexagon socket head bolt
(29) to each rail.
Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HD465-7, HD605-7 30-149

➃
2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails (22),

1) Set suspension cover (27) in position and and then install cushion rear fixing plate (21),
install 6 plastic suspension cover clips and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension cover Cushion rail mounting bolt:
clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
2) Install 3 metallic suspension cover clips (24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
30-150 HD465-7, HD605-7

➃
3. Armrest 6) Tighten armrest hinge mounting bolt (13).

• The procedure for assembling right-hand arm- ★ Tighten the bolt so that the arm will move
rest (10) is shown below. (Assemble left-hand smoothly.
armrest (11) similarly.) • Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for

each bolt and set right-hand armrest (10) in
position. 4. Seat cushion
1) Slide in the seat cushion from the front of the
fitting position.
★ If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly and

turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
mounting bolt (15A) permanently.
Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
HD465-7, HD605-7 30-151

➃
5. Seatback 3) Connect 3 air hoses (5) to the rear left of the

1) Insert the left side of seatback (4), and then seatback (4).
lower and set the right side.
6. Headrest
1) Insert headrest (3) in seatback (4).
★ Check that 2 clips (2) on both sides are
locked securely.
2) Install seatback hinge mounting bolt (6) (M8

bolt).
Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
30-152 HD465-7, HD605-7

➃
90 OTHERS
Power train hydraulic circuit diagram ...................................90- 2

Steering and hoist hydraulic circuit diagram.........................90- 3
Brake hydraulic circuit diagram ............................................90- 5
Electrical circuit diagram (1/6) ..............................................90- 7
Electrical circuit diagram (2/6) ..............................................90- 9
Electrical circuit diagram (3/6) ..............................................90-11
Electrical system diagram related to transmission control ...90-19
Electrical system diagram related to monitor .......................90-21
HD465-7, HD605-7 90-1

➁
ELECTRICAL SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROL
HD465-7, HD605-7 90-19

(7)
ELECTRICAL SYSTEM DIAGRAM RELATED TO MONITOR
HD465-7, HD605-7 90-21

(7)

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SEBM027607

MACHINE MODEL SERIAL NUMBER

HD465-7 7001 and up

• HD465-7, HD605-7 mounts the SAA6D170E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ............................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1

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

00-2 HD465-7, HD605-7

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

HD465-7, HD605-7 00-2-1

00-2-2 HD465-7, HD605-7

HD465-7, HD605-7 00-2-3

00-2-4 HD465-7, HD605-7

HD465-7, HD605-7 00-2-5

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque